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1. 60 7 3 Control Cabinet Layout AKD kz2206 61 7 4 Control Cabinet Layout AKD kz22207 mmmmmm ma mm ama mwan m aman mama mwa man 62 7 5 Dimensions AKD x00306 to 00606 63 7 6 Dimensions AKD x01206 aman wwwwa nan ee ee 64 7 7 Dimensions AKD x02406 EE ee 65 7 8 Dimensions AKDx00307 to 01207 2 222222 0 22 c ce 66 7 9 Dimensions AKDXO02407 ESE EE EE GEE EE GEE GEE GEE 67 Kollmorgen April 2011 59 AKD Installation 7 Mechanical Installation 7 1 Safety Instructions There is a danger of electrical shock by high EMC level which could result in injury if the drive or the motor is not properly EMC grounded Do not use painted i e non conductive mounting plates NOTICE Protect the drive from impermissible stresses In particular do not let any com ponents become bent or any insulation distances altered during transport and han dling Avoid contact with electronic components and contacts len The drive will switch itself off in case of overheating Ensure that there is an adequate flow of cool filtered air into the bottom of the control cabinet or use a heat exchanger Ambient Conditions Ventilation and Mounting Position gt p 33 NOTICE Do not mount devices that produce magnetic fields d
2. 103 VO Connection 2 2 2 0 e beeen ete eeeeeteeeees 109 Service Interface OT ccs Sock ei ected dE secs de SES aala 117 CANbus Interface X12 X13 eee eee eee eee eee cence ee ee ee 119 Motion Bus Interface Die 123 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 1 Safety Instructions Never remove electrical connections to the drive while it is live There is a danger of electrical arcing with damage to contacts and serious personal injury Wait at least seven minutes after disconnecting the drive from the main supply power before touching potentially live sections of the equipment e g contacts or undo ing any connections Capacitors can still have dangerous voltages present up to 7 minutes after switch ing off the supply power To be sure measure the voltage in the DC bus link and wait until it has fallen below 40 V Control and power connections can still be live even if the motor is not rotating Wrong mains voltage unsuitable motor or wrong wiring will damage the drive Check the combination of drive and motor Compare the rated voltage and current of the units Implement the wiring according to the connection diagram gt p 76 Make sure that the maximum permissible rated voltage at the terminals L1 L2 L3 or DC DC is not exceeded by more than 10 even in the most unfavorable cir cumstances see IEC 60204 1 eysle Excessively hi
3. 51 Safe Torque OSKAR de 53 Shock hazard Protection EES EE ESE ee Ee Ee ee EE ee Ee ee ee e eee ee ee ee ee 58 Kollmorgen M April 2011 AKD Installation 6 Technical description and data 6 1 The AKD Family of Digital Drives Standard features e Supply voltage range 120 V to 480 V 410 e Several housing dimensions depending on current and hardware options e Motion bus onboard e TCP IP service channel onboard e SFD Resolver Comcoder 1Vp p Sin Cos encoders incremental encoders support onboard e Support for ENDAT 2 1 8 2 2 BISS or HIPERFACE protocols onboard e Encoder emulation onboard e Second feedback support e Safe Torque Off STO according to IEC 61508 SIL 2 onboard e Usewith Synchronous servomotors linear motors and induction machines can be used Available AKD versions e B Base drive is controlled by analog torque and velocity commands electronic gearing e P Position Indexer drive adds the ability to command multiple motions process I O make decisions add time delays and modify drive process variables to the base drive e T in process Structured Text drive adds simple programmability similar to Basic to the base drive e S in process Single Axis KAS is a one axis programmable drive features KAS software built in to the drive Includes all five IEC 61131 languages PLC Open and Pipes Network e M in process Multi Axis KAS master drive runs two to four ax
4. AKD Installation 9 Setup 9 3 3 Testing Procedure 9 3 3 1 Confirm Connections You can turn on logic power to the drive through the X1 connector bus voltage is not needed for com munications After power is supplied the drive displays a sequence of LED flashes 2 3 IP 4 Drive IP address flashed sequentially for example 192 168 0 5 5 Drive status opmode 00 oi or 02 or fault code if the drive is in a fault condition Confirm that the link LEDs on the drive green LED on the RJ45 connector and on your PC are both illuminated If both LEDs are illuminated then you have a working electrical connection LED is green if drive is connected through a network device While the PC is connecting your taskbar will show the following acquiring icon e E Zeg P Wait for this icon to change to the limited functionality icon this process can take up to one minute IPE UK Although Windows displays this limited functionality icon for the drive connection the PC can communicate fully with the drive Using WorkBench you can now configure the drive through this connection Kollmorgen April 2011 131 AKD Installation 9 Setup 9 3 3 2 Install and Start WorkBench WorkBench installs automatically from the CD included with the drive WorkBench is also available on the Koll morgen Web site www kollmorgen com Once installation is complete click the WorkBench icon to start
5. April 2011 AKD Installation 7 Mechanical Installation 7 3 Control Cabinet Layout AKD xzzz06 Material M4 hexagon socket screws to ISO 4762 3 mm T handle Allen key NANANAASAANSAS QW A NN NB EE SQQXUKkDx61206 MM qq N IN Keep hatched space free Dimensions in mm with cable s 265 with cables 215 with cable 185 d N d N N N N N N N N N N N N N N N IN h Kollmorgen April 2011 61 AKD Installation 7 Mechanical Installation 7 4 Control Cabinet Layout AKD xzzz07 Material M4 SS socket screws to ISO 4762 3 mm T handle Allen o SQ Keep hatched space free Dimensions in mm VAT BA PP ae a a AE AY AY a N AY AY ME ME MP AY ME Kollmorgen April 2011 AKD Installation 7 Mechanical Installation 7 5 Dimensions AKD x00306 to x00606 1 with connectors 185 BI All Dimensions in mm Kollmorgen April 2011 63 AKD Installation 7 Mechanical Installation 7 6 Dimensions AKD x01206 187 Lo N N b 2 o D c 9 o E with connectors 215 eo ee ee ee EEN All dimensions in mm Kollmorgen April 2011 AKD Installation 7 Mechanical Installation 7 7 Dimensions AKD x02406 228 o oi N o 2 1 Cc o a E 3 with connectors 265 Dimensions in mm Kollmorgen April 2011 65 AKD Installation 7 Mechanical Installation 7 8 Dimensions AK
6. DN e gt AKD x02406 amp AKD xzzz07 X4 Pin Signal Description Kollmorgen M April 2011 AKD Installation 8 Electrical Installation 8 12 4 2 Single phase connection AKD xzzz06 only e Directly to single phase supply network gt p 83 e Supply networks gt p 83 e Leave L3 open circuit e Filtering to be provided by the user e Fusing such as fusible cut outs to be provided by the user gt p 37 bd PE F AKD x00306 to AKD x00606 X3 Pin Signal Description 5 L2 N Neutral or Line 2 Protective Earth Id EI CT UI dM OO gy ECKE AKD x01206 X3 Pin Signal BE pie 5g o tng 6 L2 N Neutral or Line 2 Ce re Protective Earth a E 2 P ie O ER 2 D pa gt N w 0 D amp Ka 6 S Kollmorgen April 2011 87 AKD Installation 8 Electrical Installation 8 12 5 External Regen Resistor X3 For technical data on the brake circuit Dynamic Braking gt p 41 Fusing such as fusible cut outs to be pro vided by the user gt p 37 RBint with types from 12A only broer D AKD x00306 to AKD x00606 X3 Pin Signal Description 1 RB External Regen Resistor negative 3 RB Extemal Regen Resistor positive Id 1 21 LU AH OO gu AKD x01206 X3 Pin Signal Description Internal RegenResistor positive 2 RB External RegenResistor negative External RegenResistor positive ad
7. Rotary Switch Setting Drive IP Address DHCP AutolP address The IP address of the drive is obtained from the DHCP server on your network If no DHCP server is found the IP addresses is an AutolP address it is internally generated following the AutolP protocol and will be of the form 169 254 xx xX 01 to 99 Static IP Address The IP address is 192 168 0 nn where nn is the number from the rotary switch This setting generates addresses in a range from 192 168 0 2 to 192 168 0 99 Example if S1 is set to O and S2 is set to 5 the IP address is 192 168 0 5 NOTE The PC subnet mask must be set to 255 255 255 0 or 255 255 255 128 NOTE When connecting the AKD directly to a PC use static IP addressing not 00 Dynamic IP addressing DHCP and Auto IP With S1 and S2 both set to 0 the drive is in DHCP mode The drive will acquire its IP address from an extemal DHCP server if present in the network If a DHCP server is not present the drive will assume an Automatic Pri vate IP Address of the form 169 254 x x If your PC is directly connected to the drive and set to obtain an IP address automatically in the TCP IP set tings a connection will be established with both devices using compatible automatic generated addresses It can take up to 57 seconds for a PC to configure an Automatic Private IP Address 169 254 x x Changing the IP address If the switches are altered while 24 V Logic power is supplied to the drive you m
8. A quad B X9 The drive calculates the motor shaft position from the cyclic absolute signals of the primary feedback gen erating incremental encoder compatible pulses from this information Pulse outputs on the SubD connector X9 are 3 signals A B and Index with 90 phase difference i e in quadrature hence the alternative term A quad B output with a zero pulse The resolution before multiplication can be set by the DRV EMUERES parameter Use the DRV EMU EZOFFSET parameter to adjust save the zero pulse position within one mechanical tum The drivers operate from an internal supply voltage Index o tv max 30ns Connection Diagram Encoder input Shield 106 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 15 3 Pulse Direction signal connection The drive can be connected to a stepper motor controller Set parameters for the drive with WorkBench The number of pulses can be adjusted so that the drive can be adapted to match any stepper controller Speed profile and signal diagram rr Pulse Direction 1 path traversed s velocity v acceleration a number of pulses pulse frequency rate of change of pulse frequency 8 15 3 1 Pulse Direction input 5 V X9 Connection to 5 V signal level stepper motor controllers Controller Pulse Pulse Direction Direction OV Shield 8 15 3 2 Pulse Direction input 24 V X7 Connecti
9. AKD Installation 6 Technical description and data 6 17 Safe Torque Off STO An additional digital input STO releases the power output stage of the drive as long as a 24 V signal is applied to this input If the STO input goes open circuit then power will no longer be supplied to the motor and the drive will lose all torque and coast to a stop Input STO X1 3 Floating reference ground is GND 24 V 10 20 mA This input is not compatible with IEC 61131 2 You can thus achieve a restart lock out for personnel safety by using the STO input in conjunction with an exter nal safety circuit Advantages of the STO function e The DC bus link remains charged since the mains supply line remains active e Only low voltages are switched so there is no contact wear e Very little wiring is required The STO safety concept is certified The safety circuit concept used for the safety function Safe Torque Off in the drive is suited for SIL 2 according to EN 61800 5 2 and PL d CAT 3 according to ISO 13849 1 6 17 1 Safety characteristic data The subsystems AKD are described with the following characteristic data Operation Mode EN 13849 1 EN 62061 PER DIN SFF STO STO single channel PL d CAT 3 SIL2 0 20 6 17 2 Use as directed The STO function is exclusively intended to provide safety for personnel by preventing the restart of a system To achieve this personnel safety the wiring of the
10. X11 Service X13 CAN Out Kan AA X1 24 V Supply Na STO X5 6 Motion Bus X2 Motor Holding Brake X7 8 VO X3 4 pin DC Bus X10 Feedback Brake Resistor X9 Encoder i Emulation X4 4 pin Power Supply Protective Earth PE Kollmorgen April 2011 75 AKD Installation 8 Electrical Installation 8 8 Connection Diagram AKD x00306 to x00606 AKD x00306 x00606 X10 Reference Safety Instructions and Use As Directed thermal control included DCOM7 DIGITAL IN7 Feedback lt DIGITAL IN4 DIGITAL INS DIGITAL OUT2 DIGITAL OUT2 DIGITAL OUTI DIGITAL OUTI DIGITAL IN2 DIGITAL IN1 Fault DCOM8 ENABLE XB DIGITAL ING DIGITAL INS AGND Analog Out Analog In Analog In X5 Motion Bus In X6 Motion Bus Out X12 CAN In X13 CAN Out xa Encoder Emulation X11 TCP IP supply unit 24v DC 1 L2 LS ny L GC Control 24V referred to 1 0 GND 1 0 GND Ref Point Home Switch Emergency Stop Circuit 1 0 GND NSTOP 24V refered to 1 0 GND tachometer voltage 10V 10V speed setpoint referred to 1 0 GND Participant Participant CAN Participant 3 CAN Participant 9 Encoder Evaluation Service PE connection protective earth HE chassis ground connection panel Q shiela connection via plu
11. 5 H 4 thermal control min 5VDC 5mA Kollmorgen April 2011 101 AKD Installation 8 Electrical Installation 8 14 9 Incremental Encoder Feedback devices which do not deliver absolute information for commutation can either work with wake amp shake commutation see AKD User Guide or can be used as a complete feedback system when combined with an addi tional Hall encoder All signals are connected using a pre assembled comcoder connection cable If cable lengths of more than 25 m are planned please consult customer support The Sense signal is optional and can be omitted if the encoder cable is short and no significant voltage drop is on the cable The voltage drop depends on the cable length and gage and the encoder current consumption FBTYPE Frequency Limit Incremental Encoder amp Hall Switches Comcoder 2 5 MHz Incremental Encoder Wake amp Shake 2 5 MHz The pin assignment shown on the encoder side relates to Kollmorgen motors ComCoder Up voltage supply OV 102 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 15 Electronic gearing Master slave operation It is possible to set up master slave systems use an external encoder as a command encoder secondary feed back device dual loop control or connect the amplifier to a third party step controller Depending on the signal voltage level connector X9 5 V TTL or X7 24 V must be used The WorkBench set
12. Invalid motion task parameters assign ment This waming can appear upon an MT SET command Activation of the motion task failed due to incompatible parameters or motion task does not exist This warning can appear upon an MT MOVE command Homing error observed during the oper ation of homing procedure Activation of any new motion will clear the warning DRV CLRFAULTS also can be used to clear warning Check fol lowing motion task settings and parameters to make sure that the values entered will produce a valid motion task Refer to the motion task documentation for additional guidance on specific causes of invalid motion tasks Activation of any new motion will clear the warning DRV CLRFAULTS also can be used to clear warning Activation of any new motion will clear the warning DRV CLRFAULTS also can be used to clear warning Activation of any new motion will clear the warning DRV CLRFAULTS also can be used to clear warning Activation of any new motion clears the warning DRV CLRFAULTS also can be used to clear warning Check motion task settings and param eters Activation of any new motion clears the warning DRV CLRFAULTS also can be used to clear warning Check motion task settings and param eters to make sure that the values entered will produce a valid motion task Refer to the motion task documentation for additional guidance on specific causes of invalid motion tasks Activation of any new m
13. 14 bit 0 022 resolution 16 bit 0 006 The pin assignment shown on the resolver side relates to Kollmorgen motors Resolver S1 SIN S3 SIN S2 COS Cosine S4 COS R1 REF Ref R2 REF CZ 43 thermal control min 5VDC 5mA Kollmorgen April 2011 95 96 AKD Installation 8 Electrical Installation 8 14 3 SFD The diagram below shows the connection of the Kollmorgen feedback system The Sense input is required only for cables longer than 50 m or if the wire resistance from drive to sensor exceeds 3 3 ohm FBTYPE Smart Feedback Device 41 5 V 5 accuracy 14 bit 0 022 resolution 24 bit 2 x 10E 5 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 14 4 Encoder with BiSS The diagram below shows the wiring of a single turn or multi tum sine cosine encoder with BISS interface as a feedback system The thermal control in the motor is connected via the encoder cable and evaluated in the drive If cable lengths of more than 50 m are planned please consult customer support FBTYPE Frequency Limit BISS type A Analog BV 5 The pin assignment shown on the encoder side relates to Kollmorgen motors OV U 5V 5 P max 350mA min 5VDC 5mA Kollmorgen April 2011 97 AKD Installation 8 Electrical Installation 8 14 5 Sine Encoder with EnDat 2 1 The diagram below shows the wiring of a single turn or multi tum sin
14. Mo ana sup ape NOTICE Maximum cable length of an external incremental encoder using X9 is dependant on cable voltage drop and external encoder power requirements See the cal culation example in the user guide s chapter Electronic Gearing 8 15 1 3 Connector X9 Output Technical characteristics e Electrical Interface RS 485 e Max frequency 3 MHz e Resolution Up to 16 bit e The pulses per revolution value are settable e Pulse phase shift 90 20 Pin Emulated Encoder Output 6 Shield Channel Zero 8 Channel Zero 104 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 15 2 Command encoder signal connection 8 15 2 1 Incremental encoder input 5 V X9 A 5 VA quad B encoder or the encoder emulation output of another drive can be connected to this input and used as acommander encoder dual loop feedback gearing or camming input Don t use for primary motor feedback connection Connection Diagram Encoder AquadB A 5V 5 POV Up max 250mA voltage supply GND OV Shield 8 15 2 2 Incremental encoder input 24 V X7 A 24V A quad B encoder can be connected to the digital inputs 1 and 2 and used as a commander encoder dual loop feedback gearing or camming input Don t use for primary motor feedback connection Connection Diagram Master Kollmorgen April 2011 105 AKD Installation 8 Electrical Installation 8 15 2 3 Emulated Encoder Output EEO
15. e AIN CUTOFF 800 Hz 16 bit Analog Input Wiring Diagram control le set point 10V Application examples for set point input Analog In e adjustable external current limit e reduced sensitivity input for setting up jog operation e pre control override Defining the direction of rotation Standard setting clockwise rotation of the motor shaft looking at the shaft end affected by positive voltage between terminal X8 10 and terminal X8 9 To reverse the direction of rotation swap the connections to terminals X8 9 10 or change the DRV DIR param eter in the Feedback screen page 110 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 16 3 Analog Output X8 Terminals X8 7 8 can be used to output converted analog values of digital measurements recorded in the drive A list of the pre programmed functions is included in the WorkBench setup software Technical characteristics e Output voltage range referring to AGND 10 V e Resolution 16 Bit and fully monotonic e Unadjusted offset lt 50 mV e Offset drift typ 250 uV C e Gain or slope tolerance 3 e Nonlinearity lt 0 1 of full scale or 10 mV e Output impedance 110 ohms e Specification complies with IEC 61131 2 Table 11 e 3dB Bandwidth gt 8 kHz e Maximum output current 20 mA e Capacitive load any value but response speed limited by max lout and by Rout e Protected for short circuit to AGND An
16. l l D Mains Supply Mains Supply Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 11 2 2 Shielding Busbar The power cable shields line in motor cable external regen resistor can be routed to an additional busbar via shield clamps Kollmorgen recommends using Weidmiiller KLBU shield clamps A possible scenario for setting up a busbar for the above shield clamps is described below 96 2 Brass 3mm thick according to the no of terminals according to the no of terminals holder busbar retaining plate coil spring shield connection terminal clamps busbar washer M6 nut spring washer assembly plate OL M6 bolt 1 Cut a busbar of the required length from a brass rail cross sec tion 10 x 3 mm and drill holes in it as indicated All shield clamps required must fit between the drill holes Risk of injury due to the spring force of the coil spring Use pincers 2 Squeeze together the coil spring and the supporting plate and push the busbar through the opening in the holder 3 Mount the busbar with the shield clamps fitted on the assembly plate Use either metal spacer bushes or screws with nuts and accessories to maintain a spacing of 50 mm Earth the busbar using a single conductor with a cross section of at least 2 5 mm 4 Strip the external cable sheath to a length of approx 30 mm tak ing care not to damage the bra
17. warning signs The individual voltages are switched on for the first time during setup Only professional staff who are qualified in electrical engineering are allowed to install the drive Wires with color green with one or more yellow stripes must not be used other than for protective earth PE wiring The ground symbol which you will find in all the wiring diagrams indicates that you must take care to provide an electrically conductive connection with the largest feasible surface area between the unit indicated and the mounting plate in the con trol cabinet This connection is for the effective grounding of HF interference and must not be confused with the PE symbol PE protective earth safety measure as per IEC 60204 NOTE Use the following connection diagrams Overview all connections AKD x00306 to x00606 AKD x01206 AKD x02406 and xzzz07 Shielding Mains power Motor Feedback Electronic gearing Encoder emulation Digital and analog inputs and outputs Service interface CANbus interface Motion bus interface Hardware options Kollmorgen April 2011 71 72 AKD Installation 8 Electrical Installation 8 4 Components of a servosystem With AKD xzzz06 NOTE Cables drawn bold are shielded Electrical ground is drawn with dash dotted lines Optional devices are connected with dashed lines to the drive The required acces sories are described in the accessories manual C
18. 1 ZI LT 9Y 00 9Y 19Y AKD x02406 amp AKD xzzz07 X3 Pin Signal Description 2 RB External RegenResistor negative External RegenResistor positive Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 12 6 DC Bus Link X3 The DC bus link can be connected in parallel so that the regen power is divided between all the drives that are connected to the same DC bus link circuit Every drive must have it s own power connection to mains voltage even if the DC bus link is used eys e The drive can be destroyed if DC bus link voltages are different Only drives with mains supply from the same mains identical mains supply voltage may be con nected by the DC bus link Use unshielded single cores cross section gt p 39 with a maximum length of 200 mm Use shielded cables for longer lengths AKDx003 AKDx012 DC 3 RB DC e AKD x00306 to AKD x00606 X3 2 S Pin Signal Description of DC Link Bus negative OF DC RB DC Link Bus positive es eg AKD x01206 X3 Pin Signal Description DC Link Bus positive JPEDOSSSAQOVNS ad El Z1 LI BEG Be gs AKD x02406 amp AKD xzzz07 X3 Pin i Description 4 DC Link Bus positive Kollmorgen April 2011 89 AKD Installation 8 Electrical Installation 8 13 Motor Connection Together with the motor supply cable and motor winding the power output of the drive forms an oscillating circuit Charac
19. 200 kA time delay The fuse must be UL and CSA listed UL recognized is not sufficient EU fuses types gRL or gL 400 V 500 V time delay Fuse holders Combined with the standard fuse blocks finger safe fuse holders must be used according to IEC 60529 Examples Bussmann CH Series Modular Fuse Holders fuse size 0 to 30A class J 3 poles CH30J3 Ferraz Ultrasafe Fuse holders fuse size 0 to 30A class J 3 poles US3Jal 6 9 1 External Power Supply fusing Model Ampere rating Cooper Bussmann Ferraz Shawmut AKD X00306 AKD X00606 15A Time Delay AKD X01206 AKD X02406 3 AKD X00307 6A Time Delay LPJ6 DFJ6 AJT6 HSJ6 AKD X00607 10A Time Delay LPJ10 DFJ10 AJT10 HSJ10 AKD X01207 15A Time Delay LPJ15 DFJ15 AJT15 HSJ15 AKD X02407 30A Time Delay LPJ30 DFJ30 AJT30 HSJ30 6 9 2 External 24 V supply fusing Drive Max Example class J Example class J Model Ampere rating Cooper Bussmann Ferraz Shawmut all AKD 8A Time Delay LPJ8 DFJ8 AJT8 HSJ8 6 9 3 External regen resistor fusing Drive Max Example class KLM xx Model Ampere rating Cooper Bussmann all AKD 6A Time Delay in process Kollmorgen April 2011 37 38 AKD Installation 6 Technical description and data 6 10 Connectors Given voltage and current data are the lowest values allowed by UL and CE Order codes gt p 145 6 10 1 AKD xzzz06 Types 120V to 240V Mains Voltage Supply Connector Type Max Cross Sec Allowed Allowed tion
20. 24V referred to 1 0 GND 1 0 GND thermal control included DCOM7 DIGITAL IN7 Feedback DIGITAL IN4 o N DIGITAL IN3 DIGITAL OUT2 DIGITAL OUT2 7 DIGITAL OUT1 DIGITAL OUT1 O 3s pe Ref Point 4 o DIGITAL IN2 O Home Switch 5 DIGITAL IN1 0 6 X8 Fault Emergency Remove oz i L SE resistor is connected 1 7 DCOM8 1 0 GND 3 ENABLE NSTOP 4 DIGITAL IN6 PSTOP DIGITAL INS 24V referred to 1 0 GND AGND i i HE tachometer Analog Out 10V speed URE referred to U 1 0 GND de IG do AA Analog In Analog In X5 Motion Bus In X6 3 Motion Bus Out Participant X12 3 CAN In CAN Participant X13 3 CAN Out CAN Participant X9 Encoder 9 Encoder Emulation Evaluation X11 7 Service TCP IP PE connection protective earth pb chassis ground connection panel sei connection via plug Participant Mains contactor fi 78 Kollmorgen April 2011 8 11 AKD Installation 8 Electrical Installation EMI Noise Reduction 8 11 1 Recommendations for EMI Noise Reduction The following guidelines will help you to reduce problems with electrical noise in your application Ensure good connections between the cabinet components Connect the back panel and cabinet door to the cabinet body using several conductive braids Never rely on hinges or mounting bolts for ground connections Provide an electrical connection acro
21. 362 594260 vi i NU I uk li li in H ii II li A il a III in III C int l il il WI up il li il UNI tii il o MAC Address 00 00 00 00 00 00 INPUT OUTPUT c US 480 Vac 0 480 Vac 50 60 Hz 0 600 Hz LISTED INO CONT EO SE Before use refer to CD for installation and safety information Assembled in USA Patents Pending www kollmorgen com 28 Kollmorgen April 2011 AKD Installation 5 Package 5 3 Part number scheme The part number is identical to the order code AKD B 003 06 NAAN 0000 AKD AKD Customization 0000 Standard USA D000 Standard EU german E000 Standard EU english F000 Standard EU french 1000 Standard EU italian Version B Base P Position Indexer Connectivity Options AN Analog Current Rating EC EtherCAT 003 3Arms CN CANopen 006 6Arms CC EtherCAT amp CANopen 012 12Arms 024 24Arms Extension Options NA None Voltage Rating 06 120 240 Vac 1 3 07 240 480 Vac 3 Version B base version is not available in Europe Voltage Rating Presently the AKD xzzz07 models only support operation at levels above 270 Vac Updates to the AKD firmware are in process to allow the operation of the AKD xzzz07 models drives at 240Vac These updates will only require a firmware modification and will be backwards compatible with all AKD xzzz07 hardware Customization this code includes language version of printed material for European countries and customer specia
22. GE GE GE ee 126 9 2 Setup software WorkBench EG cece cece ccc e cece cece cece ee eeceeeeeeeeeeeeeeees 127 9 3 Basic Drive Test sesse Baha are eee ea es ed oe ee EEN 130 9 4 Fault and Warning Messages 0 00 c cece ccc ecccecececcccececeeeeeeees 133 9 5 Troubleshooting the Akt 143 Kollmorgen April 2011 125 AKD Installation 9 Setup 9 1 Safety Instructions Ya Tel The equipment produces potentially lethal voltages up to 900 V Check that all con nection components that are live in operation are safely protected against bodily contact Never remove the electrical connections to the drive while it is live Capacitors can still have dangerous residual charges up to 7 minutes after switch ing off the supply voltage The heat sink of the drive can reach temperatures up to 80 C in operation Check the heat sink temperature before handling the drive Wait until the heat sink has cooled down to 40 C before touching it Before testing and setup the manufacturer of the machine must generate a hazard analysis for the machine and take appropriate measures so that unforeseen move ments cannot cause injury or damage to any person or property A CAUTION Only professional personnel with extensive knowledge in the fields of electrical engineering and drive technology are allowed to test and set up the drive NOTICE If the drive has been stored for more than 1 year you must re form the capacitors in the DC bus link
23. Kollmorgen motors arestored inWorkBench andcan beloaded withone click usingthe Motorscreen inthe WorkBenchsoftware An extensive online help with integrated description of all variables and functions supports you in each situation 9 2 3 Hardware requirements The Service interface X11 RJ45 of the drive is connected to the Ethernet interface of the PC by an Ethernet cable gt p 117 Minimum requirements for the PC Processor at least Pentium II or comparable Operating system Windows 2000 or XP or VISTA or 7 Graphics adapter Windows compatible color Drives hard disk with at least 20 MB free space CD ROM drive Interface one free Ethernet Interface or a Hub port or Switch port 9 2 4 Operating systems WINDOWS 2000 XP VISTA 7 WorkBench works with WINDOWS 2000 WINDOWS XP WINDOWS VISTA and WINDOWS 7 Unix Linux The functioning of the software has not been tested for WINDOWS running within Unix or Linux 128 Kollmorgen April 2011 AKD Installation 9 Setup 9 2 5 Installation under WINDOWS 2000 XP VISTA 7 The CD ROM includes an installation program for the setup software Installation e Autostart function activated Insert the CD ROM into a free drive A window with the start screen opens There you find a link to the setup software WorkBench Click it and follow the instructions e Autostart function deactivated Insert the CD ROM into a free drive Click Start task bar then Run Enter the
24. Mechanical Installation Setup Kollmorgen April 2011 128 145 111 115 116 STO Setup Setup Software SFD Shield connection Shielding Shock hazard protection SinCos encoder with Hall Site Site altitude Stacking height Stacking Height Storage Standards Standards used STO Stop Funtion Storage Supply networks Switch on switch off behavior Symbols used System components overview T Target group Temperature in operation Storage Transport Tightening torques connectors Transport Trouble Shooting U UL Markings Uninstalling Up Down Input Use as directed Drive Setup Software STO V Ventilation Ambient Conditions Mechanical Installation Vibrations W Warnings Wiring 18 108 16 127 53 133 71 AKD Installation This page intentionally left blank Kollmorgen April 2011 149 AKD Installation Sales and Service We are committed to quality customer service In order to serve in the most effective way please contact your local sales representative for assistance If you are unaware of your local sales representative please contact us Europe Kollmorgen Customer Support Europe Internet www kollmorgen com E Mail technik kollmorgen com Tel 49 0 2102 9394 0 Fax 49 0 2102 9394 3155 North America Kollmorgen Customer Support North America Internet www kollmorgen com E Mail support kollmorgen com Tel 1 540 633 3545 Fax 1
25. Motor inductance min 03 Motor inductance max Thermal dissipation output stage disable max 25 Thermal dissipation at rated current 175 Noise emission low speed high speedfan dB A N A 33 39 37 43 41 56 24V 10 check voltage drop current w o motor brake w o optioncard a 05 06 07 current w o motor brake with option card 5 EF Ro 7 Rl lt OIO o SS Di Q Dm o Cc O o lt SIS NI oO Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 6 Electrical Data AKD xzzz07 Electrical data Units AKD x00307 AKD x00607 AKD x01207 AKD x02407 Rated supply input frequency Rated input current 0 Permitted switch on off frequency 3 Do a OS eee Rated DC bus link voltage Continuous output current 3 azv am a 6 2 asov O Ars s oe ER aa asov Amo gt oe 2 24 Peak output current forapprox 5s 3 end 9 18 30 48 Continuous output power asav o Ja o is ask ET Peak output power for approx 5 s at 3x240 V 1 8 a at 3x40 3 167 SECH 36 20 Technical data for regen circuit Motor inductance min 1 max 25 Motor inductance max Thermal dissipation output stage disable Thermal dissipation at rated current 102 129 15 237 Noise emission low speed high speed fan JdB A 34 43 34 43 44 52 48 58 Au voltage supoy current w o motor brake w o option card Presently the AKD xzzz07 mode
26. Off STO ES GE GE GE Gee 23 Kollmorgen April 2011 17 18 AKD Installation 3 Approvals 3 1 Conformance with UL cUL This drive is listed under UL Underwriters Laboratories Inc file number E141084 Vol 3 Sec 5 USL CNL Power conversion equipment NMMS NMMS7 Models AKD followed by B P S M or F followed by 003 006 012 and 024 followed by 06 or 07 followed by additional suffixes USL Indicates Investigated to United States Standard for Power Conversion Equipment UL 508C Third Edition Revised February 15 2008 CNL Indicates investigation to Canadian Standard for Industrial Control Equipment CAN CSA C22 2 No 14 2005 Second Edition Revised April 2008 Note CNL Canadian National Standards Listed USL United States Standards Listed 3 1 1 UL Markings e These drives are open type adjustable frequency motor drives that provide variable speed control to motors and provides overload protection and current limit control e These devices are intended to be used in a pollution degree 2 environment e Identification of the terminals on the controller are coded so they may be identified in the instructions The instructions shall identify power connections for power supply load control and ground e Integral solid state short circuit protection does not provide branch circuit protection Branch circuit pro tection must be provided in accordance with the National Electrical Code and any
27. Therefore RCDs which are sensitive to all curents must be used in order to detect any DC fault current Refer to the chapter above for the rule of thumb for determining the leakage current Rated residual currents in the RCDs 10to30mA Protection against indirect contact personal fire protection for stationary and mobile equip ment as well as for direct contact Protection against indirect contact personal fire protection for stationary equipment NOTE Recommendation In order to protect against direct contact with motor cables shorter than 5 m Kollmorgen recommends that each drive be protected individ ually using a 30 mA RCD which is sensitive to all currents If you use a selective RCD the more intelligent evaluation process will prevent spurious tripping of the RCD 6 18 3 Isolating Transformers When protection against indirect contact is absolutely essential despite a higher leakage current or when an alter native form of shock hazard protection is sought the AKD can also be operated via an isolating transformer schematic connection gt p 83 A ground leakage monitor can be used to monitor for short circuits NOTE Keep the length of wiring between the transformer and the drive as short as pos sible Kollmorgen April 2011 AKD Installation 7 Mechanical Installation 7 Mechanical Installation 7A Safety Instructions 2 60 7 2 Guide to Mechanical Installation
28. circuit To re form the capacitors disconnect all electrical con nections and apply single phase 208 to 240 Vac to terminals L1 L2 of the drive for about 30 minutes NOTE Additional information on setting up the eguipment Programming parameters and control loop behavior are described in the online help of the setup software The setup of any expansion card described in the corresponding manual on the CD ROM Kollmorgen can provide training courses for the drive upon request 126 Kollmorgen April 2011 AKD Installation 9 Setup 9 2 Setup software WorkBench This chapter describes the installation of the setup software WorkBench for the AKD digital drives Koll morgen offers training and familiarization courses on request KOLLMORGEN 7 sam non gear Gei s Gunde Because Motion Matters Welcome to A tonk r fom age Nare Sea Deeg Name Terraces com Metres 1632547067 Wree neok Connector Connected tei BAO ase 18216871103 9 2 1 Use as directed The setup software is intended to be used for altering and saving the operating parameters for the AKD series of drives The attached drive can be set up with the help of this software and during this procedure the drive can be controlled directly by the service functions A WARNING Only professional personnel who have the relevant expertise gt p 10 are per mitted to carry out online parameter setting for a drive that is running S
29. described in this documentation Any divergence from the configuration and installation described in this documentation means that the user will be responsible for carrying out new measurements to ensure conformance with regulatory requirements AKD xzzz06 lense AKD xzzz06 drives do not have integrated EMC filters These drives can cause high frequency interferences and may require measures for interference suppression such as additional external EMC filters With external EMC filters for noise emission the drives meet the noise immunity requirements of the second envi ronmental category industrial environment to a product of the category C2 motor cable lt 10 m Witha motor cable length of 10 m orlonger and external EMC filters the drive meets the requirement of category C3 AKD xzzz07 NOTE AKD xzzz07 drives have integrated EMC filters The drive meets the noise immunity requirements to the 2nd environmental category industrial environment For noise emission the drive meets the requirement to a product of the Category C2 motor cable lt 10 m With a motor cable length of 10 m or longer the servo drive meets the requirement to the Category C3 Kollmorgen April 2011 AKD Installation 3 Approvals 3 2 1 European Directives and Standards for the machine builder Drives are components that are intended to be incorporated into electrical plant and machines for industrial use When the drives are built in
30. input and check brake function brake and no brake This function does not ensure personnel safety The Hardware Enable connector X8 pin4 does not initiate a controlled stop but switches off the power stage immediately The brake function must be enabled through a parameter The diagram below shows the timing and functional relationships between the controlled stop signal speed setpoint speed and braking force All values can be adjusted with parameters values in the diagram are default values U Analog In t DINK STATE U with DINx MODE configured for controlled stop t a iz AT AA poner EER ma VEE BRAKE 120 Braking force STO t The speed setpoint of the drive is internally driven down an adjustable ramp CS DEC to O V With default values the output for the brake is switched on when the speed has reached 120 rpm CS VTHRESH for at least 6 ms CS TO The rise teen and fall te times of the holding brake that is built into the motor are different for the various types of motor See motor manual Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 14 Feedback Connection Every closed servo system normally requires at least one feedback device for sending actual values from the motor to the drive Depending on the type of feedback device used information will be fed back to the drive using digital or analog means AKD supports the most common types of feedback d
31. not exceed 1000 V peak In accordance with IEC 61800 voltage spikes lt 50 us between phases must not exceed 1000 V Voltage spikes lt 50 us between a phase and the housing must not exceed 2000 V EMC filter measures for AKD xzzz06 must be implemented by the user Motor voltage rating The AKD family of drives is exclusively intended for driving suitable synchronous servomotors with closed loop control of torque speed and or position The rated voltage of the motors must be at least as high as the DC bus link voltage divided by V2 produced by the drive U U 12 gt nMotor Safe torque off Review the section Use as Directed in the STO chapter gt p 53 before using this safety function according to ISO 13849 category 3 2 3 Prohibited Use Other use than that described in chapter Use as directed 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 national directives or standards The use of the drive in the following environments is also prohibited e potentially explosive areas e environments with corrosive and or electrically conductive acids alkaline solutions oils vapors dusts e ships or offshore applications Kollmorgen April 2011 AKD Installation 3 Approvals 3 Approvals 3 1 Conformance with UL cUL e cece EE eie 18 3 2 CE Conformance EE EE GE eee EE EE EE eie 20 3 3 Safe Torque
32. of reasons depending on the conditions in your installation The causes of faults in multi axis systems can be especially complex If you cannot resolve a fault or other issue using the trou bleshooting guidance presented below customer support can give you further assistance NOTE More details on the removal of faults can be found in the online help and in the fault and warning messages table Fault and Warning Messages gt p 133 HMI message Communication fault Motor does not rotate Motor oscillates Drive reports following error Motor overheating Drive too soft Drive runs roughly During the instal lation a dialog box saying Please wait while the installer fin ishes determining your disk space requirements appears and never dis appears Possible Causes Wrong cable used cable plugged into wrong position on drive or PC wrong PC interface selected drive not enabled software enable not set break in setpoint cable motor phases swapped brake not released drive is mechanically blocked motor pole no set incorrectly feedback set up incorrectly gain is too high speed controller feedback cable shielding broken AGND not wired up rms or Ipeak set too low current or velocity limits apply accel decel ramp is too long motor operating above its rating Kp speed controller too low Ki speed controller too low filt
33. program call x index htm x correct CD drive letter Click OK and proceed as described above Connection to the Ethernet interface of the PC e Connect the interface cable to an Ethemet interface on your PC or to a Hub Switch and to the service interface X11 of the AKD gt p 117 Kollmorgen April 2011 129 AKD Installation 9 Setup 9 3 Basic Drive Test 9 3 pag Unpacking Mounting and Wiring the Drive Unpack drive and accessories Observe safety instructions in the documentation Mount the drive gt p 59 Wire the drive gt p 71 or apply the minimum wiring for drive testing as described below Make sure you have on hand the following information about the drive components POND e rated mains supply voltage e motor type motor data if the motor type is not listed in the motor database e feedback unit built into the motor type poles lines protocol e moment of inertia of the load 9 3 2 Minimum Wiring for Drive Test without Load A CAUTION This wiring diagram is for general illustration only and does not fulfill any require ments for EMC safety or functionality of your application X11 TCP IP a KOLLMORGEN STO 5 D 24V ON 4 N AKD NIA da ya 7 24V m 24V GNE IN X1 2 We A X8 3 Power Brake Feedback 4 When connecting the AKD directly to a PC static IP addressing not 00 is recommended Kollmorgen April 2011
34. protected against unintentional restart IEC 61508 SIL 2 NOTE If the Safety option card is integrated it provides safe drive functions in accord ance with IEC 61800 5 2 in process 6 16 1 Stop Standards The stop function shuts down the machine in normal operation The following stop functions are defined by IEC 60204 e Category 0 Shut down by immediate switching off the energy supply to the drive machinery this is an uncontrolled shut down e Category 1 A controlled shut down whereby the energy supply to the drive machinery is maintained to perform the shut down and the energy supply is only interrupted when the shut down has been completed e Category 2 A controlled shut down whereby the energy supply to the drive machinery is maintained NOTE The parameter DRV DISMODE must be set to 2 to implement the different stop cat egories Consult the User Guide for configuring the parameter The stop category must be determined by a risk evaluation of the machine In addition suitable means must be provided to guarantee a reliable shut down Category O and Category 1 stops must be operable independently of the operating mode whereby a Category 0 stop must have priority Stop functions must be implemented by disconnection of the appropriate circuitry and have priority over assigned start functions If necessary provision must be made for the connection of protective devices and lock outs If applicable the stop
35. switch on and switch off behavior of the AKD Behavior of holding brake function Drives with an enabled holding brake function have a special timing for switching on and off the output stage gt p 92 Events that remove the DRV ACTIVE signal trigger the holding brake to apply As with all electronic cir cuits the general rule applies that there is a possibility of the internal holding brake module failing Personnel safety e g with hanging load vertical axes requires an additional mechanical brake which must be safely oper ated for example by a safety control If velocity drops below threshold CS VTHRESH or timeout occurs during a stop procedure the brake is applied Behavior when undervoltage condition is present The behavior in an undervoltage condition depends on the VBUS UVMODE setting VBUS UVMODE DC Bus Undervoltage Mode Consult the AKD User Guide for configuring the parameter The drive will report a F502 undervoltage fault any time an undervoltage condition occurs The drive will report a warning n502 if not enabled The drive will report a fault if the drive is enabled when the condition occurs or an attempt is made to enable while an under voltage condition occurs Safety function STO With the personnel safe function STO the drive can be secured on standstill using its intemal electronics so that even when power is being supplied the drive shaft is protected against unintentional restart The chapte
36. the program WorkBench will show a list of all the drives that it can find on your local network Select the drive you wish to configure and then click Next If multiple drives are detected a drive can be uniquely identified using one of the following methods 1 The MAC address of the drive This address is printed on the sticker on the side of the drive 2 The name of the drive The drive name is set using WorkBench A new drive defaults to No Name 3 Blinking the display Select a drive and click Blink to force the display on the front of the drive to blink on and off for 20 seconds 9 3 3 3 Set Drive IP Address in WorkBench If WorkBench does not automatically show your drive then you can set the IP address manually in WorkBench as follows 1 Display the IP address You can show the drive IP address on the drive display by pressing button B1 The display shows the digits and dots of the IP address in sequence for example 192 168 0 5 You can also display the IP address by disconnecting and then reconnecting the Ethernet cable Press B1 to display IP address 2 Enter the drive IP address Once the IP address has been determined manually enter the drive IP address into the Specify Address box in WorkBench Then click Next to connect 9 3 3 4 Enable the Drive Using the Setup Wizard Once a comnection to the drive has been established the AKD Overview screen appears Your drive appears in the navigation area on the left
37. the specific motion task trigger a motion task with an invalid bit combination in the motion task control word see also MT CNTL This warning is cleared upon a successful start of any new motion or upon a DRV CLRFAULTS command This warning appears with n160 This 1 1 profile table motion tasks warning is triggered when you try to should be started from velocity trigger a 1 1 profile table motion task 0 while another motion task is currently run ning This warning is cleared upon a suc cessful start of any new motion or upon a DRV CLRFAULTS command This warning appears with n160 This Change the MT TNUM param warning is triggered when you try to eter for this specific motion task trigger a motion task that uses a cus in order to use an initialized pro tomer profile table for generating the file table Velocity profile and when the selected profile table is empty see MT CNTL and MT TNUM This warning is cleared upon a successful start of any new motion or upon a DRV CLRFAULTS command F201 Internal RAM failed Hardware failure detected Restart drive If issue persists contact technical support Hardware failure detected Restart drive If issue persists contact technical support Kollmorgen April 2011 137 AKD Installation 9 Setup Fault Message Warning Cause Remedy F203 Code integrity failed Software failure detected FPGA reg Restart drive If issue persists a ae ees ve spon F204
38. valid motion task Refer to the motion task documentation for additional guidance on specific causes of invalid motion tasks Activation of any new motion will clear the warning DRV CLRFAULTS also can be used to clear warning Check motion task target velocity set tings and parameters to make sure that the values entered will not exceed the VL LIMITP and VL LIMITN setting Kollmorgen April 2011 135 AKD Installation 9 Setup Fault Message Warning n154 Following motion failed check motion parameters T position crossed due n157 Homing index pulse not found n160 Failed to set motion task parameters Motion task activation failed We procedure failed Kollmorgen April 2011 Activation of the following motion task failed due to incompatible parameters or motion task does not exist The motion task crosses the target posi tion after triggering a DRV STOP com mand This situation can happen when processing a change on the fly motion task and triggering a DRV STOP com mand close to the target position of the currently running motion task A homing mode with index detection is activated and index pulse is not detected while moving across the range determined by the hardware limit switches Homing reference switch not JA homing mode with reference switch detection is activated and the reference switch is not detected while moving across the range determined by the hard ware limit switches
39. 5 1 Digital Outputs 1 and 2 The drive supplies 2 digital outputs X7 5 to X7 8 gt p 109 Choose the required function in the setup software Messages from pre programmed functions stored in the drive can be output here A list of these pre programmed functions can be found in the setup software If an output is to be assigned to a pre programmed function then the parameter set must be saved in the drive Technical characteristics e 24V IO power supply at terminals X7 8 and X7 6 20 Vdc to 30 Vdc e All digital outputs are floating DIGITAL OUT 1 2 terminals X7 7 8 and X7 5 6 max 100 mA e Can be wired as active low or active high see examples below e Update rate 250 us Wiring diagram control ACTIVE LOW control 424V Digital 1 ACTIVE HIGH 1 0 GND 24V Digital 1 Kollmorgen April 2011 115 116 AKD Installation 8 Electrical Installation 8 16 5 2 FAULT relay contacts Operational readiness terminals X8 1 and X8 2 is signaled by a floating relay contact The fault relay can be programmed to two modes of operation Contact closed when there is no fault Contact closed when there is no fault and the drive is enabled The signal is not influenced by the enable signal the I limit or the regen threshold Technical characteristics e FAULT Relay output max 30 Vdc or 42 Vac 1A e Time to close max 10 ms e Time to open max 10 ms NOTE All faults cause the FAULT contact to open an
40. 540 639 4162 150 Kollmorgen April 2011
41. 56 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 17 8 3 Functional test A CAUTION You must test the restart lock function after initial start of the drive after each inter ference into the wiring of the drive or after exchange of one or several components of the drive First Method 1 Stop drive with setpoint O V Keep drive enabled DANGER Do not enter hazardous area 2 Activate the STO function for example by opening protective screen voltage at X1 3 0 V 3 The fault contact opens the net contactor releases and the drive displays fault F602 Second Method 1 Stop all drives with setpoint 0 V disable drive 2 Activate the STO function for example by opening protective screen voltage at X1 3 0 V 3 The drive displays waming n602 6 17 8 4 Mains supply circuit example Corresponding control circuit gt p 56 mains 3 d Ke S PE amplifier 2 amplifier 3 amplifier 4 gt gt Screen switch 1 Screen switch 2 Kollmorgen April 2011 5 YA 58 AKD Installation 6 Technical description and data 6 18 Shock hazard Protection 6 18 1 Leakage Current Leakage current via the PE conductor results from the combination of equipment and cable leakage currents The leakage current frequency pattern includes a number of frequencies whereby the residual current circuit break ers definitively evaluate the 50 Hz current For t
42. AKD Installation Manual Edition E April 2011 Valid for Hardware Revision C Part Number 903 200003 00 Original Document CE V IND cout EQ Patents Pending Keep all manuals as a product component during the life span of the product Pass all manuals to future users and owners of the product KOLLMORGEN i Record of Document Revisions Revision Remarks 11 2009 Beta launch version 12 2009 Digital 1 0 corrections several updates A 03 2010 CAN termination connector optional data dynamic brake updated resolver signals renamed CE certificate X9 description updated technical data completed Hardware Revision HR Hardware Revision Firmware WorkBench Remarks M 010322222 A SM 0105000117 31 30zz222 STO certified EnDat is a registered trademark of Dr Johannes Heidenhain GmbH EtherCAT is a registered trademark and patented technology licensed by Beckhoff Automation GmbH HIPERFACE is a registered trademark of Max Stegmann GmbH WINDOWS is a registered trademark of Microsoft Corporation AKD is aregistered trademark of Kollmorgen Corporation Current patents US Patent 5 646 496 used in control card R D and 1 Vp p feedback interface US Patent 5 162 798 used in control card R D US Patent 6 118 241 used in control card simple dynamic braking Technical changes which improve the performance of the device may be made without prior notice Printed in the United States of A
43. Current Voltage 05mm ad TA lt 100V 05mm 21awg TA lt 100V_ 0 5mm 21ang TA 2100V 0 5mm 21ang TA 2100V 0 5mm 21ang 1A lt 100V 1single line connection 2single line connection with recommended conductor cross section gt p 39 3rated voltage with pollution level 2 6 10 2 AKD xzzz07 Types 240V to 480V Mains Voltage Supply Connector Type Max Cross Sec Allowed Cur Allowed Volt tion rent age3 1single line connection 2single line connection with recommended conductor cross section gt p 39 3rated voltage with pollution level 2 Kollmorgen M April 2011 AKD Installation 6 Technical description and data 6 11 Cable and Wire Requirements 6 11 1 General For information on the chemical mechanical and electrical characteristics of the cables please refer to the accessories manual or contact customer support NOTE To reach the maximum permitted cable length you must use cable material with the following capacitance phase to shield requirements e Motor cable less than 150 pF m e Resolver Encoder cable less than 120 pF m Motor cables longer than 25 m may require the use of a motor choke 6 11 2 Cable Cross Sections and Requirements Thetablebelow describes therecommendedinterfacecross sections andcablerequirements forsingle axis systems inaccordancewithlEC 60204 Formulti axis systems observethespecific operatingconditions foryoursystem Interface Cross Section Cable Re
44. DC Using the built in regen circuit several drives of the same series can be operated from a common DC bus link gt p 89 without any additional measures 90 of the combined power of all the coupled drives is always avail able for peak and continuous power The switch off on over voltage takes place as described under 1 above for the drive that has the lowest switch off threshold resulting from tolerances NOTE Observe the regeneration time some minutes for the dynamic brake circuit after full load with peak regen power Kollmorgen April 2011 41 42 AKD Installation 6 Technical description and data 6 14 1 2 Technical Data for AKD xzzz06 Technical data for the regen circuit depends on the drive type and the mains voltage Supply voltages capacitances and switch on voltages are all nominal values Brake circuit Supply voltage Type Rated data Units 120V 240V AKD xzzz06 Switch on threshold of regen circuit all types Switch off threshold of regen circuit Maximum regen duty cycle 157 Type R Units 120V 240V at AKD x00306 External regen resistor Onm 3 Peak regen power extemal is w s Absorption energy in capacitors 20 Ws 60 20 DC Bus Capacitanse JUD Joe w AKD x00606 Extemalregenresistr Ai s SSS EE EK b 5 9 1 Peak regen power extemal resistor 1s kW 5 Absorption energy in capacitors 20 Ws 60 20 9 1 5 DC Bus Capacitance Pea
45. Dx00307 to 01207 185 S KEEKEEEER with connectors 221 All Dimensions in mm Kollmorgen April 2011 AKD Installation 7 Mechanical Installation 7 9 Dimensions AKDx02407 28 All Dimensions in mm Kollmorgen April 2011 68 AKD Installation 8 Electrical Installation 8 Electrical Installation 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 8 11 8 12 8 13 8 14 8 15 8 16 8 17 8 18 8 19 Safety Instructions 69 Guide to electrical installation 70 Winnog EER AR OE EE RE ae IE N EE OE OE see 71 Components of a servosystem EES SEE GEE GEGEE GEGEE eie 72 Connector Assignments AKD x00306 to 00606 74 Connector Assignments AKD x01206 SESSE SS Ge ee 74 Connector Assignments AKD x02406 and AKD rkzzz07 75 Connection Diagram AKD x00306 to 00606 76 Connection Diagram AKD O1206 SESSE SESSE SG GEGEE Ge eie 77 Connection Diagram AKD x02406 and AKD kzzz07 22 2222 2 78 EMI Noise Reduction 79 Electrical Supply Connection 83 Motor Connection ESE EE EE Ee EE EE EE ee ee EE ee ee Ee ee ee ee ee ee ee ee ee ee ee 90 Feedback Connection aaa 93 Electronic gearing Master slave operation
46. E GE GE GEGEE 55 6 17 8 2 Control circuit example 2 000000 e cece eee eee cece aiaa a naan 56 6 17 8 3 Functional test 57 6 17 8 4 Mains supply circuit example EES c eee c eee e eee cccceececccececeeees 57 6 18 Shock hazard Protection 0 202 0 SESSE SESSE cece cece cece cece cece cece cece cee ceeceeceeeeeeeeees 58 6 18 1 Leakage Current e cece cece eee eao aaraa oraaa rriari 58 6 18 2 Residual Current Protective Device CD 58 6 18 3 Isolating Transformers SG e cee mmama nwa mwan mwa mw nama nw wanume 58 7 Mechanical Installation mm cece cecceeecececceeeeeeees 59 7 1 Safety Instructions 60 7 2 Guide to Mechanical Installation 2 2 2 0 02222 c cece cece eee cece cece cece cece ccc c cece eee eeeeeeeeeeees 60 7 3 Control Cabinet Layout AKD xzZZ06 occ eee e cece eeeeeeeeeeeeeeees 61 7 4 Control Cabinet Layout AKD xz7207 e cece ranana 62 4 Kollmorgen April 2011 AKD Installation Table of Contents 7 5 Dimensions AKD x00306 to x00606 EE ee eie 63 7 6 Dimensions AKD Xx01206 a 64 7 7 Dimensions AKD Kk024086 mmmmmmama mwan cece cece ee eeeeeeeeeeteeeeeeeees 65 7 8 Dimensions AKDx00307 to 01207 LL e cece cece wwa naww nwa nana 66 7 9 Dimensions AkKDvO2A0 e cece cece raaraa aa raran annann 67 8 Electrical Installation Ge eie 68 8 1 Safety INStrUCtiONS w wmm wwa wwa wwa n
47. EEPROM failure detected EEPROM failure detected Restart drive If issue persists exchange drive Temperature sensor high High temperature limit reached Check cabinet ventilation sys tem Temperature sensor low Low temperature limit reached Check cabinet ventilation sys tem F245 External fault This fault is user generated and is Users can configure a digital caused by user settings input to trigger this fault DINx MODE 10 The fault occurs according to this input setting Clear the input to clear the fault F247 Bus voltage exceed allowed Hardware problem in bus measurement Troubleshoot and repair hard thresholds ware problem F301 Motor overheated Motor overheated Check ambient temperature Check motor mounting heat sink capability F302 Over speed Motor exceeded VL THRESH value Look for overshoot or lower requested speed F303 Runaway Motor did not follow command values Gains are too low motor is being over driven F304 Motor foldback Maximum motor power has been Motion is requiring too much exceeded the power has been limited to power Change move profile to protect the motor reduce load on motor Check for load jamming or sticking Check that current limits are set cor rectly F305 Brake open circuit Motor brake open circuit Check cabling and general func tionality F306 Brake short circuit Motor brake short circuit Check cabling and general func tionality F307 Brake cl
48. FD feedback fault Bad communication with the SFD Check primary feedback X10 device connection If fault persists internal feedback failure Return to manufacturer for repair F417 Broken wire in primary feed In primary feedback a broken wire was Check feedback cable con detected incremental encoder signal tinuity amplitude F418 Primary feedback power Power supply fault for primary feedback Check primary feedback X10 supply connection F419 Encoder init procedure failed Phase find procedure did not complete Check encoder wiring successfully reduce balance motor load prior to phase finding F424 Resolver amplitude low Resolver signal amplitude is below mini Check primary feedback X10 TT ee E F425 Resolver amplitude high Resolver signal amplitude is above max Check primary feedback X10 pamana angg Ee F426 Resolver error Resolver excitation fault Check primary feedback X10 TT WT GT F427 Analog low Analog signal amplitude low Check primary feedback X10 eee DST GETT F428 Analog high Analog signal amplitude high Check primary feedback X10 mane TT TT F429 Incremental low Incremental encoder signal amplitude is Check primary feedback X10 TT GT someoton F430 Incremental high Incremental encoder signal amplitude is Check primary feedback X10 TT de o F431 Secondary feedback Hall Secondary feedback illegal Hall state Check X9 connection error 000 111 F432 Communicatio
49. GEGEE 26 5 Package IE cect wee a EE AA GE GE EE NAA Baa Asaan 27 5 1 Package Supplied 28 5 2 Nameplate ESEG SEG SG GE Ge ee ee 28 5 3 Part number EE 29 6 Technical description and data 30 6 1 The AKD Family of Digital Drives EES SESSE ESE EG Ge eie 31 6 2 Ambient Conditions Ventilation and Mounting POSsition 33 6 3 Mechanical Data 33 6 4 Inputs Outputs a 33 6 5 Electrical DataAkiixvzza0mp GE 34 6 6 Electrical Data AKD XZZZOT a 35 6 7 Performance Data 36 6 8 Recommended tightening tordues SS SS SS SS SG mwa mwa mwaname wnn 36 G59 FUSING N RE EE OR EE EE AE AE 37 6 9 1 External Power Supply using Ge 37 6 9 2 External 24 V supply fusing 2000 e cece cece ec naraon m nwa wanume 37 6 9 3 External regen resistor fusing a 37 Kollmorgen April 2011 3 AKD Installation Table of Contents 6 10 34 CONNECLONS MEE ER Es nara ahas EA ila a kap LAW a nA od N AE ERA 38 6 10 1 AKD xzzz06 Types 120V to 240V Mains Voltage Supply EE ESE Gee 38 6 10 2 AKD xzzz07 Types 240V to 480V Mains Voltage Supply GESE See 38 6 11 Cable and Wire Requirements GE GE EE mim laam ia la 39 eh WEE 39 6 11 2 Cable Cross Sections and Requirements SESSE ee eee cece e cece eceececeeeeees 39 6 12 Re TE EE 40 6 13 Grounding System 2 222 220 eee 40 6 14 Dynamic Brakimg SG GES r oaoaraa See 41 6 14 1 Regen Ci
50. Repair and Disposal cco eee ccc n cece eee c cece eee eceeeeeceeeeteeeeees 26 Kollmorgen April 2011 AKD Installation 4 Handling 41 Transport Transport the AKD in accordance with IEC 61800 2 as follows e Transport only by qualified personnel in the manufacturer s original recyclable packaging e Avoid shocks while transporting e Transport only within specified temperature ranges 25 to 70 C max rate of change 20 K hour class 2K3 e Transport only within specifiedhumidity max 9596 relative humidity no condensation class 2K3 eys e The drives contain electrostatically sensitive components that can be damaged by incorrect handling Electrostatically discharge yourself before touching the drive Avoid contact with highly insulating materials such as artificial fabrics and plastic films Place the drive on a conductive surface 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 AKD packaging consists of recyclable cardboard with inserts and a label on the outside of the box Package Dimensions mm Model HxWxL Total Weight kg AKD x00306 and AKD x00606 77 x 280 x 222 AKD x01206 158 x 394 x 229 4 3 Storage Store the AKD in accordance with IEC 61800 2 as follows e Store only in the manufacturer s original recyclable packaging e Store at or below maximum stacking height e AKD x0306
51. aan 126 9 2 Setup software orkf ench cece cece eee eeeeeeeeeeeeeeeeeeees 127 9 2 1 Useas directed wwa ww eee m nanaon arrearen ameen 127 9 2 2 Software description EE mmama mama GE eie 128 9 2 3 Hardware reduirements EE GE GE GE 128 9 2 4 Operating systeMS G nwa cee nw wanan wwa wanawa m aam mean 128 9 2 5 Installation under WINDOWS 2000 XP VISTAI7 2 aa 129 93 Basic Dive Test ang anan laba dees Ee bet aes EE ED NG ako wh AD UNAN WE GEOES ER EE E 130 9 3 1 Unpacking Mounting and Wiring the Drive SS SG e cece Gee 130 9 3 2 Minimum Wiring for Drive Test without Load SESSE SESSE SES SS SG SG SG SG Gee ee 130 9 3 3 Testing Procedure GES cece cece cece ence eeeeeeeeeeeeeeeseeeees 131 9 3 3 1 Confirm Connections EE c ee cece cece cc eeeeeececececeeeeeeeeeees 131 9 3 3 2 Install and Start WorkBench 2 22 0 2 22 aaa 132 9 3 3 3 Set Drive IP Address in WorkBench 22222 ccc cece cece GE mmama 132 9 3 3 4 Enable the Drive Using the Setup Wizard 132 9 4 Fault and Warning Messages e cece eee mumewe nma nwa nm raiar amene 133 9 5 Troubleshooting the AKD 0 0 a 143 10 Option Cards a 144 ah Oider Codes ee a OE EE EE GP ase GE AD EE EG 145 12 Index EE ER PG AA ee 147 Kollmorgen7M April 2011 7 AKD Installation Table of Contents This page intentionally left blank 8 Kollmorgen April 2011 AKD Installation 1 Gener
52. additional local codes or the equivalent e This product is suitable for use on a circuit capable of delivering not more than 200 000 rms symmetrical amperes 240 V AKD xzzz06 480 V AKD xzzz07 volts maximum when protected by Fuses or equivalant e The following fuse types are recommended Model Fuse class Rating Max Fuse Rating aKD x00306 J eoovac 200ka AKD x00606 J 600Vae 200 KA AKD x0T206 J 600Vae 200 kA CIC C C AKDx02405 J 6obVac 200kA IA AKDx00807 1 s ovaa SA 77 AKDx00607 J 600Vac 200kA Im pa J Ss BA AKDx02407 IJL 600Vac 200k IA Ca Ca C Cc e These drives provide solid state motor overload protection at 125 of the rated FLA Current e Use minimum 75 C copper wire Kollmorgen April 2011 AKD Installation 3 Approvals e The following table illustrates the torque requirements for the field wiring connectors Model Mains Connector Motor Phase Connector 24 Vdc Input Connector AKD x00307 AKO X00607 AKD x01207 AKD x02407 e Maximum surrounding air temperature of 40 C or equivalent Kollmorgen April 2011 19 AKD Installation 3 Approvals 3 2 CE Conformance Conformance with the EC EMC Directive 2004 108 EC and the Low Voltage Directive 2006 95 EC is mandatory for the supply of drives within the European Community The drives have been tested by an authorized testing laboratory in a defined configuration using the system com ponents that are
53. aid durably and protectedfrom outsidedamage 6 17 8 1 Signal diagram sequence The diagram below shows how to use STO function for a safe drive stop and fault free operation of the drive 1 Brake the drive in a controlled manner speed setpoint 0 V 2 When speed 0 rpm disable the drive Enable O V 3 Activate the STO function STO OV n speed WY Zak U Enable t 2100ms U STO A WARNING Suspended loads can set themselves in motion on motors without a brake because the motor loses all torque when STO function is engaged STO open and or 0 V Use motors with a built in holding brake Kollmorgen April 2011 55 AKD Installation 6 Technical description and data 6 17 8 2 Control circuit example The example shows a control circuit with two separated work areas connected to one emergency stop circuit mains supply circuit gt p 57 For each work area safe stop of the drives is switched by a protective screen The safety switchgears used in the example are manufactured by Pilz and fulfill at least the PLd according to ISO 13849 1 or SIL CL2 according to IEC 62061 Safety switchgears from other manufacturers may also be used Review the wiring instructions gt p 54 24VDC Fault Fault Fault Fault 1 2 3 4 D O O 0 0 0 0 6 UN 9 10 9 10 9 10 Emergency stop circuit acc to ISO 13849 1 PLe Safe stop acc to ISO 13849 1 PLd for 2 drives Ai Siisi2 521 s22 A2 STO STO
54. ains Supply Networks AKD xzzz07 240V to 480V 84 8 12 3 24V Auxiliary Supply 71 85 8 12 4 Mains Supply Connection X3 XA 86 8 12 4 1 Three Phase connection all AKD twvpes cece cece ee eeeeeeeeeeees 86 8 12 4 2 Single phase connection AKD xzzz06 only 87 8 12 5 External Regen Resistor X3 c cece cece ccc ccecccccecceceeees 88 8 12 6 DC Bus Link X3 cece cece cece cece cece cece ERRE 89 8 13 Motor Connection mmama nwa man man wama A E wwa n waamua naume 90 8 19 1 Motor Power X2 AA 91 8 13 1 1 Cable Length 525m SESSE SESSE GE Ge ee 91 8 13 1 2 Cable length gt 25 m 00 00200 e cece eee eeeeeeeeeecceeeeeeees 91 8 13 2 Motor Holding Brake 21 92 8 14 Feedback Connection c cece cece cece cece cece cece cece ceececeeceeeeeeeeees 93 8 14 1 Feedback Connector GC 94 AR RE N EE OR ORE OR EE N N N 95 BA EE 96 8 14 4 Encoder with DG 97 8 14 5 Sine Encoder with EnDat 2 98 Kollmorgen April 2011 5 AKD Installation Table of Contents 8 14 6 Encoder with EnDat 272 99 8 14 7 Sine Encoder with Hiperface GE 100 8 14 8 Sine Encoder EG GE EE 101 8 14 9 Incremental Encoder EG GE GE Ge 102 8 15 Electronic gearing Master slave operation EES SESSE eie 103 8 15 1 Technical characteristics and pinout EES EG GE ie 103 8 15 1 1 ConpnectorX lnput e cece cece cee eeeeceeeeccceeeeeeeeees 103 8 15 1 2 Connector X9 Input 104 8 15 1 3 Connector X9 O
55. ak regen power internal resistor 0 5s 35 20 ls ale Q SIS oIS HE 0 9 at KO D lt 91 5 ajo D CH Di CH S oi SAAG bw N 2 Ee O GE S Ta i Q de N CA QI o o on P w ba N _ P k AKD x01207 Internal regen resistor Continuous power internal resistor Peak regen power internal resistor 0 5s O O Ww c a O Di o D O af 5 5 OD Ole x Q z o N di DI o o on P w o N pa a P External regen resistor Maximum continuous regen power external resistor Peak regen power external resistor 1s AKD x02407 Internal regen resistor Continuous power internal resistor Peak regen power internal resistor 0 5s e Qi gt g N Q o a O ko D bei Q Q lt 5 O D o o Q EN o a Pg m N S Es z x x Q zx O gt 3 Go A sa CH O O Og E N O Di Oo Di o D O Dm N Q o N N o w o D N N 30 6 110 60 x x Olx O CO CH g O Wa c D O D o D Q oj fo D u depends on connected regen resistor power Presently the AKD xzzz07 models only support operation at levels above 270 Vac Updates to the AKD firm ware are in process to allow the operation of the AKD xzzz07 models drives at 240Vac Kollmorgen April 2011 43 AKD Installation 6 Technical description and data 6 15 Switch on and Switch off Behavior This chapter describes the
56. al 1 General 1 1 About this Manual 2 22 2 0 00000 eee eee mama wamama mama ee eeeeeteeees 10 1 2 Target Group esc setae hs ehh ad tet whee dd asa nG En EE DE abcess a Meee diese hhaha salsa 10 1 3 Using the PDF Format c cece eee e eee aman wamama 10 14 Abbreviations used aa ana jo de Seege scene 11 1 5 Symbols used 22 2 0 0000 22 eee cee eee tence ee umama me 12 1 6 Standards Used 20 0 0 ccc ccc ccc ccc ccc ec cece ec ene ene ence ec ene ence ee ee ee ee ee ee ee ee ee ee ee ee ee 13 Kollmorgen April 2011 9 AKD Installation 1 General 11 About this Manual This manual AKD Installation Manual describes the AKD series of digital drives and includes information needed to safely install an AKD A digital version of this manual pdf format is available on the CD ROM included with your drive Manual updates can be downloaded from the Kollmorgen website www kol Imorgen com This document fulfills all requirements for an Instructions Manual under the EC Machinery Directive 2006 42 EC Additional documents on the accompanying CD ROM include the following e AKD Quick Start also provided in hard copy This guide provides instructions for basic drive setup and connection to a network e AKD Users Manual This manual describes how to use your drive in common applications lt also pro vides tips for maximizing your system performance with the AKD e AKD Parameter and C
57. alog Output Wiring Diagram control CNC GND Kollmorgen April 2011 111 AKD Installation 8 Electrical Installation 8 16 4 Digital Inputs X7 X8 The drive provides 8 digital inputs gt p 109 These can be used to initiate pre programmed functions that are stored in the drive A list of these pre programmed functions is included in the WorkBench Digital Input 8 is not programmable but is fixed to the ENABLE function If an input is programmed it must be saved to the drive The inputs can be used with switched 24 V source type or switched GND sink type See diagrams below for typical examples of digital input wiring Digital Input Wiring Diagram Source type connection example Controls HOME Switch DIGITAL IN1 DCOM7 24V e LA DIGITAL INS DCOM8 against O GND 112 Kollmorgen April 2011 AKD Installation 8 Electrical Installation Digital Input Wiring Diagram Sink type connection example E DIGITAL IN7 di ae ot DIGITAL IN4 EF DIGITAL IN3 CR DIGITAL IN2 Ka DIGITAL IN1 ef DCOM7 i EA DIGITAL IN5 Controls HOME Switch S against O GND Kollmorgen April 2011 113 114 AKD Installation 8 Electrical Installation 8 16 4 1 Digital Inputs 1 and 2 These inputs X7 9 and X7 10 are particularly fast and are therefore suitable for latch functions for example They can also be used as 24 V inpu
58. artificial fabrics plastic film etc Place the drive on a con ductive surface Kollmorgen April 2011 15 AKD Installation 2 Safety 2 2 Use as Directed Drives are components that are built into electrical plants or machines and can only be operated as integral com ponents of these plants or machines The manufacturer of the machine used with a drive must generate a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements cannot cause per sonnel injury or property damage Cabinet and wiring Drives must only be operated in a closed control cabinet suitable for the ambient conditions gt p 30 Ventilation or cooling may be necessary to keep the temperature within the cabinet below 40 C Use only copper conductors for wiring The conductor cross sections can be derived from the standard IEC 60204 alternatively for AWG cross sections NEC Table 310 16 75 C column Power supply Drives inthe AKD series can be supplied as follows e AKD xzzz06 1 or 3 phase industrial supply networks not more than 200 kA symmetrical rated current at 120 V and 240 V e AKD xzzz07 3 phase industrial supply networks not more than 200 kA symmetrical rated current at 240 V 400 V and 480 V Connection to other voltage types of supply networks is possible with an additional isolating transformer gt p 83 Periodic overvoltages between phases L1 L2 L3 and the housing of the drive must
59. be available in future drives 144 Kollmorgen April 2011 AKD Installation 11 Order Codes 11 Order Codes The order numbers for accessories such as cables mating connectors regen resistors and mains filters are included in the accessories manual for your region available on the CDROM or website Accessories specified may be different for each region based on regulatory and market differences The part number scheme gt p 29 determines the order number for the drives Kollmorgen April 2011 145 AKD Installation 11 Order Codes This page intentionally left blank 146 Kollmorgen April 2011 12 Index A Abbreviations AKD Family Ambient temperature Analog inputs Analog setpoints Assembly Aux supply 24V interface B Basic Drive Test BISS encoder C Cable and Wire Requirements CANbus Baud rate Cable CANopen interface Node address Termination CE conformance Comcoder interface Connection diagram AKD x00306 to x00606 AKD x01206 AKD x01206 amp AKD xzzz07 Connector assignments AKDx00306 to AKDx00606 AKDx01206 AKDx02406 Connectors D DC Bus Capacitance DC bus link interface Dig Encoder emulation interface Digital inputs Dimensions AKD x00306 to 00606 AKDx00307 to 00607 AKDx01206 AKDx02406 AKDx02407 Disposal Dynamic Braking E EC Declaration of Conformity 130 97 39 120 22 AKD Installation 12 Index Emergency Stop Funtion Emula
60. ction 1 000 to 2 500 meters AMSL with power derating 1 5 100 m Pollution level Pollution level 2 as per IEC 60664 1 The drive shuts down fault F234 gt p 133 motor has no torque in case of excessively high temperature in the control cabinet Make sure sufficient forced ventilation is supplied within the control cabinet AMSL above mean sea level 6 3 Mechanical Data Mechanical data Units AKD x00306 AKD XO00606 AKD x01206 AKD x02406 168 260 228 Mechanical data ig Depth without connectors mm Depth with connectors mm 6 4 Inputs Outputs Electrical Data Int Analog input resolution 16 bit 10 Vdc Max common mode voltage 10 Vdc Analog output resolution 16 bit 10 Vdc erface Digital inputs min 3 5 Vdc max 30 Vdc max 30 Vdc 100 ma max 30 Vdo max 42Vac TA Kollmorgen April 2011 33 34 AKD Installation 6 Technical description and data 6 5 Electrical Data AKD xzzz06 Electrical Data Units AKD x00306 AKD x00606 AKD KO1206 AKD x02406 1x 120 V to 240 V 10 110 Rated input current amv o faf 90 09 2 NA amoy O Taf 50 99 e NA Rated DC bus link voltage Continuous output current 3 arv O O o m a 6 a NA azv lam 8 e ea f a Peak output curent or approx 5s 3 Ams 9 18 90 Continuous output power at 1x240 V W Peak output power for approx 5 s at 3x120 V NIA EET KVA 10 Technical data for regen circuit
61. curs brake is applied Category 0 stop according to IEC 60204 gt p 51 Use controlled stop to disable drive if velocity drops below threshold CS VTHRESH or time out occurs brake is applied Category 1 stop according to IEC 60204 gt p 51 Standard Operation DRV DIS 24V DRV DIS DRV ACTIVE Power Stage o enable ll t a i uncontrolled stop Motor Speed CS VTHRESH a t D O l Power Stage eN enable ll t LL l Q controlled stop Q n Motor Speed CS VTHRESH t 5 If velocity drops below threshold CS VTHRESH or timeout occurs brake is applied gt p 92 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 15 2 2 Switch off behavior using a digital input controlled stop This is a category 2 stop according to IEC 60204 gt p 51 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 See the AKD User Guide for information on configuring Digital Inputs Standard Operation Dinx mode 13 24V Digital Input x Power Stage enable l controlled Motor Speed CS VTHRESH If velocity drops below threshold CS VTHRESH or timeout occurs brake is applied gt p 92 6 15 2 3 Switch off behavior using HW Enable input uncontrolled stop This is a category 0 stop according to IEC 60204 gt p 51 The hardware enable input disables the power stag
62. d data Switch off behavior for faults that cause dynamic braking This is a category 0 stop according to IEC 60204 gt p 51 Standard Operation F418 example Feedback power 24V F418 example t I FAULT Relay t l l DC Bus t l Power Stage l enable t I STO t l ENABLE extern t uncontrolled I Motor Speed Dynamic braking Motor Holding Brake t If velocity drops below threshold CS VTHRESH or timeout occurs brake is applied gt p 92 Kollmorgen April 2011 49 AKD Installation 6 Technical description and data Switch off behavior for faults that cause a controlled stop This is a category 1 stop according to IEC 60204 gt p 51 Standard Operation F306 Example Brake short circuit controlled stop 24V F306 example FAULT Relay t DC Bus Power Stage enable t l l STO t l ENABLE extern t l Motor Speed 1 CS VTHRESH t l Dynamic braking Motor Holding Brake t If velocity drops below threshold CS VTHRESH or timeout occurs brake is applied gt p 92 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 16 Stop Emergency Stop Standards With the personnel safe approved restart lock STO gt p 53 the drive can be secured on standstill torque free using its internal electronics so that even when power is being supplied the drive shaft is
63. d for 120V networks to get a minimum voltage of 240 V 41096 aa a a a a a a nr a a a a a a a a aa a a a a an a a a a a a a aan an am CH Presently the AKD xzzz07 models only support operation at levels above 270 Vac Updates to the AKD firm ware are in process to allow the operation of the AKD xzzz07 models drives at 240Vac 84 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 12 3 24 V Auxiliary Supply X1 The following diagram describes extemal 24 Vdc power supply electrically isolated for example via an isolating transformer The required current rating depends on the use of motor brake and option card gt p 34 or following Pin Signal Description 24 Vdc Auxiliary voltage 24V Supply GND STO enable Safe Torque Off Kollmorgen April 2011 85 86 AKD Installation 8 Electrical Installation 8 12 4 Mains Supply Connection X3 X4 8 12 4 1 Three Phase connection all AKD types e Directly to 3 phase supply network supply networks gt p 83 e Filtering for AKD xzzz06 to be provided by the user e Fusing such as fusible cut outs to be provided by the user gt p 37 ee Oo PE AKD x00306 to AKD x00606 X3 Pin Signal DE on a oa net Cs mz Cg liseg Id 1 Z1 LI dM OO gy AKD x01206 X3 Pin Signal Description Ce Bles Ce Pe Protective Earth D w 2 p 9 O a D Lex rc N w ae m g e e
64. d the output stage to be switched off if the FAULT contact is open the output stage is inhibited gt no power output List of the fault messages gt p 133 Wiring diagram control Emergency Stop Circuit Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 17 Service Interface X11 Operating position control and motion block parameters can be set up by using the setup software on an ordi nary commercial PC Hardware requirements gt p 128 Connect the service interface X11 of the drive to an Ethernet interface on the PC directly or via a network hub switch while the supply to the equipment is switched off Use standard Cat 5 Ethernet cables for either connection configuration but note that in most cases crossover cables will also work Confirm that the link LED on the AKD the green LED on the RJ45 connector and on your PC or network Hub Switch are both illuminated If both lights are illuminated then you have a good electrical connection 8 17 1 Possible Network Configurations Kollmorgen April 2011 117 118 AKD Installation 8 Electrical Installation 8 17 2 Setting the IP Address with Rotary Switches You can use the fieldbus to select the IP address value or IP address mode for accessing the drive over the serv ice interface For CANopen and some other fieldbuses the rotary switches also set the node address of the drive for that specific network
65. d wait until the voltage is below 40 V before touching or handling the drive 2 Remove the connectors Disconnect the potential earth connection last 3 Check temperature A CAUTION During operation the heat sink of the drive may reach temperatures above 80 C 176 F Before touching the device check the temperature and wait until it has cooled below 40 C 104 F 4 Uninstall Remove the drive and power supply from the conductive grounded mounting plate in the cab inet 4 6 Repair and Disposal Only the manufacturer can repair the drive Opening the device voids the warranty Uninstall the drive as described in Uninstalling gt p 26 and send it in the original packaging to the manufacturer see table below In accordance with the WEEE 2002 96 EC Guidelines and similar the manufacturer accepts returns of old devices and accessories for professional disposal Transport costs are the responsibility of the sender Send the devices to the manufacturer addresses shown in the table below Kollmorgen KOLLMORGEN Europe 201 West Rock Road GmbH Radford VA 24141 Pempelfurtstr 1 D 40880 Ratingen Kollmorgen April 2011 AKD Installation 5 Package 5 Package 5 1 Package Supplied SG SG cece cece eee e cece cece c cece eeeeeeeeeeeveeeesseeeeeees 28 52 Nameplal EE ee ae a ase RE bc cde at ghee mses a AE ceeds wees been ee heehee Leena hate 28 5 3 Part number scheme 29 Kollmorgen Apri
66. e and Shake Loop The angle between complete loops was Modify WS IMAX or WS T and n479 angle delta too large larger than 72 deg try again F480 F481 F482 Commutation not initialized The motor requires the commutation sequence has been performed F483 Motor U phase missing F484 Motor V phase missing F485 Motor W phase missing F501 Bus over voltage n501 Fieldbus command velocity Fieldbus command velocity exceeds initialization there are no encoder com mutation tracks Hall sensors etc and no successful Wake and Shake try again Increase WS VTHRESH value or reduce WS IMAX or WS T Lower fieldbus command tra jectory or increase the value of VL LIMITP Increase fieldbus command tra jectory or decrease the value of VL LIMITN Clear any faults activate the Wake and Shake procedure WS ARM and enable the drive No current was detected in the motor s U Check the motor connections phase during initialization Mode 0 only and WS IMAX very low current may produce this error No current was detected in the motor s V Check the motor connections phase during initialization Mode 0 only No current was detected in the motor s W phase during initialization Mode 0 only Bus voltage too high Usually this prob lem is load related and WS IMAX very low current may produce this error Check the motor connections and WS IMAX very low current may produce this error Reduce load o
67. e cosine encoder with EnDat 2 1 interface as a feedback system Preferred types are the ECN1313 and EQN 1325 encoders The thermal control in the motor is connected via the encoder cable and evaluated in the drive All signals are connected using our pre assembled encoder connection cable If cable lengths of more than 50 m are planned consult customer support FBTYPE Freguency Limit ENDAT 2 1 The pin assignment shown on the encoder side relates to Kollmorgen motors Encoder EnDat 2 1 5V 4 5 max 350mA min 5VDC 5mA 98 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 14 6 Encoder with EnDat 2 2 The table and figure below describe wiring of a single tum or multi tum encoder with EnDat 2 2 interface as a feedback system Preferred types are the ECN 1313 and EQN 1325 encoders The thermal control in the motor is connected via the encoder cable and evaluated in the drive All signals are con nected using our pre assembled encoder connection cable If cable lengths of more than 50 m are planned please consult customer support FBTYPE Frequency Limit ENDAT 2 2 Adjust on screen page FEEDBACK The pin assignment shown on the encoder side relates to Kollmorgen motors Encoder EnDat 2 2 5V 5 max 350mA Kollmorgen April 2011 99 AKD Installation 8 Electrical Installation 8 14 7 Sine Encoder with Hiperface The diagram below shows the wiring of a single turn o
68. e immediately Standard Operation Disable 24V HW Enable X8 4 Power Stage enable uncontrolled Motor Speed CS VTHRESH If velocity drops below threshold CS VTHRESH or timeout occurs brake is applied gt p 92 Kollmorgen April 2011 47 AKD Installation 6 Technical description and data 6 15 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 DRV DISMODE VBUS UVFTHRESH CS VTHRESH and others see the AKD User Guide or WorkBench help for more details See the Drive Fault and Warning Messages and Remedies section of the AKD User Guide for a table describing the specific behavior of each fault The follwing pages show examples for the possible fault behaviors Switch off behavior for faults that cause an immediate power stage disable This is a category 0 stop according to IEC 60204 gt p 51 Standard Operation F301 example Motor overheat Power stage disable 24V F301 example FAULT Relay t Turned off via Main ar mains contactor fault relay DC Bus i t l Power Stage enable t l l STO i t l ENABLE extern t uncontrolled Motor Speed Motor Holding Brake If velocity drops below threshold CS VTHRESH or timeout occurs brake is applied gt p 92 Kollmorgen April 2011 AKD Installation 6 Technical description an
69. e input STO must be connected directly with 24 V The function is then bypassed and cannot be used If the STO function is in use then the input STO must be con nected to the exit of a security control or a safety relay which at least meets the requirements of PLd CAT 3 according to ISO 13849 connection diagram gt p 56 Possible states of the drive referring to STO function STO ENABLE Display Motor has Torque Safety SIL 2 F602 24 v 24V Jopmode with dot When STO function is engaged during operation by separating input STO from 24 V the motor slows down with out control and the drive displays the fault F602 It is not possible to perform a controlled brake if the drive STO Enable is off If con trolled braking before the use of the STO function is necessary the drive must be braked and the input STO must be separated from 24 V time delayed The STO function does not provide an electrical separation from the power output If access to the motor power terminals is necessary the drive must be dis connected from mains supply considering the discharging time of the intermediate circuit There is a danger of electrical shock and personnel injury Sincethe STOfunctionis a single channel system erroneous engaging will not berecognized Whenwiring theinput STOwithin oneenclosure thecables andthe enclosure must meetthe requirements of IEC 60204 1 If you arewiring leads outside thespecified enclosure thenthe cables must bel
70. e voltage is below 40 V before handling components Incorrect handling of the drive can lead to personnel injury or material damage Read this doc umentation before installing and commissioning the drive It is vital that you keep to the tech nical data and information on connection requirements nameplate and documentation Only properly qualified personnel may perform activities such as transport installation com missioning and maintenance Properly qualified persons are those who are familiar with the transport assembly installation commissioning and operation of the product and who have the appropriate qualifications for their job The qualified personnel must know and observe the following standards e IEC 60364 and IEC 60664 e national accident prevention regulations The manufacturer of the machine must produce a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements do not result in personnel injury or material damage It is not allowed to modify this device without permission by the manufacturer Alej H Check the Hardware Revision Number of the product see product label This revision number must match the Hardware Revision Number on the cover page of the manual lone The drives contain electrostatically sensitive components which may be damaged by incor rect handling Electrostatically discharge your body before touching the drive Avoid contact with highly insulating materials
71. eedback type If the motor has Biss Analog Endat or SFD feedback feedback with memory then these parameters are set auto matically when MOTOR A UTOSET is set to 1 TRUE F534 Failed to read motor param Motor either does not have motor feed Try to read parameters again by eters from feedback device back memory or the motor feedback clicking the Disable and Clear memory is not programmed properly so Faults button or by issuing the the parameters cannot be read DRV CLRFAULTS command If this attempt is not successful then set MOTOR AUTOSET to 0 false and program the param eters using the setup wizard or manually set up the parameters If the motor has motor memory Biss Analog Endat and SFD motors have motor memory return the motor to have the memory programmed F602 Safe torque off Safe torque off function has been trig Reapply supply voltage to STO gered if safe to do so F701 Fieldbus runtime Runtime communication fault Check fieldbus connections X11 settings and control unit F702 Fieldbus communication All fieldbus communication was lost Check fieldbus connections n702 lost X11 settings and control unit occurred while axis should stop parameters improve tun F703 Emergency timeout Motor did not stop in the timeout defined Change timeout value change disable ing 142 Kollmorgen April 2011 9 5 Troubleshooting the AKD Drive problems occur for a variety
72. eees 117 8 17 1 Possible Network Configurations cece cece cece Ge ie 117 8 17 2 Setting the IP Address with Rotary Switches cece cece eee e cece cece eee ees 118 8 18 CANbus Interface X12X13 EG GE GE ee 119 8 18 1 BaudrateiorCANbus 120 8 18 2 Node Address for CANbus 121 8 18 3 CANbus Termination EE EE GE GE ie 121 8 18 4 CANbus Cahier 121 8 18 5 CANbus Wimg cece cece e cece eeeeeeeeeeeeeeeseeeeeeeeees 122 8 19 Motion Bus Interface X5 X6 cc ccc cece cece cece aa naonnana 123 8 19 1 Pinout X5 X6 aaa 123 8 19 2 Optional Motion Bus Protocols 2 22 2 02222 c cece cece cece EE Gee 123 8 19 3 EherCAT maimam ma imiim iwa 124 8 19 4 SyngNet in porocess mwm nm eee ceeeeeeeeeeceeceeeeeeeees 124 6 Kollmorgen April 2011 AKD Installation Table of Contents 8 19 5 Motion Busses in Process 22 22 222222 e ec cc cece cece ccc cece ee mama mamaa mamae laaa 124 8 19 5 1 PROFINET CBA RT IRT in process 2 0 0 2 02220 cece cece cece ccc cceceeeeeeeceeeeees 124 8 19 5 2 SERCOS Ill in process SG cece cece cece cece cece ec Gee 124 8 19 5 3 Ethernet IP A B IN process cece cece ccc cece Gee 124 8 19 5 4 Powerlink nprocessl ESEG cece cece Gee 124 8 19 5 5 Modbus TCP IP in process 2 0 00 22 cece eee cece cece cece cece cece cece ceeeeeceeeeeeees 124 O SelUp ee en See e ng EE AE DE ed ni Pap eee 125 9 1 Safety Instructions mwm wm wamama wan wa nw wama w waw m nwa umama n m
73. eparated time delayed from 24 V A CAUTION The STO function does not provide an electrical separation from the power output If access to the motor power terminals is necessary the drive must be dis connected from mains supply considering the discharging time of the intermediate circuit There is a danger of electrical shock and personnel injury feysle Use the following functional sequence when the STO function is used 1 Brake the drive in a controlled manner speed setpoint 0 V 2 When speed 0 rpm disable the drive enable 0 V 3 If a suspended load is present block the drive mechanically 4 Activate the STO function 6 17 5 Technical data and pinning STO STO enable Safe Torque Off 6 17 6 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 6 17 7 Wiring If you are wiring leads that are outside the specified enclosure IP54 the cables must be laid durably firmly pro tected from outside damage for example by laying the cable in a duct placed in different sheathed cables or protected individually by grounding connection Wiring remaining within the specified enclosure must meet the requirements of the standard IEC 60204 1 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 17 8 Functional description When STO function Safe Torque Off is not needed then th
74. er Z1C Vaga Wepayim P C E 3019 Petach Tikva 49130 israel Tel S72 3 9273200 www danahermotiorcom 22 Kollmorgen April 2011 AKD Installation 3 Approvals 3 3 Safe Torque Off STO An additional digital input STO releases the power output stage of the drive as long as a 24 V signal is applied to this input If the STO input goes open circuit then power will no longer be supplied to the motor and the drive will lose all torque and coast to a stop The STO safety concept is certified by the IFA Institut f r Arbeitsschutz der Deutschen Gesetzlichen Unfall versicherung The safety circuit concept for realizing the safety function Safe Torque Off in the drive is suited for SIL 2 according to EN 61800 5 2 and PL d CAT 3 according to ISO 13849 1 The subsystems AKD drives are totally described for safety technics with the characteristic data Operation Mode EN 13849 1 EN 62061 PFH 1 h IS STO STO single channel PL d CAT 3 SIL2 0 20 Kollmorgen April 2011 23 24 AKD Installation 4 Handling 4 Handling 4 1 4 2 4 3 4 4 4 5 4 6 MANS OOK ace AE EA DE ee tre ee re AD DE Ee ot ata at 25 SET Ee UU oi sare ene BAN EE a TRA dene ce RB Ba An a aa aces 25 SO AC ER a a aa te es ee ees 25 Maintenance and Cleaning 2 22000 0 cece ccc cc cece cece cece cece cece ceeeeeeeeeeeeeeeesees 26 Uninstalling e cece cece eee eeeeeeeeceececsecceseceeeeees 26
75. ers set too high Kp speed controller too high Ki speed controller too high filters set too low MSI installer issue AKD Installation 9 Setup plug cable into the correct sockets on the drive and PC select correct interface apply ENABLE signal set software enable check setpoint cable correct motor phase sequence check brake control check mechanism set motor pole no set up feedback correctly reduce VL KP speed controller replace feedback cable join AGND to CNC GND verify motor drive sizing verify that IL LIMITN IL LIMITP VL LIMITN or VL LIMITP is not limiting the drive reduce DRV ACC DRV DEC verify motor drive sizing verify motor continuous and peak current values are set correctly increase VL KP speed controller increase VL KI speed controller refer to documentation regarding reducing fil tering VL AR feduce VL KP speed controller reduce VL KI speed controller refer to documentation regarding increasing fil tering VL AR Cancel the installation Make sure that you have enough disk space on your hard disk 500MB to allow Windows NET update if necessary if not make some space Relaunch the installer you may need to try sev eral times the problem is random Kollmorgen April 2011 143 AKD Installation 10 Option Cards 10 Option Cards Option cards will
76. es Includes all five IEC 61131 languages PLC Open and Pipes Network Power section e One or three phase supply voltage range 120 to 480 V 10 50 to 400 Hz 5 or DC e Connection to higher voltage mains only via isolating transformer gt p 84 e B6 bridge rectifier integral soft start circuit e Single phase supply possible with output power derating e Fusing to be provided by the user e Shielding star point close to the drive e DC bus link voltage range 170 to 680 Vdc can be connected in parallel e Output stage IGBT module with floating current measurement e Regen circuit with dynamic distribution of the generated power between several drives on the same DC bus link circuit e Internal regen resistor for all 240 480 Vac AKD xzzz07 models only 120 240 Vac 3 A and 6 A AKD xzzz06 models lack internal regen resistors external regen resistors if required Kollmorgen April 2011 31 32 AKD Installation 6 Technical description and data Integrated safety e Appropriate insulation creepage distances and electrical isolation for safe electrical separation per IEC 61800 5 1 between the power input motor connections and the signal electronics e Soft start overvoltage detection short circuit protection phase failure monitoring e Temperature monitoring of the drive and motor e Motor overload protection foldback mechanism e SIL2 safe torque off in accordance with IEC 61508 gt p 53 e Optional safe
77. ets of data that have been stored on data media are not safe against unintended alteration by other persons Unexpected move could be the result if you use unchecked data After loading a set of data you must therefore always check all parameters before enabling the drive Kollmorgen April 2011 127 AKD Installation 9 Setup 9 2 2 Software description Each drive must be adapted to the requirements of your machine For most applications you can use a PC and WorkBench the drive setup software to set up the operating conditions and parameters for your drive The PC is connected to the drive by an Ethernet cable gt p 117 The setup software provides the communication between the PC and AKD You can find the setup software on the accompanying CD ROM and in the download area of the Kollmorgen website With very little effort you can alter parameters and instantly observe the effect on the drive since there is a con tinuous online connection to the drive You can also read important actual values from the drive which are dis played on the monitor of the PC oscilloscope functions You can save sets of data on data media archiving and load them them into other drives or use them for backup You can also print out the data sets Moststandard feedbacks SFD EnDAT 2 2 2 1 and BiSS are plugand play compatible Motor nameplatedata is storedin thefeedback deviceand readby thedrive automatically at startup Non plugand play
78. everal cases contact technical support according to flowchart including incom patible image to FPGA type and fieldbus type Operational FPGA failed Software failure detected Load oper Restart drive If issue persists ational FPGA failure occurred several contact technical support cases according to flowchart F105 NV memory stamp invalid NV memory stamp is corrupted or Reset the drive to default mem invalid ory values using Parameter Load in WorkBench F106 NV memory data might NV memory data is corrupted or invalid Reset the drive to default mem occur when downloading When this fault occurs after a firmware ory values using Parameter firmware download it is not an indication of a prob Load in WorkBench lem clear the fault and perform a save to the drive F107 Positive switch limit Positive software position limit is Move the load away from the lim n107 exceeded exceeded its F108 Negative switch limit Negative software position limit is Move the load away from the lim n108 exceeded exceeded its F121 Homing error Drive did not finish homing sequence Check homing sensor Kollmorgen April 2011 133 AKD Installation 9 Setup Fault Message Warning F123 Invalid motion task Invalid motion task Check motion task settings and n123 parameters to make sure that the values entered will produce a valid motion task Refer to the motion task documentation for addi
79. evice Two feedback devices can be used at the same time and all feedbacks are connected to X10 Feedback functions are assigned with parameters in WorkBench the setup software Scaling and other settings are also performed in WorkBench For a detailed description of the parameters please refer to the WorkBench online help The table below provides an overview of the supported feedback types their corresponding parameters and a ref erence to the relevant connection diagram in each case Feedback Types Wiring Connector FBTYPE Kollmorgen April 2011 93 94 AKD Installation 8 Electrical Installation 8 14 1 Feedback Connector X10 SE EE 22 face Hall Hall E E Hall U CH 2 CLOCK CLOCK CLOCK Halv Hall V EE EIERE EE Hall W 4 SENSE _ SENSE SENSE SENSE SENSE SENSE SENSE 5 SENSE _ SENSE SENSE SENSE SENSE SENSE o cous Ierger DATA DATA DATA DATA Zero Zero Zero ret Themalconmprg II Bl Thermal control PTC GND 5 Kollmorgen April 2011 BiSS EnDAT EnDAT Hiper Sine Encoder Incremental Encoder AKD Installation 8 Electrical Installation 8 14 2 Resolver The diagram below shows the connection of a resolver 2 to 36 poles as a feedback system The thermal control in the motor is connected via the resolver cable and evaluated in the drive If cable lengths of more than 100 m are planned please contact customer support Accuracy
80. extended since the shielding would be interrupted and the signal processing may be disturbed Install all feedback cables with an adequate cross section per IEC 60204 gt p 39 and use the requested cable material to reach maximum cable length Splice cables properly If you need to divide cables use connectors with metal backshells Ensure that both shells connect along the full 360 of the shields No portion of the cabling should be unshielded Never divide a cable across a terminal stripe Use differential inputs for analog signals Noise susceptibility in analog signals is greatly reduced by using differential inputs Use twisted pair shielded signal lines connecting shields on both ends Lines between drives and filters and external regen resistor must be shielded Install all power cables with an adequate cross section as per IEC 60204 gt p 39 and use the requested cable material to reach maximum cable length Kollmorgen April 2011 79 AKD Installation 8 Electrical Installation 8 11 2 Shielding with External Shielding Busbar EMC filtering must be done externally by the user if necessary which requires the use of shielded cables Kol Imorgen recommends a star point shield connection for example with a shielding busbar 8 11 2 1 Shielding Concept as short as possible Shielding busbar Ie Drive cut out 24 Vdc Regen resistor Power Supply optional
81. function must signal its status to the control logic A reset of the stop function must not create a hazardous situation Kollmorgen April 2011 51 AKD Installation 6 Technical description and data 6 16 2 Emergency Stop Standards The emergency stop function is used for the fastest possible shutdown of the machine in a dangerous situation The emergency stop function can be triggered by the actions of a single person It must be fully functional and available at all times The user must understand instantly how to operate this mechanism without consulting ref erences or instructions The emergency stop function is defined by IEC 60204 In addition to the requirements for stop the emergency stop must fulfil the following requirements e Emergency stop must have priority over all other functions and controls in all operating situations e The energy supply to any drive machinery that could cause dangerous situations must be switched off as fast as possible without causing any further hazards such as by using mechanical latching devices that do not require an external supply of energy or by counter current braking in Stop Category 1 e The reset must not initiate a restart If necessary provision must be made for the additional connection of emergency stop devices see IEC 60204 Requirements for emergency stop devices The emergency stop must be effective as a stop of either Cat egory Dor Category 1 The emergency stop categ
82. g 76 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 9 Connection Diagram AKD x01206 AKD x01206 Control 424V referred to 1 0 GND Reference Safety Instructions and Use As Directed thermal control included DCOM7 1 0 GND DIGITAL IN7 Feedback lt w DIGITAL IN4 DIGITAL INS DIGITAL OUT2 DIGITAL OUT2 DIGITAL OUT1 DIGITAL OUT1 Ref Point DIGITAL IN2 o o fo Jo FN Jo Ju ts wh Home Switch DIGITAL INT 0 eh X8 pm Remove jumper if Fault external regen resistor is connected Emergency Stop Circuit DCOM8 1 0 GND Bb FG IN ENABLE o NSTOP DIGITAL ING em DIGITAL INS o 24V referred u o to 1 0 GND AGND a ry ad Analog Out 0 10V Analog in L d 1 10V speed Analog In 1G i MLL refered to X5 8 Participant Motion Bus In X6 a Motion Bus Out Participant ma 3 CAN CAN In Participant aa 3 CAN baha Participant e Encoder 3 Encoder Emulation Evaluation x1 3 Service TCP IP D PE connection protective earth A chassis ground connection panel Q see connection via plug GC D Li L2 L3 gei Kollmorgen April 2011 77 AKD Installation 8 Electrical Installation 8 10 Connection Diagram AKD x02406 and AKD xzzz07 Reference Safety Instructions Control and Use As Directed Feedback AKD x02406 AKD xxxx07 X10
83. gh external fusing will endanger cables and devices The fusing of the AC supply input and 24 V supply must be installed by the user best values gt p 37 Hints for use of Residual current circuit breakers RCD gt p 58 iekgie The drive status must be monitored by the PLC to acknowledge critical situations Wire the FAULT contact in series into the emergency stop circuit of the installation The emergency stop circuit must operate the supply contactor NOTE It is permissible to use the setup software to alter the settings of the drive Any other alterations will invalidate the warranty Kollmorgen April 2011 69 AKD Installation 8 Electrical Installation 8 2 Guide to electrical installation Install the drive electrical system as follows 1 Select cables in accordance with IEC 60204 gt p 39 2 Install shielding and ground the drive For EMC compliant shielding and grounding gt p 79 EMI Noise Reduction gt p 79 amp Connection Diagram AKD x00306 to x00606 gt p 76 and following Ground the mounting plate motor housing and CNC GND of the control system 3 Wire the drive and connectors Observe the Recommendations for EMI noise reduction gt p 79 Wire the FAULT contact in series into the emergency stop circuit of the system Connect the digital control inputs and outputs Connect up analog ground also if fieldbuses are used Connect the analog input source if required Con
84. his reason the leakage current cannot be measured using a con ventional multimeter As a rule of thumb the following assumption can be made for leakage current on our low capacity cables at a mains voltage of 400 V depending on the clock frequency of the output stage lsak n x20 mA L x1 mA m at 8 kHz clock frequency at the output stage lisa n x20 mA L x 2 mA m ata 16 kHz clock frequency at the output stage where Ileak leakage current n number of drives L length of motor cable At other mains voltage ratings the leakage current varies in proportion to the voltage Example 2 x drives a 25m motor cable at a clock frequency of 8 kHz 2x 20 mA 25 m x 1 mA m 65 mA leakage current NOTE Since the leakage current to PE is more than 3 5 mA in compliance with IEC61800 5 1 the PE connection must either be doubled or a connecting cable with a cross sec tion gt 10 mm must be used Use the PE terminal and the PE connection screws in order to fulfill this requirement The following measures can be used to minimize leakage currents e Reduce the length of the engine cable e Uselow capacity cables gt p 39 6 18 2 Residual Current Protective Device RCD In conformity with IEC 60364 4 41 Regulations for installation and IEC 60204 Electrical equipment of machin ery residual current protective devices RCDs can be used provided the requisite regulations are complied with The AKD is a 3 phase system with a B6 bridge
85. ided shield Push the shield clamp up and route the cable to it Via the busbar TEE Make sure there is good con tact between the shield clamp and the braided shield Kollmorgen April 2011 81 AKD Installation 8 Electrical Installation 8 11 3 Shielding Connection to the Drive You can connect cable shielding directly to the drive by using grounding plates shield connection clamps and a motor connector with strain relief and grounding plate 8 11 3 1 Grounding Plates Mount the grounding plates to the drive as shown in the photos below AKD x0306 to x1206 types AKD x02406 amp zzz07 types L shape grounding plate EU only flat grounding plate 8 11 3 2 Shield connection clamps Use shield connection clamps see accessories manual These hook into the grounding plate and ensure optimum contact between the shield and the grounding plate Kollmorgen recommends using Phoenix Contact SK14 shield clamps with clamp range of 6 13mm de 8 11 3 3 Motor Connector X2 with shielding connection Alternative connection for the motor power connection by mating connector with strain relief Strip the extemal cable sheath to a length of approx 120 mm taking care not to damage the braided shield Push the braided shield 1 back over the cable and secure with a rubber sleeve 2 or shrink sleeve Shorten all the wires apart from the protective earth PE wire green yellow by about 20 mm so that the PE wire is no
86. ing brake internal digital ground encoder emulation output service channel Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 14 Dynamic Braking Dynamic braking is a method to slow down a servo system by dissipating the mechanical energy driven by the motor back EMF The AKD has a built in advanced patent pending dynamic braking mode which operates fully in hardware When activated the drive shorts the motor terminals in phase with the back EMF q axis but con tinues to operate the non force producing current loop d axis with 0 current This forces all of the dynamic brak ing current to be stopping current and insures the fastest stopping amp of motor terminal current e When current is not being limited the mechanical energy is being dissipated in the motor resistance e When current is being limited energy is retumed to the drive bus capacitors e The drive also limits the maximum dynamic braking motor terminal current via the DRV DBILIMIT param eter to insure that the drive motor and customer load do not see excessive currents forces Whether and how the AKD uses dynamic braking depends on the disable mode DRV DISMODE 6 14 1 Regen Circuit When the amount of retumed energy builds the bus capacitor voltage up enough the drive activates the regen cir cuit to start dumping the returned energy in the regen resistor also called regenerative or braker resistor This resistor could be inte
87. ip the power stage of the drive or fault relay output The left side of the LED displays F for a fault or n for a warning The right side displays the fault or warning number as follows 1 0 1 break The highest priority fault is displayed on the LED Multiple faults may be present when a fault condition is occurring Check the AKDWorkBench Fault Screen or read the status of DRV FAULTS through the controller or HMI for the entire list of faults NOTE More information about fault messages and clearing faults can be found in the WorkBench online help Procedures for clearing faults are described in the online help topic entitled Faults and Warnings Fault Message Warning Cause Remedy Fo Reserved F101 FPGA type mismatch Installed firmware is not compatible with Load compatible firmware into the drive hardware the drive n101 The FPGA is a lab FPGA The FPGA is a lab version FPGA Load the released FPGA version that is compatible with the oper ational firmware F102 Resident firmware failed Software failure detected Restart drive If issue persists contact technical support n102 Operational FPGA is nota The FPGA minor version is larger than Load the released FPGA version default FPGA the operational firmware default FPGA What is compatible with the oper minor version ational firmware F103 Resident FPGA failed Software failure detected Load resident Restart drive If issue persists FPGA failure occurred s
88. irec tives must be applied to the machine plant Kollmorgen only guarantees the conformance of the servosystem with the standards cited in this chapter if the components motor cables chokes etc are those supplied by Kollmorgen Kollmorgen April 2011 21 AKD Installation 3 Approvals 3 2 2 EC Declaration of Conformity KOLLMORGEN F EC DECLARATION OF CONFORMITY We the company Kolimorgen Hereby in sole responsibility declare the conformity of the product series AKD Advanced Kollmorgen Drive models AKD X 003 06 XX YY ZZZ AKD X 003 07 XX YY ZZZ AKD X 006 06 XX YY ZZZ AKD X 006 07 XX YY ZZZ AKD X 012 06 XX YY ZZZ AKD X 012 07 XX YY ZZZ AKD X 024 06 XX YY ZZZ AKD X 024 D7 XX YY ZZZ With the following standards EC Directive 2004 108 EC Electromagnetic Compatibility Standard EN 61800 3 2004 LVD Directive 2006 95 EC Electrical Safety Low voltage directive Standard IEC 61800 5 1 2007 This Declaration does not contain any assurance of properties in the meaning of product liability The notes on safety and protection in the operating instructions must always be observed The above mentioned company has the following technical documentation for examination Proper operating instructions Setup Software Test certificates for EU authority only Other technical documentation for EU authority only Signed ME Alex Matskin November 17 2009 Title Validation and compliance team lead
89. irectly beside the drive Strong magnetic fields can directly affect internal components Install devices which produce magnetic field with distance to the drives and or shield the magnetic fields 7 2 Guide to Mechanical Installation Thefollowingtools arerequired ataminimum toinstall the AKD yourspecificinstallationmay require additionaltools e M4 hexagon socket cap screws ISO 4762 e 3mm T handle Allen key e No 2 Phillips head screwdriver e Small slotted screwdriver Install the drive unit as follows 1 Prepare the site Mount the drive in a closed control cabinet gt p 33 The site must be free from conductive or corrosive materials For the mounting position in the cabinet gt p 61 respectively gt p 62 2 Check ventilation Check that the ventilation of the drive is unimpeded and keep within the permitted ambient temperature gt p 33 Keep the required space clearance above and below the drive gt p 61 respectively gt p 62 3 Check cooling system If cooling systems are used for the control cabinet position the cooling system so that condensation water cannot drip onto the drive or peripheral devices 4 Mount the drive Assemble the drive and power supply near each other on the conductive grounded mounting plate in the cabinet 5 Ground the drive For EMC compliant shielding and grounding gt p 79 Ground the mounting plate motor housing and CNC GND of the control system 60 Kollmorgen
90. is homed Axis must be homed before motion task can start F136 FPGA version mismatch The FPGA version does not match the Load the FPGA version that is Firmware and FPGA ver firmware FPGA version constants compatible with the firmware sions are not compatible n137 Homing and feedback mis The configured homing mode is not sup Change homing mode match ported by the motor feedback type used 134 Kollmorgen April 2011 Fault n Message Warning Instability during autotune Not enough distance to move motion exception Not enough distance to move following motion exception Velocity limit violation exceeding max limit Drive current IL CMD or velocity feed back VL FB exceeds allowable limit BODE IFLIMIT or BODE VFLIMIT This fault only occurs in BODE MODE 5 which uses a stability checking algo rithm This fault often occurs when com plex mechanics belts and compliant loads are present which make accurate measurement hard to obtain with the PST settings For trapezoidal and customer table motion tasks The target velocity spec ified in the motion task cannot be reached via using the selected accel eration and deceleration since the dis tance to travel is not sufficient Fora 1 1 profile The selected accel eration and deceleration will be extended since there is too much distance to travel and the motion task would exceed its maximum allowed velocity Refer also to the app
91. ivity Option EhoCAT Kano SynaNet X5 X6 Base housing in process ano aa Kollmorgen April 2011 123 124 AKD Installation 8 Electrical Installation 8 19 3 EtherCAT You can connect to the EtherCAT network via RJ 45 connectors X5 in port and X6 out port The com munication status is indicated by the built in LEDs Connector LED IN Fela ale Function X5 LED1 IN port Link ON active OFF not active LED2 RUN ON running OFF not running X6 LED3 OUT port Link ON active OFF not active EK 8 19 4 SyngNet in process You can connect to the SynqNet Network via RJ 45 connectors X5 in port and X6 out port The communication status is indicated by the built in LEDs Connector LED Name Function X5 LED1 LINK IN ON receive valid IN port OFF not valid power off or reset LED2 CYCLIC ON network cyclic BLINK network not cyclic OFF power off or reset O ee LINK_OUT ON receive valid OUT port OFF not valid power off or reset isi REPEATER ON repeater on network cyclic BLINK repeater on network not cyclic OFF repeater off power off or reset 8 19 5 Motion Busses in Process 8 19 5 1 PROFINET CBA RT IRT in process 8 19 5 2 SERCOS III in process 8 19 5 3 Ethernet IP A B in process 8 19 5 4 Powerlink in process 8 19 5 5 Modbus TCP IP in process Kollmorgen April 2011 AKD Installation 9 Setup 9 Setup 9 1 Safety Instructions 22 GE
92. k regen power intemal resistor 055 KW 17 Exemalregenresster i om S Maximum continuous regen power extemalresistor KW 3 Absorption regen power extemal resistors KW s4 Storeable energy in capacitors 7 20 ws o s AKD x02406 Imtemal regen ressor poAmp gt Continuous power infemalresister w Peak regen power ntemalresistor 05 w 2 Etemel regen resistor i fom S Maximum continuous regen power extemalresistor KW 6 Peak regen power atema resistors JW 8 Absorption energy in capacitors 20 ws oro depends on connected regen resistor power ed data i 33 4 sorption energy in capacitors 20 i 40 i 33 f 5 i 4 S S Z i AKD x01206 h Continuous power intemalresistor w w 5 stor 0 55 i 33 A E 3 sorption regen power external resistor 1s A f F 00 ui i 22 i 15 i orption energy in capacitors 20 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 14 1 3 Technical Data for AKD xzzz07 Brake circuit Supply voltage Type Rated data Units 240V 400 V 480 V AKD xzzz07 Switch on threshold of regen circuit all types Switch off threshold of regen circuit Maximum regen duty cycle Type Rated data Units 240 V 400 V 480V AKD x00307 0 HERE o w w o CO N N 0 77 oa Peak regen power extemal 1s kw 21 4 2076 AKD x00607 Internal regen resistor Continuous power internal resistor Pe
93. l 2011 27 AKD Installation 5 Package 5 1 Package Supplied When a drive from the AKD series is ordered gt p 145 the following items are included in the drive package e AKD e Printed copy of AKD Installation Manual EU only e Printed copy of AKD Quick Start e Printed copy of fault and waring card e CD ROM containing the setup software WorkBench and all product documentation in digital format e Mating connectors X1 X2 X3 X4 if required X7 and X8 e Grounding plate with AKD voltage type 07 with voltage type 06 for EU only NOTE The mating SubD and RJ45 connectors are not included in the package Accessories Sold Separately Accessories must be ordered separately if required refer to your regional accessories manual e EMC filters for 24 V and mains supply voltage categories C2 or C3 e External regen resistor e Motor cable Assembled motor cables are available for all regions e Feedback cable Assembled feedback cables are available for all regions e Motor choke for motor cables longer than 25 m e CAN termination connector with CAN drives only e Service cable to the network e Power cable control cables and fieldbus cables as cutoff lengths 5 2 Nameplate The nameplate depicted below is attached to the side of the drive sample data entries are for a 12 A type KOLLMORGEN Customer Support North America 1 540 633 3400 ZOTW Rock Road Europe 49 0 20369790 Radford VA 24141 Italy 99 0
94. lication note about customer table motion tasks A new motion task activated when one motion task is already active and the tar get position specified in the motion task parameters cannot be reached with spec ified target velocity acceleration and deceleration parameters The motion AKD Installation 9 Setup Change BODE MODE if appro priate If BODE MODE 5 is appropriate and the fault occurs at the end of an Autotuning then the motor is not robustly stable You can manually adjust Auto tuner settings to increase FFT point resolution record points and current excitation Manual tuning may be required to make the motor stable Activation of any new motion will clear the warning DRV CLRFAULTS also can be used to clear warning Check motion task settings and param eters to make sure that the values entered will produce a valid motion task Refer to the motion task documentation for additional guidance on specific causes of invalid motion tasks Activation of any New Motion will clear the Waring DRV CLRFAULTS also can be used to clear Warning Check motion task settings and param eters to make sure that the task will directly decelerate to into the tarjvalues entered will produce a get position or ramps down to velocity 0 and start another move to reach target position of the next motion task A new target velocity calculated inter nally due to an exception and is being limited due to user velocity limit
95. ls Connectivity Options The drive models with connectivity option CC are fitted with both the EtherCAT X5 and X6 and CANopen X12 and X13 fieldbus connectors A software parameter DRV TYPE allows you to select what features the drive supports you cannot use EtherCAT and CANopen at the same time Kollmorgen April 2011 29 30 AKD Installation 6 Technical description and data 6 Technical description and data 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 6 18 The AKD Family of Digital Drtves 00000 eee ee cece e cece eeeees 31 Ambient Conditions Ventilation and Mounting Position 33 Mechanical Data 33 ld el Ee A3 Electrical Data Aksxszzsng EES GEES GEE GEE GEE GEE 34 Electrical Data AKD xzzZz07 SG eee ence Ge ee 35 Performance Data 36 Recommended tighteningtorgueSs 36 FUSING oe LEES AE AA ER face 37 COMMGCIONS tes tes et ee eS le RE AA 38 Cable and Wire Requirements 2 00 0000 00 0 0 cece cece cece ccceeeeeeeees 39 m i De L e mmama EG w www mwanamama mama w nuna 40 Grounding Systen ee 40 Dynamic Braking 0 2 22 000000 0 0 LA ccc cece cc ccccecccceececeeeeeeeeeeeeeeeeeeeeeeenes 41 Switch on and Switch off Behavior EES GESE GEGEE GEE eie 44 Stop Emergency Stop Standards
96. ls only support operation at levels above 270 Vac Updates to the AKD firm ware are in process to allow the operation of the AKD xzzz07 models drives at 240Vac 20 w max 20 Go s 3 3 3 3 os ee Oe I N N A Sal ECEE SSC as ujoj m e ez PEN OO Oo gt O O oO lt lt a Kollmorgen April 2011 35 36 AKD Installation 6 Technical description and data 6 7 Performance Data AKD xzzz06 AKDx AKDx AKDx AKDx 00306 00606 01206 02406 GEELEN Voltage rise speed dU dt kV us Performance Data Units Bandwidth of current controller kHz 2 5to4 Bandwidth of velocity controller scalable 0 to 1000 Oto800 Oto 600 Bandwidth of position controller scalable 1to 250 AKD xzzz07 AKDx AKDx AKDx AKDx 00307 00607 01207 02407 Switching frequency of output stage kHz 8 8 6 8 Votapenise speed duvet Wo 9g Bandwidth of curent controler khz 2504 203 Bandwidth of velocity controler Scalable Hz 010800 777 E Performance Data Units 6 8 Recommended tightening torques Tightening Torque Nm Connector AKD xO00306 to 00606 AKD x01206 AKD x02406 and AKD xzzz07 0 22 to 0 25 0 22 to 0 25 0 7 to 0 8 X2 0 5 to 0 6 0 7 to 0 8 0 7 to 0 8 OG 05t006 oswos Te Ca p ao o oO Oo o See Conformance with UL cUL gt p 18 for in Ibs values Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 9 Fusing US fuses Class J 600 Vac
97. merica 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 dis tributed by electronic means without the written permission of Kollmorgen Kollmorgen April 2011 2 AKD Installation Table of Contents Table of Contents 1 Genera 9 1 1 About this Manual 10 ka marger ND EE 10 1 3 Using the PDF Format aa 10 1 4 Abbreviations use 11 1 5 Symbols use 12 1 6 Standards Used as EE eich ene EE SE 13 AA n EE DE wa EP He ER Ge EE Ge EE GE 14 2 1 Safety Instructions ESE GE GE GE ei 15 2 2 Use as Directed amak geseet ER SESSE EE SEE ER EA ER Ge ee ER Ge Ee GE EE AE EG Ee DEE GE Ee 16 2 3 Prohibited se ti si an ieee ea SR SE ee GR eg EE 16 3 Approvals EE aa 17 3 1 Conformance with Uc 18 3 1 HL Manege dE EE Ee ER AA 18 3 2 CE Conformance SEG GEGEE eie 20 3 2 1 European Directives and Standards for the machine builder 21 3 2 2 EC Declaration of Conformity SG e cece eeeeeeeeeeeeees 22 3 3 Safe Torque Off STO EE 23 4 Handling ie EE a PE EE EE EE Ee 24 4 1 Transport GE GE Ge ee 25 4 2 Packaging EE EL ED EE De tn eee ies N EG AA es 25 4 3 Giorage aa 25 4 4 Maintenance and Cleaning SES SG cece cece cece cece mmama mmama eeeeeeeceeeeeeeeeeeeees 26 4 5 Uninmstallmg aa 26 4 6 Repair and Disposal
98. mission speed As a guide you can use the following values which Kollmorgen has measured however these values are not assured limits Cable data e Characteristic impedance 100 120 ohms e Cable capacitance max 60 nF km e Lead loop resistance 159 8 ohms km Cable length depending on the transmission rate Transmission Rate kBaud Maximum Cable Length m 1 000 10 250 Lower cable capacitance max 30 nF km and lower lead resistance loop resistance 115 ohms 1000m make it possible to achieve greater distances Characteristic impedance 150 5 ohmsrequires terminating resistor 150 5 ohms Kollmorgen April 2011 121 AKD Installation 8 Electrical Installation 8 18 5 CANbus Wiring according to line impedance CAN ref to ISO 11898 Internal 1320 Resistor 13 Termination connector 122 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 19 Motion Bus Interface X5 X6 The motion bus interface has two RJ 45 connectors and can be used for communicating with various fieldbus devices depending on the used drive version JE NOTICE Do not connect the Ethernet line for the PC with the set up software to the motion bus interface The set up Ethernet cable must be connected to the service interface on X11 8 19 1 Pinout X5 X6 Pin Signal X5 Signal X6 e Sege Transm a ne ne 8 19 2 Optional Motion Bus Protocols Motionbus Connector Location Connect
99. n fault General communication problem with Check secondary feedback F437 Close to limit Drive or motor over current or over Check for increased load jam Speed warning ming or sticking Is position error Kollmorgen April 2011 139 AKD Installation 9 Setup Fault F439 Following error user n439 F450 Following error pre sentation Message Warning F438 Following error numeric n439 Motor did not follow command values Motor exceeded maximum allowed posi tion following error numeric Motor did not follow command values Motor exceeded maximum allowed posi tion following error user Motor did not follow command values Motor exceeded maximum allowed posi tion following error presentation Check for increased load jam ming or sticking Is position error set too low Check feedback commutation setup and tuning parameters Check feedback commutation setup and tuning parameters F473 Wake and Shake Insuf There was less movement than defined Increase WS IMAX and or ficient movement by WS DISTMIN WS T F475 Wake and Shake Excess WS DISTMAX has been exceeded movement Wake and Shake Fine coarse delta too large Increase WS DISTMAX value or reduce WS IMAX or WS T The angle difference between the coarsel Modify WS IMAX or WS T and and fine calculation was larger than 72 deg F478 Wake and Shake Over WS VTHRESH was exceeded n478 speed F479 Wak
100. nect the feedback device Connect the hardware option Connect the motor cable Connect shielding at both ends Use a motor choke if cable gt 25m Connect motor holding brake connect shielding at both ends If required connect the extemal regen resistor with fusing Connect the auxiliary supply maximum permissible voltage values see electrical data gt p 34 or gt p 35 Connect the mains filter with AKD xzzz06 shielded lines between filter and drive Connect the main electrical supply Check maximum permitted voltage value gt p 34 or gt p 35 Check proper use of residual current circuit breakers RCD gt p 58 Connect the PC gt p 117 for setting up the drive 4 Check the wiring against the wiring diagrams 70 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 3 Wiring The installation procedure is described as an example A different procedure may be appropriate or necessary depending on the application of the equipment Kollmorgen can provide training courses for this procedure upon request Sinti There is a danger of electrical arcing which can cause serious personnel injury Only install and wire the equipment when it is not live that is when neither the electrical supply nor the 24 V auxiliary voltage nor the supply voltages of any other connected equipment is switched on Make sure that the cabinet is safely disconnected for instance with a lock out and
101. o the non volatile memory The new setting will be taken with the next power up of the drive If an error occurred the following error messages will flash 5 times e E1 Drive is enabled e E2 Non volatile storage of the new setting failed e E3 Invalid rotary switch selection 120 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 18 2 Node Address for CANbus ui ee The rotary switches on the front of the AKD S1 amp S2 correspond to the CAN node address The S1 amp S2 switches also correspond to the IP address setting of the drive Both CAN and IP network address schemes have to be configured to account for this dependence if both TCP IP and CAN networks are running at the same time in an application Example CAN address 45 192 168 0 4 8 18 3 CANbus Termination The last bus device on both ends of the CANbus system must have termination resistors The AKD has built in 132 ohms resistors that can be activated by connecting pins 1 and 6 An optional termination plug is available for AKD P AKD CAN TERM The optional termination plug is an RJ 12 connector with an enclosed wire jumper between pins 1 amp 6 A plug should be inserted into the X13 connector of the last drive in the CAN network 8 18 4 CANbus Cable To meet ISO 11898 a bus cable with a characteristic impedance of 120 ohms should be used The maximum usable cable length for reliable communication decreases with increasing trans
102. of the screen Right click on your drive name and select Setup Wizard from the drop down menu The Setup Wizard guides you through the initial drive configuration which includes a simple test motion After completing the Setup Wizard your drive should be enabled If the drive is not enabled check the following 1 The hardware enable HW must be in the enabled state pin 4 on X8 connector 2 The software enable SW must be in the enabled state Activate using the Enable Disable button on the upper toolbar on WorkBench or in the Overview screen 3 No faults may be present click the Clear Fault button on the upper tool bar to clear any faults The status of HW enable SW enable and Faults is displayed in the lower toolbar of the WorkBench software The drive is connected if the lower right corner shows Online You can now use the Settings View in WorkBench to complete advanced configuration of your drive 132 Kollmorgen April 2011 AKD Installation 9 Setup 9 4 Fault and Warning Messages When a fault occurs the drive fault relay is opened the output stage is switched off motor loses all torque or the load is dynamically braked The specific drive behavior depends on the type of fault appThe LED display on the front panel of the drive shows the number of the fault that occurred If a warning is issued prior to the fault the warning is shown on the LED and has the same number as the associated fault Wamings do not tr
103. ommand Reference Guide This guide provides documentation for the parameters and commands used to program the AKD 1 2 Target Group This manual addresses personnel with the following qualifications e Transport only by personnel with knowledge of handling electrostatically sensitive components e Unpacking only by electrically qualified personnel e Installation only by electrically qualified personnel e Basic tests only by qualified personnel with extensive knowledge of electrical engineering and drive tech nology The qualified personnel must know and observe the following standards e ISO 12100 IEC 60364 and IEC 60664 e National accident prevention regulations A WARNING During operation hazards exist that can cause death severe injury or material dam age To safely operate the AKD you must follow all safety instructions in this man ual The operator of systems using the AKD must require that all personnel who work with the drive read and understand the manual before using the drive 1 3 Using the PDF Format This document includes several features for ease of navigation Cross References Table of contents and index include active cross references Table of contents and index Lines are active cross references Click on the line and the appropriate page is accessed Page chapter numbers in the Page chapter numbers with cross references are active links text Kollmorgen April 2011 AKD Installati
104. on 1 General 1 4 Abbreviations used Abbreviation Meaning COW o 1zop O OO yO ROD Incrementalencoder A quad B Kollmorgen April 2011 11 AKD Installation 1 General 1 5 Symbols used Warning Symbols Symbol Indication A D AN G E pa Indicates a hazardous situation which if not avoided will result in death or serious injury A WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or mod erate injury NOTICE Indicates situations which if not avoided could result in property damage NOTE This is not a safety symbol This symbol indicates important notes Drawing symbols Symbol ym Protective earth Relays switch off delayed Normal open contact eo Pr NE NN N Kollmorgen April 2011 AKD Installation 1 General 1 6 Standards Used Standard Content IEC 61491 Electrical equipment of industrial machines Serial data link for real time communications between controls and drives UL 840 UL Standard for Safety for Insulation Coordination Including Clearances and Creepage Distances for Electrical Equipment UL 508C UL Standard for Safety Power Conversion Equipment ANSI American National Standard Institute Inc IEC International Electrotechnical Commission ISO International Organization for Standardization UL Underwriters Laboratorie
105. on to 24 V signal level stepper motor controllers Controller Pulse Direction GND 24V Kollmorgen April 2011 107 AKD Installation 8 Electrical Installation 8 15 4 Up Down signal connection 8 15 4 1 Up Down input 5 V X9 The drive can be connected to a third party controller which delivers5 V up down signals Controller Shield 8 15 4 2 Up Down input 24 V X7 The drive can be connected to a third party controller which delivers 24 V up down signals Controller Up Down GND 24V 8 15 5 Master Slave Control Several AKD can be connected as slave drives to an AKD master The slave drives use the master s encoder output signals as command input and follow these commands velocity and direction Master Slave Connection Diagram example for 5V signal level X9 108 Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 16 I O Connection All standard digital and analog I O signals are connected to X7 and X8 8 16 1 MO Connectors X7 and X8 Pin Signal Abbreviation Function Specials Dora DIGTALIN Programmable Digtalnput4 DIGITALING Programmable Digtalnput3 DIGITALINS Programmable Digital Output 2 DIGITALOUTZ Programmable Digital Output 2 DIGITAL OUT2 Programmable 7 Digtal Output DIGITALOUT Programmable 1 Digital Output 1 DIGITALOUTI Programmable DIGITALAN2 Fault Relay Output Fault Relay Out
106. ontrol PLC j Regen resistor optional N Mains Filter mg N Motor choke optional Terminals Kollmorgen April 2011 AKD Installation 8 Electrical Installation With AKD xzzz07 NOTE Cables drawn bold are shielded Electrical ground is drawn with dash dotted lines Optional devices are connected with dashed lines to the drive The required acces sories are described in the accessories manual KOLLMORGEN E AKD D sR Regen resistor optional Drive Gene Motor choke optional Terminals Zeene Kollmorgen April 2011 73 74 AKD Installation 8 Electrical Installation 8 5 Connector Assignments AKD x00306 to x00606 X12 CAN In X13 CAN Out z La ee KOLLMORGEN X1 24 V Supply STO X2 Motor Holding Brake X3 7 pin Power Supply DC Bus Brake Resistor 8 6 Connector Assignments AKD x01206 X12 CAN In X13 CAN Out X1 24 V Supply STO X2 Motor Holding Brake X3 8 pin Power Supply DC Bus Brake Resistor Kollmorgen April 2011 X11 Service X5 6 Motion Bus X7 8 VO X10 Feedback x9 Encoder Emulation Protective Earth PE X11 Service X5 6 Motion Bus X7 8 VO X10 Feedback KI Encoder Emulation Protective Earth PE AKD Installation 8 Electrical Installation 8 7 Connector Assignments AKD x02406 and AKD xzzz07 X12 CAN In
107. ory must be determined by a risk evaluation of the machine Category 0 Only hard wired electromechanical components may be used for the Category 0 Emergency Stop function It must not be triggered using switching logic hardware or software by transferring commands via a com munication network or via a data link The drive must be shut down using an electromechanical circuit If the connected servomotor has an integrated brake this brake must always be controlled by an electromechanical circuit as well Category 1 With the Category 1 emergency stop function the final power supply switch off must be ensured by using elec tromechanical components Additional external emergency stop equipment may be connected The motor is stopped by interrupting the mains supply and using controlled electronic braking The 24 V supply for the drive must remain constant The issue of which circuit should be used highly depends on the requirements of the appli cation at hand In most servomotors a brake has only the function of a holding brake To ensure an emergency stop function the braking torque that is required must be checked If the holding brake fulfills the dynamic requirements it must be taken into account that this application will cause increased wear NOTE The parameter DRV DISMODE must be set to 2 to implement the different stop cat egories Consult the AKD User Guide for configuring the parameter Kollmorgen April 2011
108. osed during enable Motor brake closed unexpectedly Check cabling and general func state tionality F308 Voltage exceeds motor rat Drive bus voltage exceeds the motors Make sure that the motor fits the ing defined voltage rating driving rating F401 Failed to set feedback type Feedback is not connected or wrong Check primary feedback X10 feedback type selected connection F402 Analog signal amplitude Analog signal amplitude is too low Check primary feedback X10 Analog fault resolver signal amplitude or connection resolver and sin cos amplitude sine cos encoder only F403 EnDat communication fault General communication problem with Check primary feedback X10 feedback connection EnDat only 138 Kollmorgen April 2011 AKD Installation 9 Setup Fault Message Warning F404 Hall error Hall sensor retums invalid Hall state Check the feedback wiring 111 000 either all Hall sensors are on check all feedback connectors or off Legal Hall states are 001 011 to ensure all pins are positioned 010 110 100 and 101 This fault can bel correctly caused by a broken connection in any one of the Hall signals F405 BiSS watchdog fault Bad communication with the feedback Check primary feedback X10 device connection Biss only F406 BiSS multicycle fault Check primary feedback X10 connection Biss only F407 BiSS sensor fault Check primary feedback X10 connection Biss only S
109. otion will clear the warning DRV CLRFAULTS also can be used to clear warning Fault n170 F202 Message Warning MT NUM exceeds limit Motion task is not initialized Motion task target position is out Invalid bit combination in the motion task control word 1 1 profile cannot be trig gered on the fly Customer profile table is not initialized External RAM failed AKD Installation 9 Setup This warning appears with n160 This Trigger only motion tasks warning is triggered when you try to between 0 and 128 trigger a motion task gt 128 such as MT MOVE 130 This warning is cleared upon a successful start of any new motion or upon a DRV CLRFAULTS command This warning appears with n160 This Initialize the motion task first warning is triggered when you try to before starting the task trigger a non initialized motion task This warning is cleared upon a successful start of any new motion or upon a DRV CLRFAULTS command This warning appears with n160 This Move the absolute target posi warning is triggered when you try to tion of the motion task within the trigger a motion task with an absolute tar modulo range get position outside of the selected mod ulo range see also MT CNTL This warning is cleared upon a successful start of any new motion or upon a DRV CLRFAULTS command This warning appears with n160 This Correct the MT CNTL setting for warning is triggered when you try to
110. put Fault Relay Output Fault Relay Output Fault Relay Output Fault Relay Output MP Common line for 3 Digital Common X8 DCOM8 X8 pins 4 5 6 Digital Input 8 DIGITAL IN8 Output stage enable not programmable Digital Input 6 DIGITAL IN 6 Progammable 6 Digital Input 5 DIGITAL IN 5 Programmable Analog Ground AGND Analog GND NE N 8 Analog Output Analog Out Actual velocity voltage Po o Analog input Analog n EER HA Sa Velocity set t Analog Input Anogir ON RT ET DigitalcommonlinesforX7andX8arenotcommontoeachother TheDCOMxlineshouldbeconnectedtotheOVofthel O supply whenusingsensors oftype Source withdigital inputs TheDCOMxlineshouldbeconnectedtothe24V ofthel O supply when using sensors oftype Sink withdigitalinputs Kollmorgen April 2011 109 AKD Installation 8 Electrical Installation 8 16 2 Analog Input X8 The drive is fitted with one differential input for analog torque velocity or position control Technical characteristics e Differential input voltage range 12 5 V e Maximum input voltage referring to I O Return 12 5 16 0 V e Resolution 16 Bit and fully monotonic e Unadjusted offset lt 50 mV e Offset drift typ 250 V C e Gainor slope tolerance 3 e Nonlinearity lt 0 1 of full scale or 12 5 mV e Common Mode Rejection Ratio gt 30 dB at 60 Hz e Input impedance gt 13k Ohms e Signal to noise ratio referred to full scale e AIN CUTOFF 3000 Hz 14 bit
111. quirements AC connection AKD x003 to 6 1 5 mm 16 awg 600 V minimum 75 C AKD x012 2 5 mm 14 awg AKD x024 4 mm 12 awg DC bus link AKD x003 to 6 1 5 mm 16 awg 1000 V minimum 75 C shielded AKD x012 to 24 2 5 mm 14 awg for lengths gt 0 20 m Motor cables without AKD x003 to 6 1 5mm 16 awg 600 V minimum 75 C shielded choke max 25m AKD x012 2 5 mm 14 awg capacitance lt 150 pF m AKD x024 4 mm 12 awg Motor cables with AKD x003 to 6 1 5 mm 16 awg 600 V minimum 75 C shielded choke 25 50m AKD x012 2 5 mm 14 awg capacitance lt 150 pF m AKD x024 4 mm 12 e capacitance 2120 pE m SFD max 50m 1x2x0 25 mm 24 awg twisted pairs shielded GomCoder max 25 8x2x0 25 mm 24 awa Kollmorgen April 2011 39 AKD Installation 6 Technical description and data 6 12 LED display A two character LED seven segment display indicates the status of the drive after the 24 V supply is switched on Fault codes or warning codes are displayed constantly if present The IP address can be flashed across the LED display if the B1 button is pressed or if the RJ45 cable is re inserted into the X11 connection Press B1 to display IP address 6 13 Grounding System There are four ground networks in the drive AGND analog ground DCOM7 common line for digital inputs on I O connector X7 DCOM8 common line for digital inputs on I O connector X8 GND 24 V supply STO input hold
112. r Safe Torque Off STO describes how to use the STO function gt p 53 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 15 1 Switch on behavior in standard operation The diagram below illustrates the correct functional sequence for switching the drive on U 24V FAULT Relay L1 L2 L3 U DC Bus Link STO U HW ENABLE amp SW ENABLE U Power Stage enable n Motor Speed l l t Fault F602 occurs when STO does not have current when HW enable becomes active gt p 53 for more infor mation about STO function Kollmorgen April 2011 45 46 AKD Installation 6 Technical description and data 6 15 2 Switch off behavior NOTE The drive s 24 V supply must remain constant Hardware Enable input disable the power stage immediately Configured Digital Inputs and fieldbus commands can be used to perform controlled stops 6 15 2 1 Switch off behavior using the DRV DIS command The enable disable button in WorkBench issues a drv dis command internally to the drive See AKD User Guide for configuring inputs and software commands Sometimes this enable signal is called Software Enable SW Enable DRV DISMODE DRV DISMODE controls the behavior of the drv dis command issued through WorkBench terminal or fieldbus Consult the AKD User Guide for configuring Disable axis immediately if velocity drops below threshold CS VTHRESH or timeout oc
113. r change motion profile Check system regen capacity add capacity if needed Check mains voltage F502 Bus under voltage Bus voltage below threshold value Check mains voltage Warning issued prior to fault F503 Bus capacitor overload n503 Kollmorgen April 2011 Single phase AC input on a drive only rated for three phase input or excessive single phase power load Check mains voltage AKD Installation 9 Setup Fault Message Warning F504 Internal supply voltage fault Internal supply voltage fault detected Check wiring for elec F518 tromagnetic compatibility EMC If issue persists exchange drive F519 Regen short circuit Regen resistor short circuit Regen IGBT short circuit Con tact technical support F520 Regen overload Regen resistor overload Motor is being overhauled or motor is being stopped too quickly F521 Regen over power Too much power stored in regen Increase regen resistor capac n521 resistor ity Either get larger regen resistor or use DC bus sharing to dissipate power F523 Bus over voltage FPGA Bus over voltage hard fault Check mains voltage and check system brake capacity F524 Drive foldback Maximum drive power has been Motion requires too much power n524 exceeded The power has been limited Change profile to reduce load to protect the drive F525 Output over current Current exceeds drive peak Check for short or feedback faults F526 Current sen
114. r multi tum sine cosine encoder with Hiperface interface as a feedback system The thermal control in the motor is connected via the encoder cable and evaluated in the drive All signals are con nected using our pre assembled encoder connection cable If cable lengths of more than 50 m are planned please consult customer support FBTYPE Frequency Limit Connecting pin 4 and 5 together causes Up to be 8 to 9 V The pin assignment shown on the encoder side relates to Kollmorgen motors Encoder HIPERFACE SIN REFSIN COS REFCOS Up voltage supply OV Motor BG 4 thermal control min 5VDC SmA dag Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 14 8 Sine Encoder Feedback devices which do not deliver absolute information for commutation can either work with wake amp shake commutation see AKD User Guide or can be used as a complete feedback system when combined with an additional Hall encoder All signals are connected to X10 and evaluated there If cable lengths of more than 25 m are planned please consult customer support The Sense signal is optional and can be omitted if the encoder cable is short and no significant voltage drop is on the cable The voltage drop depends on the cable length and gage and the encoder current consumption FBTYPE Frequency Limit sin cos SinCos 1 V pp with Hal 5 V 5 SinOos TV pip Wake8Shako SV EER Encoder At 5V
115. rcuit 41 6 14 1 1 Functional description 41 6 14 1 2 Technical DatatorAkixzzz0mgp e eee ee GE 42 6 14 1 3 Technical Data for AKD xZZZ07 ESEG e awn cece GE 43 6 15 Switch on and Switch off Behavior 0 00000000 c cece cece ccc ee eie 44 6 15 1 Switch on behavior in standard operation 22 02 2222 GE EE Gee 45 6 15 2 Switch off bebavior SESSE GEES GEGEE Ge 46 6 15 2 1 Switch off behavior using the DRV DIS commande 46 6 15 2 2 Switch off behavior using a digital input controlled stop 47 6 15 2 3 Switch off behavior using HW Enable input uncontrolled stop 47 6 15 2 4 Switch off behavior in the event of a fault SG c Gee 48 6 16 Stop Emergency Stop Standards 51 6 16 1 Stop Standards EE GE GE eie 51 6 16 2 Emergency Stop Standards 52 6 17 Safe Torque Off STO SG ee eeeeeeeeeeeeeeeeeeereeees 53 6 17 1 Safety characteristic data 53 61 2 Useas directed na EED AA BA NAG NG Deeded ANONG acide cha ane ew AANO NT SE DE ut 53 6 17 3 Prohibited Use 2 22 mma mm amma aman man ww mmama nama aaeain 53 6 17 4 Safety instructions amma m cece mwan eeeeeeeeeeeeeeeesereeeeeees 54 6 17 5 Technical data and pinning mwa ma www SG GE SES ee 54 6 17 6 Enclosure mwm mwa mw amma wwa mama m wamama Aa aaora anaana 54 MAA is BEE 54 6 17 8 Functional description EG GEE Gee 55 6 17 8 1 Signal diagram Sequence EES GEGEE GE G
116. rnal or connected external to the drive depending on drive model and drive wiring AKD x00306 to AKD x00606 No internal regen resistor Depending on the application requirements an external resistor can be connected AKD x01206 to AKD x02406 and AKD xzzz07 With internal resistor plus the capability to connect an external resistor depending on the application requirements NOTE External regen resistors are described in the AKD Accessories Manual 6 14 1 1 Functional description When the amount of returned energy builds the bus capacitor voltage up enough the drive activates the brake chopper to start dumping the returned energy in the regen resistor 1 Individual drives not coupled through the DC bus link circuit DC DC When the energy fed back from the motor has an average or peak power that exceeds the preset level for the regen power rating the drive generates the warning n521 Regen Over power After the warning is issued if the power increases past the fault level the regen circuit will switch off With the regen circuit switched off the drive intemal DC bus link voltage is supervised The drive reports an over voltage fault if the DC bus threshold is exceeded The drive power stage is disabled and the load coasts to a stop with the fault message F501 Bus Over voltage gt p 133 The Fault contact terminals X8 9 10 is opened gt p 116 due to this fault 2 Several drives coupled through the DC bus link DC
117. ry kBit s FBUS PARAMO1 switch S1 switch S2 12 125 a 20 e ho 2 w In ln o gl Wa Incase of a fix baud rate the drive sends the boot up message with the baud rate saved in the drive s non volatile memory after a power cycle In case of auto baud detection the drive listens fora valid CAN frame on the bus When avalid frame is received the drive sends the boot up message with the measured bit time Afterwards the baud rate can either be stored to non volatile memory via object 1010 sub 1 orthe auto baud mechanism is used always NOTE For reliable auto baud detection it is recommended to use suitable cabling of the CANbus two terminators GND connection etc Spikes or other noise effects on the CANbus can disturb the measurement The drive needs to be disabled if auto baud is in use For setting the baudrate with rotary switches follow the procedure below drive state disabled 1 Disable the drive Set the rotary switches to one of the addresses 90 to 94 see above table 51 NS S1 MSB s2 SN S2 LSB KEN Zo Gr ere H 2 Push the button B1 on the AKDfor at least 3 seconds until the rotary switch setting is displayed on the AKD display Press B1 to display baudrate 3 When the display blinks with the set rotary switch setting stop pushing B1 and wait until the blinking stops During that time the parameter FBUS PARAMO1 is set to the new value and all parameters are stored t
118. s Kollmorgen April 2011 13 14 AKD Installation 2 Safety 2 Safety 2 1 Safety Instructions 2 2 0 2200 eee eee cence nnne 15 2 2 Use as Directed 1 2 2 2 ccc cece ccc ccc ccc aaa 16 2 3 Prohibited Use Za 16 Kollmorgen April 2011 AKD Installation 2 Safety 2 1 Safety Instructions PG BAN 0 3 During operation hazards exist that can cause death severe injury or material damage Do not open or touch the equipment during operation Keep all covers and cabinet doors closed during operation Only properly qualified persons may handle the equipment during instal lation and commissioning During operation drives may have uncovered live components depending on their level of enclosure protection Control and power connections may be live even though the motor is not rotating Drives may have hot surfaces during operation The heat sink can reach tem peratures above 80 C The danger of electrical arcing is present Electrical arcing can damage contacts and injure personnel Never undo any electrical connections to the drive while it is live Wait at least 7 minutes after disconnecting the drive from the main supply power before touching potentially live sections of the equipment such as contacts or removing any con nections Capacitors can have dangerous voltages present up to seven minutes after switching off the supply power Always measure the voltage in the DC bus link and wait until th
119. safety circuits must meet the safety requirements of IEC 60204 ISO 12100 and ISO 13849 6 17 3 Prohibited Use The STO function must not be used if the drive is to be made inactive for the following reasons 1 Cleaning maintenance and repair operations long inoperative periods In such cases the entire system should be disconnected from the supply and secured main switch 2 Emergency stop situations In an emergency stop situation the main contactor is switched off by the emergency stop button Kollmorgen April 2011 53 54 AKD Installation 6 Technical description and data 6 17 4 Safety instructions Drives with a suspended load must have an additional safe mechanical blocking for instance by a motor holding brake The drive cannot hold the load when STO is active Serious injury could result when load is not properly blocked A CAUTION If the safety function STO is automatically activated by a control system then make sure that the output of the control is monitored for possible malfunction The mon itoring can be used to prevent a faulty output from unintentionally activating the STO function Since the STO function is a single channel system erroneous engag ing will not be recognized A CAUTION t is not possible to perform a controlled brake if the drive controlled STO Enable is off If controlled braking before the use of the STO function is necessary the drive must be braked and the input STO must be s
120. sor short circuit Current sensor short circuit Restart drive If issue persists contact technical support F527 lu current AD converter Hardware failure detected Restart drive If issue persists stuck contact technical support F528 Iv current AD converter Hardware failure detected Restart drive If issue persists stuck contact technical support F529 lu current offset limit Hardware failure detected Restart drive If issue persists exceeded contact technical support F530 Iv current offset limit Hardware failure detected Restart drive If issue persists exceeded contact technical support F531 Power stage fault Hardware failure detected Restart drive If issue persists replace drive Kollmorgen April 2011 141 AKD Installation 9 Setup Fault Message Warning F532 Drive motor parameters Before a motor can be enabled you Issue the command DRV S setup incomplete must configure a minimum set of param ETUPREQLIST to display the eters These parameters have not been list of the parameters that you configured must configure Configure these parameters either manually or automatically You can manually configure these parameters in three ways 1 set each param eter individually 2 use the setup wizard to select the motor or 3 select the motor type from the motor data base in the Motor window MOTOR AUTOSET must be set to 0 FALSE If you use the Motor window you must first select the f
121. ss the entire back surface of the drive panel Electrically conductive panels such as aluminum or galvanized steel are preferred For painted and other coated metal panels remove all coating behind the drive Ensure good ground connection Connect from cabinet to proper earth ground Ground leads should be the same gauge as the leads to main power or one gauge smaller Use Kollmorgen cables Experience has shown that customers who use Kollmorgen s power and feedback cables have far fewer problems than customers who build cables Route power and control cables separately Kollmorgen recommends a distance of at least 200 mm to improve interference immunity If a motor power cable is used that includes cores for brake control the brake control cores must be sep arately shielded Ground the shielding at both ends Ground all shielding with large areas low impedance with metalized connector housings or shield con nection clamps wherever possible For cables entering a cabinet connect shields on all 360 of the cable Never connect a simple pigtail For more information on shielding concepts gt p 80 With separate mains filter maintain separation of leads entering and exiting the mains filter line power filter Locate the filter as close as possible to the point where the incoming power enters the cabinet If it is nec essary for input power and motor leads to cross cross them at 90 Feedback lines may not be
122. ted Encoder Connector Emulated Encoder Output ENABLE Enclosure protection EnDat 2 1 encoder interface EnDat 2 2 encoder interface EtherNet EtherCAT Protocol Ethernet IP Protocol Modbus TCP IP Powerlink Protocoll ProfiNet NR Protocol SERCOS III Protocol SynqNet Protocol F Fault messages FAULT relay Feedback Feedback Connection Fusing G Grounding Grounding Plates H Hardware requirements Hiperface encoder interface Humidity in operation Storage Transport VO Connection Inputs Analog Basic Data Digital Enable Programmable STO Installation Electrical Mechanical Software L Leakage current Kollmorgen April 2011 124 124 124 124 124 124 124 70 82 128 100 33 25 109 110 112 114 114 68 129 58 147 148 AKD Installation 12 Index Mains supply interface Maintenance Master slave Master Slave Motor holding brake Motor interface Motor Power Connection Mounting position N Nameplate Noise Emission O Operating systems Option Cards Order codes Outputs Analog Basic Data Digital Fault P Package supplied Packaging Part number scheme PC connection Pollution level Prohibited Use General STO Pulse Direction interface R Re forming Regen circuit Regen resistor interface Repair Resolver interface ROD 5V with Hall interface Rotary Switches RS232 PC interface S Safety Instructions Electrical Installation General
123. teristics such as cable capacity cable length motor inductance and frequency Electrical Data AKD xzzz06 gt p 34 or Electrical Data AKD xzzz07 gt p 35 determine the maximum voltage in the system eysle The dynamic voltage rise can lead to a reduction in the motor operating life and on unsuitable motors to flashovers in the motor winding e Only install motors with insulation class F acc to IEC 60085 or above e Only install cables that meet the requirements Wiring gt p 71 Connector X2 AKD xzzz06 12 264 Em Signal Description 1 BR Motorhoiding brake negative e w Maes Connector X2 AKD xzzz07 3 24A Pin Signal Description Motor holding brake negative e w moorpmassw Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 13 1 Motor Power X2 8 13 1 1 Cable Length s 25 m 8 13 1 2 Cable length 525 m eys e With long motor cables leakage currents endanger the output stage of the drive For cable lengths from 25 m to 50 m a motor choke must be wired into the motor cable near the drive Kollmorgen April 2011 91 92 AKD Installation 8 Electrical Installation 8 13 2 Motor Holding Brake X2 A 24 V holding brake in the motor can be controlled directly by the drive A CAUTION The brake only works with sufficient 24 V voltage level gt p 34 or gt p 35 Check voltage drop measure the voltage at brake
124. tional guidance on specific causes of invalid motion tasks F125 Synchronization lost The fieldbus lost synchronization Check fieldbus connection X5 n125 and X6 if you are using Ether CAT XF12 and XF13 if you are using CANopen or the settings of your EtherCAT or CANopen master F126 Too much movement Too much movement was created dur Check that the system is closed n126 ing a Bode plot Motor is unstable and is loop stable Refer to the system not following drive instructions tuning guide F127 Incomplete emergency stop Incomplete emergency stop procedure Disconnect power from drive problem with the emergency stop and check emergency stop pro motion task cedure F128 MPOLES FPOLES not an Ratio of motor poles to feedback poles Change to a compatible feed TG ease ee F129 Heartbeat lost Heartbeat lost Check CANopen cabling Reduce bus load or increase the F130 Secondary feedback supply Problem in secondary feedback Check X9 connection over current detected F131 Emulated encoder line Problem in secondary feedback Check secondary feedback X9 SN ee GT F132 Emulated encoder Z break Problem in secondary feedback Check secondary feedback X9 detected connection F133 Fault number changed to to lid AE EE F134 Secondary feedback illegal Problem in secondary feedback Check X9 connection state detected F135 Homing is needed Attempt to issue motion task before the Change opmode or home axis axis
125. to 0606 models 8 cartons e All other models 6 cartons e Store only within specified temperature ranges 25 to 55 C max rate of change 20 K hour class 1K4 e Storage only within specified humidity 5 to 95 relative humidity no condensation class 1K3 e Store in accordance with the following duration requirements e Less than 1 year without restriction e More than 1 year capacitors must be re formed before setting up and operating the drive To re form the capacitors remove all electrical connections and apply single phase 120 Vac for about 30 minutes to the L1 L2 terminals Kollmorgen April 2011 25 AKD Installation 4 Handling 4 4 Maintenance and Cleaning The drive does not require maintenance Opening the drive voids the warranty The inside of the unit can only be cleaned by the manufacturer To clean the drive exterior e Casing Clean with isopropanol or similar cleaning solution e Protective grill on fan Clean with a dry brush NOTICE Do not immerse or spray the drive 4 5 Uninstalling If a drive must be uninstalled such as for replacement remove the drive as follows 1 Switch off the main switch of the switchgear cabinet and the fuses that supply the system I WARNING Wait at least seven minutes after disconnecting the drive from the main supply power before touching potentially live sections of the equipment e g contacts or undoing any connections Always measure the voltage in the DC bus link an
126. to machines or plant the drive must not be used until it has been established that the machine or equipment fulfills the requirements of the e EC Machinery Directive 2006 42 EC e EC EMC Directive 2004 108 EC e EC Low Voltage Directive 2006 95 EC Standards to be applied for conformance with the EC Machinery Directive 2006 42 EC e IEC 60204 1 Safety and Electrical Equipment in Machines e ISO 12100 Safety of Machines A CAUTION The manufacturer of the machine must generate a hazard analysis for the machine and must implement appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property Standards to be applied for conformance with the EC Low Voltage Directive 2006 95 EC e IEC 60204 1 Safety and Electrical Equipment in Machines e IEC 60439 1 Low voltage switchgear and controlgear assemblies Standards to be applied for conformance with the EC EMC Directive 2004 108 EC e IEC 61000 6 1 2 Interference Immunity in Residential amp Industrial Areas e IEC 61000 6 3 4 Interference Generation in Residential amp Industrial Areas The manufacturer of the machine plant is responsible for ensuring that it meets the limits required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding treatment of connectors and cable layout is shown in this manual NOTE The machine plant manufacturer must check whether other standards or EC D
127. ts for electronic gearing gt p 103 Technical characteristics e Floating reference common line is DCOM7 e Sink or Source type sensors possible e High 3 5 to 30 V 2 to 15 mA Low 2 to 2 V lt 15 mA e Update rate Hardware 2 us 8 16 4 2 Digital Inputs 3 to 7 These inputs are programmable with the setup software By default all inputs are not programmed off For more information refer to the setup software Technical characteristics Choose the function you require in WorkBench e Floating reference common line is DCOM7 or DCOM8 e Sink or Source type sensors possible e High 3 5 to 30 V 2 to 15 mA Low 2 to 2 V lt 15 mA e Update rate Software 250 us 8 16 4 3 Digital Input 8 ENABLE Digital Input 8 terminal X8 4 is set to Enable function e Floating reference common line is DCOM8 e Sink or Source type wiring is possible e High 15 to 30 V 2 to 15 mA Low 3 to 5 V lt 15 mA e Update rate direct connection to hardware FPGA Theoutput stageof thedrive is enabled by applying the ENABLE signal Terminal X8 4 active high Enable is pos sibleonly ifinput STOhas a24 V signal gt p 53 In thedisabled state low signal the connected motor has no torque A software enable by means of the setup software is also required AND link although this can also be per manently enabled with WorkBench Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 16 5 Digital Outputs X7 X8 8 16
128. ty functions for the safe operation of drive shafts in accordance with IEC 61800 5 2 in proc ess Auxiliary supply voltage 24V DC e From an extemal safety approved 24 V 10 power supply Operation and parameter setting e Using the setup software WorkBench for setup via TCP IP Full digital control e Digital current controller 670 ns e Adjustable digital velocity controller 62 5 us e Software option position controller 125 us Inputs Outputs e 1 programmable analog input gt p 110 e 1 programmable analog output gt p 111 e 7 programmable digital inputs gt p 112 e 2 programmable digital outputs gt p 115 e 1 Enable input gt p 112 e 1STO input gt p 53 Option Cards in process Several option cards are in process These options will affect the device width Connectivity e Analog 10 V control with encoder feedback output Onboard Serial Interface gt p 119 optional e CANopen gt p 119 Onboard Ethernet interface gt p 123 optional e SyngNet gt p 124 e EtherCAT gt p 124 Kollmorgen April 2011 AKD Installation 6 Technical description and data 6 2 Ambient Conditions Ventilation and Mounting Position Ambient temperature 0 to 40 C under rated conditions in operation 40 to 55 C with continuous current derating 4 per Kelvin Humidity in operation Relative humidity 5 to 85 no condensation class 3K3 Site altitude Up to 1000 meters AMSL without restri
129. up software is used forconfiguration See the Feedback 2 screen in WorkBench for setup FB2 SOURCE FB2 MODE FB2 ENCRES and others are used for setting up an application with these interfaces Connector X9 can be configured as an input or as an output for 5 V TTL level signals Input modes X9 Input modes X9 X9 Output mode 53 Output TEN Pulse amp Direction 5 V Emulated Encoder Output quad B 5 V eae AI 5V Ca Encoder A quad B 5 V Input modes X7 Output mode DIGITAL IN 1 2 Incremental Encoder A guad B 24 V 8 15 1 Technical characteristics and pinout 8 15 1 1 Connector X7 Input Technical characteristics e Floating reference common line is DCOM7 e Maximum signal input frequency 500 kHz e Sink or Source type connection possible e High 15 to 30 V 2 to 15 mA Low 3 to 5 V s15 mA e Update rate Hardware 2 us Pin Pulse Direction Up Down Incremental Encoder o Pue Ww ER Down CCW ChamelB Kollmorgen April 2011 103 AKD Installation 8 Electrical Installation 8 15 1 2 Connector X9 Input Technical characteristics e Electrical interface RS 485 e Maximum signal input frequency 3MHz e Input signal voltage range 12 V to 7 V e Supply voltage only applicable to Incremental Encoder Input 5 V 5 e Maximum supply current 250 mA Pin Pulse Direction Up Down Incremental Encoder PS Direction Dom ho C6 Shed Shed shed EI ze EE tO Uo
130. ust unplug the network cable from the drive for 3 seconds or more This action will reset the address Kollmorgen April 2011 AKD Installation 8 Electrical Installation 8 18 CANbus Interface X12 X13 Two 6 pin RJ 12 connectors X12 X13 are used for CANbus connection The integrated profile is based on the CANopen DS301 communication profile and the DS402 drive profile default 125 kBaud The following functions are available in connection with the position controller jogging with variable speed homing run zeroing to ref erence start motion task start direct task digital setpoint provision data transmission functions and others Detailed information is included in the CANopen documentation X13 CAN Out X12 CAN In Conn Pin Signal Conn Pin Signal Internal Termination Resistor Internal Termination Resistor CAN Shield CAN Shield X12 CANH in X13 CANH out CANLin CANL out XI x1 GND X12 6 Internal Termination Resistor X13 6 Internal Termination Resistor Kollmorgen April 2011 119 AKD Installation 8 Electrical Installation 8 18 1 Baudrate for CANbus The user can decide to use a fixed baud rate or an auto baud detection algorithm for the startup behaviour of the drive The transmission rate can be set via the parameter FBUS PARAM01 The parameter FBUS PARAM01 can either be set via WorkBench or via a special mechanism with the rotary switches in the AKD front Baudrate Upper rotary Lower rota
131. utput 104 8 15 2 Command encoder signal connection 0022 e cece eeeeeeeeeeee 105 8 15 2 1 Incremental encoder input 5 V GO 105 8 15 2 2 Incremental encoder input 24VG ee 105 8 15 2 3 Emulated Encoder Output EEO A quad B X9 SS eee Gee 106 8 15 3 Pulse Direction signal connection SESSE SESSE SESSE e cece ce eeccceecececeeeeees 107 8 15 3 1 Pulse Direction input 5 V X9 c eee ma cece eeeeeeeeeeeeeees 107 8 15 3 2 Pulse Direction input 24 V X7 e cece cece ceeceeeeeeeeeeeeees 107 8 15 4 Up Down signal connection cece cece cece cece ccc cc cece cece cece ceeeeeeeeees 108 8 15 4 1 Up Down input V O 108 8 15 4 2 Up Down input 24VG e cece cece cece ee eeeeeeeeeeeeeeeeeees 108 8 15 5 Master Slave Control 108 8 16 eers ie eN N N RE ER NN 109 8 16 1 I O Connectors X7 and X8 EES SG cece cece cece eeeeeeeeeeeeeeeeeeees 109 8 16 2 Analog Input X8 ESE SESSE SG GE cece cece cece ccc cece cece cece aeea eade eoar 110 8 16 3 Analog Output 81 111 8 16 4 Digital Inputs G 112 8 16 4 1 Digital Inputs and 114 8 16 4 2 Domtallnputsiio mwm ma daona oaa adnan anaana annaran nn 114 8 16 4 3 Digital Input G ENARLE c eee cece eeeeceeeeeeeeeeeeees 114 8 16 5 Digital OutputesGOvp e cece cece eee cece eeeeeeeeeeeeeeeeeeees 115 8 16 5 1 Digital Outputs and 115 8 16 5 2 FAULT relay contacts e cece ee eeeecececceeeeeeees 116 8 17 Service Interface X11 SG cee eeeeeeeeeeeeeeeeeee
132. w the longest wire Strip all wires and fit wire end ferrules Secure the braided shield of the cable to the shroud with a cable tie 3 and use a second tie 4 to fasten the cable over the rubber sleeve Wire the connector as shown in the connection diagram Plug in the connector to the socket on the front of the AKD Screw the connector in place This ensures that there is con ductive contact over a large surface area between the braided shield and the front panel Kollmorgen M April 2011 AKD Installation 8 Electrical Installation 8 12 Electrical Supply Connection 8 12 1 Connection to Various Mains Supply Networks AKD xzzz06 120V to 240V This page illustrates all the possible connection variations for different electrical supply networks A WARNING There is a danger of electrical shock with serious personnel injury if the drive is not properly grounded An isolating transformer is always required for 400 to 480 V net works to get a maximum voltage of 240 V 1095 3 120 240 V Kollmorgen April 2011 83 AKD Installation 8 Electrical Installation 8 12 2 Connection to Various Mains Supply Networks AKD xzzz07 240V to 480V This page illustrates all the possible connection variations for different electrical supply networks A WARNING There is a danger of electrical shock with serious personnel injury if the drive is not properly grounded An isolating transformer is always require
133. wa eee e cece cece cess eeteeeeeeeeeneees 69 8 2 Guide to electrical installation EES SESSE e cece cece cece ce cece cece ccc ceecceceeeeeees 70 8 3 Wiring 71 8 4 Components of aservosystem ESEG mmw aman man ww man aroa aa ranan nanan 72 8 5 Connector Assignments AKD x00306 to x00606 Se See 74 8 6 Connector Assignments AKD XO1206 SG SG GEGEE 11 ra SG eie 74 8 7 Connector Assignments AKD x02406 and AKD xzzZ07 SG GE ee 75 8 8 Connection Diagram AKD x00306 to x00606 76 8 9 Connection Diagram AKD x01206 ee See 77 8 10 Connection Diagram AKD x02406 and AKD xZZZ07 22 0000 mmama mmama nwa nanma 78 8 11 EMI Noise Reduction mmama mwm ma mmama wan wwa aonana ranana nonen 79 8 11 1 Recommendations for EMI Noise Reduction mmama cece ce eens 79 8 11 2 Shielding with External Shielding Dusbar cece SG Gee 80 8 11 2 1 Shielding Concert 80 8 11 2 2 Shielding Busbar c cece cece cece ccc cece cee ceceeeeeeeeees 81 8 11 3 Shielding Connection to the Drive c ccc SG ES ee eie 82 8 11 3 1 Grounding Pilates 82 8 11 3 2 Shield connection clamps 22 2 2222 eee cee cc cece cece GE amewa mame 82 8 11 3 3 Motor Connector X2 with shielding connection 82 8 12 Electrical Supply Connection SESSE SESSE SEG Ge 83 8 12 1 Connection to Various Mains Supply Networks AKD xzzz06 120V to 240V 83 8 12 2 Connection to Various M

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