Installation Manual
Contents
1. 3 Determine the value of resistor 12 Omit this component if a lead network is not used This resistor determines how much effect the lead network has on the system This resistor is simply set to 44 the value of resistor 8 for most systems In systems ising some lead but more sensitive to noise issues or having larger inertial variations this resistor can be set higher 4 Determine the value of capacitor 15 Omit this component if a lead network is not used Install a capacitor substitution box Start with the lowest value and raise it until the tachometer shows a square response Remove the overshoot inserted in step 2 This is the value to use for 15 5 For systems requiring the best performance it is possible to repeat steps 2 and 4 once while expecting only a marginal increase in overall bandwidth For best results this procedure must be performed with a load on the motor that is very similar to the actual machine load for the motor The stability pot allows some adjustment in the actual system gain to compensate for small differences Higher frequency noise is eliminated using a resistor and capacitor in locations 12 and 15 if required Resistor 12 is typically 1 4 the value of resistor 8 Capacitor components 3 and 4 allow the ability to add torsional resonance filters and are not generally used SERVOSTAR S CD Product Family 33 Danaher Motion Operation Information The velocity loop monitors the tachometer feedb2. General Information SERVOSTAR SBD Series ST CT Product Family Danaher Motion System Description System Description The SERVOSTAR SBD Series is a four quadrant analog brush type servo motor drive amplifier that meets the needs of many servo applications such as machine tooling packaging electronic assembly and document handling The SBD Series of drives comes in standard packages of 3 6 10 20 30 55 and 85 amps A wide range complementary of Power Supply Modules are also available A CT series Compact Drive that includes an integrated BUS module is available in 3 6 and 10 amp sizes All are packaged in a small frame size perfect for minimizing cabinet space This product is a velocity controller commanded through an industrial standard 10V analog interface using a DC tachometer generator for velocity feedback PRODUCT FEATURES The SERVOSTAR SBD is a brush motor drive capable of controlling the motor s velocity using a tachometer generator mounted to the motor as the feedback device The drive is designed as a modern update to Kollmorgen s SBD Series of brush drive amplifiers produced over the past 25 years The drive is fully analog and can receive the exact comp compensation card that was used in existing SBD2 application The drive is built on Kollmorgen s SERVOSTAR S Series platform which uses modern technology and has a long life expectancy The SERVOSTAR S Series of brush drives is modular in design meaning that it h
3. Product Model CT03 CT06 CT10 x TAR ie Frequency 76 TT a TT 94 9 EEE LL sia RN MEN PET x Peak Cure amps for 500 msec TISVAC 17 T 23 pF Prk Carmen amp for 25ee HSVAC RES eva ert 05 18 1 Coins Current amps 223009 39 7 9 x Peak Curent amps for s00mSee 23008 117 TJ a TT 234 pF Peak Curent amps for 25es 250010 78 54 ag Fs FRNR LPN orequivalen 19 29 o TO a a 28 4 Fens Current amps amp 23088 35 7 r x Peak Current amp for S 0mSec amp 23089 193 21 C x Peak Curent amps for 250 2300 7 _ Fie ses RN R IPA orequivalent 10 29 gt x RIVER Tege Carareassaa 1 x Charge Time Se SSCS We ee a OverTemperature trip C 80 C Rated Main Output Continuous Power KVA 115VAC 16 Line Ma Mb Mc Input 45 Ambient fo Continuous Power KVA 230VAC 16 Line 1 4 Input 45 C Ambient Input 45 Ambient tins Curent LL J a C ra Ado Tor 50080 REES ak Current d Tor 2806 r gt O PWMBemewy amp g REES A ES CAE Protective Functions A a age Tip v J x e O repara tap E a CC mesi at dissipation wat a E a E BEE x Am Der SE er OR Go sse SAU mm TT UU TT SERVOSTAR SBD Series ST CT Product Family 5 Danaher Motion System Description CT Regen Information Internal Shunt Regulator Peak current
4. Kit Models ERH 26 ERH 40 Resistor Resistance Q Power Rating Watts Kollmorgen Part No P 97742 001 Overload Relay Fast Trip Haus 125 C SERVOSTAR SBD Series ST CT Product Family 13 Danaher Motion Power Supplies 14 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Hardware Installation Hardware Installation UNPACKING AND INSPECTION Electronic components in this amplifier are design hardened to reduce static sensitivity However proper procedures should be used when handling Remove all packing material and equipment from the shipping container Be aware that some connector kits and other equipment pieces may be quite small and can be accidentally discarded if care is not observed when unpacking the equipment Do not dispose of shipping materials until the packing list has been checked Upon receipt of the equipment inspect components to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Check all shipping material for connector kits manuals diskettes and other small pieces of equipment MOUNTING For proper ventilation the SERVOSTAR and BUS module units should be mounted vertically No horizontal distance between the drive and BUS module is required In systems using more than two SERVOSTARs per BUS module divide the drives equally on either side of the BUS module They are designed for mounting in an electrical enclosure to protect them fro
5. The signal must be tied to common C2 pin 7 to enable the power to the motor The toggling of this input Open to common will also initiate an attempt to recover from a fault condition External Current Limit C2 pin 11 This input can be left open to obtain full torque to the motor Taken to common this input will reduce the amount of current to the motor by a percentage determined by the compensation component 27 See current clamp description for values Torque Hold Input C2 pin 12 This input can be tied to common C2 pin 7 to cage the velocity loop amplifier This prevents the drive from creating any significant current command to the motor Analog Input C2 pins 13 and 14 The drive receives its command from an analog voltage source connected to these terminals The voltage range of this input is from 10 volts to 10 volts The analog input to the SERVOSTAR is differential meaning that the signals received at the two inputs are subtracted from each other to create a difference used to command the rest of the system This type of input has a high degree of noise immunity and in many cases allows for ground isolation between systems The input voltage from the differential receiver is applied to a gain adjust potentiometer called Scale located on the compensation card to allow you to adjust the volts RPM scaling of the drive The SERVOSTAR adds an analog offset to allow for drift control through the adjustment of the trimmer
6. amps N A o 0 0 Wi 0 EE External Shunt Regulator Peak coment amps E Minimum reste ohms OA AS A O O 58 x O r x ete TT TH PP DD For guidance on application sizing of Regen Kits see Application Note SERVOSTAR S C Series Regeneration Requirements on the PSP CD ROM or the Kollmorgen website www MotionVillage com ST ELECTRICAL SPECIFICATIONS BU bO so Ts O Continuous Power KVA 115VAC 16 0 55 1 1 1 6 n a n a n a n a Continuous Power KVA 230VAC 16 Line Input 45 C Ambient Rated Main Output Continuous Power KVA 230VAC 36 MA MB MC Line Input 45 Ambient PRM Moe Cre Ripple Hf x 8VDC Supply Current amps 8VDC Supply Current amps Current amps 15VDC Supply Voltage 14 T 5 EISVDC Supply Current emp 37 38 5 47 ws 57 UnderVoltage Trip on power up 90 VDC 255 VDC Can be defeated Protective UnderVoltage Trip nominal 90 VDC 125 VDC Functions Can be I GeVeltase Tip er Trip 430 VDC Internal heat dissipation in 45 ambient e 37 w 84 w 120 w 240 w 254w 465w 675 w continuous current Maximum Watts ERT NM N Environment 10 to 90 w o corrosive gasses or dust Derate 5 per 1000ft above 3300ft 05g 6 SERVOSTAR SBD Series ST CT Product Family Danaher Motion System Description CONTROL SPECIFICATIONS I O Connector C3 by pinout Analog Input 2 3 Fault
7. Corporation Therefore information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to former issues Table of Contents Danaher Motion Table of Contents General ani jel E PART NUMBER DESCRIPTION CT Regen Information ST ELECTRICAL SPECIFICATIONS IUNPACKING AND INSPECTION MOUNTING System Phasing Information icsvizzziI2UUTITIUTITIUIIIIIUIIIDUTIIQULIIZUZII ITN 18 ST Wiring Diagram with PS 08 20 or 40 251 SERVOSTAR SBD Series ST CT Product Family i Danaher Motion Table of Contents ii SERVOSTAR SBD Series ST CT Product Family General Information Danaher Motion Safety Instructions Only qualified personnel are permitted to transport assemble install and maintain this equipment Properly qualified personnel are persons who are familiar with the transport assembly installation commissioning and operation of motors and who have the appropriate qualifications for their jobs The qualified personnel must know and observe the following standards and regulations IEC 364 resp CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 Read all available documentation before assembly and installation Incorrect handling of products in this manual can result in injury and damage to persons and machinery Strictly adhere to the technical information
8. current and torque are proportional in a Permanent Magnet PM motor the current loop is often referred to as the torque loop The purpose of the current loop is to control the current through the motor for protection and the creation of output torque The commanded current is compared against the actual motor current allowing any error between the two to adjust the voltage at the motor terminals by raising or lowering the current appropriately The amount of current supplied by the current loop is a function of commands drive size ratings and clamp conditions see below The ability to supply current to drive the motor and the ability to remove energy from the motor while being able to command the motor in either direction are characteristics referred to as four quadrant operation During deceleration energy must be removed from the motor This energy is pumped back into the capacitors on the DC Bus This action is referred to as regeneration or regen The energy causes the bus voltage to raise The drive monitors this bus voltage for unsafe levels and shuts the drive down in an over voltage fault if the voltage gets too high SERVOSTAR S CD Product Family 31 Danaher Motion Operation Information The current loop compensator circuit is a simple integrating double low pass filter 5 19 and 6 17 with a lead network 20 18 and the ability to scale the current feedback 10 9 The current feedback signal is scaled to 8 Vo
9. environmental IP rating of the end product ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45 C Reserved di le Sm an sm Gas E za xx x x x xin xx xn xn x x x xx xa TTT xw m ser SARAN DE BE BASE REN DEKI ET E Teri en jeri am ln wai A A IC ir Eeer el Ee lt n This system is suitable or use on a circuit capable of E not more than 5000 RMS symmetrical amperes 240V maximum SERVOSTAR SBD Series ST CT Product Family Kollmorgen Operation Information Operation Information The normal operation of the LEDs is that all are off to indicate no fault and the drive is disabled When the drive is enabled Enable Input C2 pin 10 tied to Common C2 pin 7 the green Enabled LED is illuminated Illumination of any red LEDs indicates a fault A special reset circuit is provide to automatically reset an Under Voltage fault condition if power is applied after the drive is enabled This allows separate power up of logic and bus voltage without the need to reset an under voltage fault SYSTEM UO Tachometer Input C2 Pins 1 and 3 The DC tachometer generator signals are brought to these terminals The voltage must not exceed 100 volts The system is normally phased such that a clockwise motor rotation causes a positive voltage on these terminals The tachometer signal is considered a low level analog signal and careful routing and shielding must be performed to minimize noise pickup
10. manual is also useful 38 SERVOSTAR SBD Series ST CT Product Family Kollmorgen ADJUSTMENTS SERVOSTAR S CD Product Family System Startup 39 Danaher Motion SERVOSTAR Help SERVOSTAR Help Problems with the drive can be through actual faults bad compensation values installed on the comp card or self inflicted by misunderstanding of the system s operation If the system has been running and is experiencing faults review the fault codes in the following section Be certain that remote inputs Enable CW Limit CCW Limit External Current Limit and Torque Hold are in the correct and expected state A miss wired system such as a reverse polarity tachometer or a missing tachometer connection can cause many faults FAULT MONITORING SYSTEM The SERVOSTAR SBD Series is constantly monitoring the status of many different components In general the philosophy of the SERVOSTAR is to latch all fault conditions so you can readily determine the source of the problem When a fault is detected it is latched indicated in an LED and causes a drive disable Many faults can be reset by toggling the hardware remote enable input rising edge sensitivity or by depressing the reset switch The following is a list of some of the more frequent faults the drive may detect in the unit hardware Drive Over Temperature The internal heatsink temperature is monitored for an unsafe condition Heat sink over 80 degrees C The drive eventua
11. should be used in multi axis applications where the bus power supply already exists This unit comes with three green LEDs that verify the presence of the 15V 15V and 8V sources A See BUS Elgaria Specification page l ra Bookmark mol defined far details on the features PART NUMBER DESCRIPTION Month Manutactured A January B February Year Manufactured L December Unit Manufactured 98A 589 P S 20 160 SERVOSTAR BUS Module 90 90 Vdc 120 120 Vdc 10 20 40 60 85 100 LM 160 160 Vdc 225 225 Vdc 325 325 Vdc 10 SERVOSTAR SBD Series ST CT Product Family Power Supplies Danaher Motion SIMPLIFIED SCHEMATIC L1NV4 NI3934 O 031 A au amp WEN MOTA N393H UNI usbBay JOjJUO A NOILY OSI m TWOlLdO Y 038019 ATIVINHON S 3AIHG OL 1 INV O 7S snd O NINO 82 t L Vd H3MOd N3o3u jw O Q snaga uo3ouuadAnr i Gy ATIVNH3LX3 HOLSIS3H N393H IWNH3LX3 1VNOILdO sna CE S S yney lel jueunoJeAQ JOJUO A oDejoAJ9AQ JOJUO A JoAJepuf Jonuoo WEISYOS 11 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Power Supplies BUS ELECTRICAL SPECIFICATIONS Voltage VAC Nominal 64 85 115 160 230 10 16 36 16 36 19 30 19 30 16 36 Line Frequency 47 63 47 63 47 63 47 63 47 63 a gt Main Input PS20 Rated su Power PS40 Rated Cont
12. tft x 9 9 ST20 110319921 24 4 67 1 96 1 35 228 937 795 689 x ST3O 110310951 24 5 59 295 L32 228 9 37 827 6 89 SI55 18 111024630 400 113208 10 39 830700 srs us rior do zor 400 164 228 10 7 631 Lessons 18 LILIO 24 Less 400 1221 208 oast ess 291 1X Millimeters PRODUCT A R C D I FI FEF G j u roy IK 0 0 ST10 252 0 60 90 50 0 20 580 238 202 175 X ST20 252 0 60 118 6 500 343 580 238 202 1 175 1X 238 210 175 X 264 211 178 X 26 238 202 175 X 38 202 175 X 264 202 178 SERVOSTAR SBD Series ST CT Product Family 19 Danaher Motion Hardware Installation CT Units Cx10 lt 99 0 3 90 Cx 06 lt 88 4 3 48 gt Cx 03 67 4 2 65 36 5 15 5 163 0 gt lt lt ege _______ gt 0 44 61 42 20 gt EN 08 3x55 22 PA lt _ 6 7 i H Le I l 2x 10 0 I 39 l I 256 0 rv 244 0 216 0 10 08 iz 9 61 8 50 Kz I E ul x I I I I I I l l 33 7 1 33 PA LM Units 185 4 7 30 MAX 175 5 gt 26 2 6 91 1 03 3 1 12 EARTH fe 255 147 3 5 80 LA LINE N C INPUT LC Q 20 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Hardware Installation INSTALLATION PRACTICES The environment that any electronic contr
13. the problem exists If it does replace the drive If it does not correct the short Over Speed Fault The drive continuously monitors the actual feedback speed If the motor speed exceeds the typical value of 20 above the motor s rated speed the drive is disabled This normally occurs when there is an improperly tuned system and the load overshoots its commanded speed or the tachometer or armature is wired in the wrong polarity causing a positive feedback run away condition 40 SERVOSTAR SBD Series ST CT Product Family Kollmorgen SERVOSTAR Help TROUBLESHOOTING LIST Symptom Likely Cause Motor Runs Uncontrolled 1 Incorrect phasing on armature or tachometer 2 Broken or missing tachometer connection 3 Bad tachometer 4 Improper compensation components Motor turns in wrong direction 1 Improper command phasing 2 Both Armature and tachometer are reverse phased Motor does not obtain desired speed 1 Insufficient bus voltage to drive motor 2 Incorrect tachometer scaling Enable LED does not come on 1 Missing logic voltage supply 2 RED Fault LED is indicating a fault condition Under Volts fault occurs while running 1 Bus voltage source sags during acceleration Motor lags in position loop 1 Insufficient DC Gain Motor Overshoots 1 Insufficient DC Gain 2 Too much AC Gain Motor drifts slowly 1 DC Offset in system Balance pot Syst
14. this resets fault LEDs The fault contacts must be wired in series with the overload relay as shown in the iiie Attempting to enable the drive before this BUS OK becomes active may cause gt BUS module to remain inactive The ground of the BUS module drive and motor best minimizes ground currents and noise when connected in a star point configuration Up to 2 drives can be supplied from a PS08 or PALM All other power supplies can drive up to 4 drives for logic power The BUS module line ud are not por sensitive Cables should be properly bonded to the ee and implemented as close to the drive side of the cable as possible for EE grounding If JE is installed the shield on the cable details Units must be installed in an enclosure that meet the environmental IP rating of the end product ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45 C Reserved L Control logic input can be tapped directly off the main line input If this source is used the user must recognize that if the main line power is lost all latched fault data will be reset and unavailable See SERVOSTAR ST Hardware Specifications on page and IBUS Module Hardware Specifications on page 18 for spade and ring terminal sizes This system is suitable for use on a circuit capable of delivering not more than 5000 RMS symmetrical amperes 240V maximum SERVOSTAR SBD Series ST CT Product Family Hardware I
15. 9 Shielded terminal block for SK20 Type AB SS mount ground bus 0402174 Bus bar material 10mm x 3mm N A Hyewscuv L t The figure below represents a side and top view of the SK device that clamps down on the shield of the cable The use of the Phoenix SK device is an excellent method for providing a low impedance path between cable shield and the back panel Thumb screw to tighten down shield to bus bar Sy cable shield compressed on copper bus bar Es copper bus bar SK 8 14 20 Shielded terminal block SERVOSTAR SBD Series ST CT Product Family 23 Danaher Motion Hardware Installation SYSTEM INTERCONNECT The following sections provide connector information and the system connections up to the motor power and feedback connections Cabling purchased from Kollmorgen directly completes the system connections Views olaa P3 P4 Top View C2 User I O Connector Function o o o o o o o o o o o o o o o o o o o o ES 8 9 CCW Direction Limit Input EN E OT UV OV OC RS EN Embd OT Over Temperature Uv Under Voltage OV Over Voltage OC Over Current Over Temp Pl P2 P3 P4 Front View DC Gain Scale DC Balance Offset Current Limit Adjustment Pi P2 AC Gain Stability P3 P4 24 SERVOSTAR SBD Series ST CT Product Family Hardware Installation Kollmorgen ST Wiring Diagram with P
16. Danaher Motion SERVOSTAR SBD Series Installation Manual KOLLMORGEN giving our customers freedom of design M ST 009 2031 Record of Manual Revisions ISSUE NO DATE BRIEF DESCRIPTION OF REVISION 1 08 11 2000 Initial Release 2 11 23 2000 Revised Power Supply Information for PS Series 3 11 05 2001 Revised Hardware Specifications Copyright Information Copyright 2000 Kollmorgen All rights reserved Printed in the United States of America Kollmorgen GOLDLINE SILVERLINE MOTIONEERING PLATINUM and SERVOSTAR are registered trademarks of Kollmorgen Corporation a Danaher Motion Company NOTICE Not for use or disclosure outside of Kollmorgen except under written agreement All rights are reserved No part of this book shall be reproduced stored in retrieval form or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the book the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Kollmorgen that is furnished for customer use ONLY No other uses are authorized without written permission of Kollmorgen Information in this document is subject to change without notice and does not represent a commitment on the part the Kollmorgen
17. It is recommended that a shielded twisted pair wire be used with the shield connection tied to earth ground at the drive end of the cable The cable should be routed free from noise sources such as solenoid and relay wires and the motor armature cable The analog signal wires should be twisted shield pair cable run free from any noise signals such as relay and solenoid wires as well as the motor armature and power line wires The cable shield should be tied to earth ground at the drive While a shield pin C2 pin 4 is provided it is best to bring this drain directly to the drive case Current Monitor C2 Pin 5 The current supplied to the motor can be monitored at this pin referenced to common C2 pin 7 The scaling of this output is 8 volts drive peak current rating Tachometer Monitor C2 pin 6 The motor velocity can be monitored on this pin referenced to common C2 pin 7 The scaling of this output is 8 volts 2 motor s rated speed CW and CCW Limit Inputs C2 pins 8 and 9 The CW CCW Limit inputs are used to limit the ability of the motor to produce toque in the stated direction Assuming proper motor phasing Each input may be tied to common C2 pin 7 to disable torque in that direction SERVOSTAR S CD Product Family 29 Danaher Motion Operation Information Remote Enable Input C2 Pin 10 The Remote Enable input provides a hardware drive enable switch This input disables or enables the power stage output to the motor
18. Output Relay 5 6 User Controls Enable Operation Tie to common to activate circuit CW CCW Lim Torque Hold DO NOT APPLY VOLTAGE Ext I Limit FEEDBACK DEVICES The SERVOSTAR SBD is designed for use with analog tachometer feedback only The absolute maximum voltage that the tachometer is allowed to generate and send to the control electronics is 100V SERVOSTAR SBD Series ST CT Product Family 7 Danaher Motion System Description 8 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Power Supplies Power Supplies The SERVOSTAR family includes a variety of BUS modules that convert a single phase logic voltage and a single or three phase AC line into the drive s DC logic power and main DC BUS Brush motor design makes them more sensitive to high voltage conditions than brushless motors The PS power supply family offers a number of voltage ratings designed to shunt regulate regenerated power to maintain safe operating voltage levels Operating these power supplies with higher than designed input voltages can cause regen circuit failure FEATURES Converts single or three phase AC main lines or transformer outputs into a rectified DC BUS check BUS module Electrical Specifications table to verify specific BUS module operation The input consists of a 36 diode bridge soft start circuitry and BUS capacitors These capacitors help to minimize BUS ripple and therefore BUS drooping during the peak power demands of the l
19. S 08 20 or 40 m E a a CH Lu a a AO Teer e e e DOVER AMT NO BINOSI 1 3LarTVYO OL 25 SERVOSTAR S CD Product Family Danaher Motion Hardware Installation ST System Wiring Diagram Notes Note 1 A Note 2 Note 3 Note 4 a Note 5 Note 6 Note 7 Note 8 Note 9 Note 10 Note 11 Note 12 Note 13 Note 14 Note 15 Note 16 Note 17 26 Resistor is connected to high voltage Please ensure sufficient electrical clearance when mounting Resistor may become very hot during operation Do not mount near materials that are flammable or damaged by heat Ventilation may be required Each kit has different series parallel resistor connectors to obtain specific resistance and power rating For guidance on application sizing of Regen Kits see Application Note SERVOSTAR S C Series Regeneration ls on Br PSP CD ROM or the SORTE website When using internal regen mus jumper installed between terminals R and C Remove when using external regen kit A thermal overload relay is supplied in the regen resistor kit The thermal overload relay was sized for the resistance and power rating of the resistor The output contacts of the relay must be wired to drop power to the main power contactor during a fault condition as shown in the drawing Do not wire Logic Control power through the main power contactor Control power should not be removed if BUS module s fault contacts open as
20. TY INFORMATION All products covered in this manual are warranted to be free of defects in material and workmanship and to conform to the specifications stated either in this document or product catalog description All Kollmorgen brushless motors and electronics are warranty for a period of 24 months from the time of installation or 30 months from time of shipment which ever comes first There are no other warranties expressed or implied including the warranty of merchantability and fitness for a particular purpose which extends beyond this warranty Kollmorgen warrants that the products covered in the manual are free from patent infringement when used for normal purposes SERVOSTAR SBD Series ST CT Product Family 1 Danaher Motion ABBREVIATIONS AC AppNote CCW KHz KCSN KW LED Lim NEC PSP P N PWM Regen RMS Tach UL Clockwise and counterclockwise reference as viewing the motor output shaft Alternating Current Application Note Counter Clockwise Common Mode Rejection Clockwise Direct Current Differential Electro Motive Force Electromagnetic Compatibility Electromagnetic Interference Electrostatic Discharge External Hertz Current Information Input Output KiloHertz Kollmorgen Customer Support Network KiloWatts Light Emitting Diode Limit National Electrical Code Product Support Package Part Number Pulse Width Modulation Regeneration Root Mean Square Tachometer Underwriters Laboratories
21. ability to adjust aDC Gain component When the pot is fully clockwise the input is scaled so that full rated motor speed occurs with a 10V input When the drive is used inside an external positioner control loop it is typical to adjust this potentiometer to allow full speed with an 8V input to allow for overshoot The velocity feedback is from an external tachometer generator going through a 5kHz low pass filter before entering the comp card where it must be scaled for the velocity loop with resistor component 11 The appropriate value for this resistor can be calculated using the following formula R11 In Ohms Tachometer Voltage V KRPM Rated Speed 1 2 1 875 1 150 32 SERVOSTAR SBD Series ST CT Product Family Kollmorgen Operation Information The velocity loop has the ability to be bandwidth limited for stability purposes Resistor 8 and capacitor 16 are used for this purpose Resistor 8 establishes a minimum gain while capacitor 16 determines the roll off frequency The stability pot allows some adjustment in the AC gain portion of the compensator to allow for changing external characteristics such as inertia Components resistor 7 and capacitor 14 allow for even more roll off at higher frequencies which is sometimes required to reduce higher frequency noises The velocity compensator offers a feed forward or lead network for the tachometer using components 12 and 15 Resistor 12 is nominally chosen as 1 3 the value o
22. ack signal for an over speed condition and is typically set to detect speeds in excess of 120 of the motor s rated speed Resistor components 1 and 2 set the reference trip voltage for the over speed comparator Considering the absolute tach signal is scaled for 8V max speed adjusting the voltage divider to provide a 10 volt trip point allows this circuit to perform satisfactorily and is established using 1 2k ohms for 2 and 7 2k ohms for 1 The tachometer must also be scaled for the over speed circuit using resistor component 13 calculated as follows R13 in Ohms Tachometer Voltage V KRPM Rated Speed 1 2 1150 Current Clamps 12V ES SCH CH SE Vv The current to the motor is clamped according to 3 separate signals as shown in the above figure Torque Limit pot External Current Limit Input and the Horsepower contour circuit All clamps work on the following fundamental scaling Full speed is 8V and peak drive current is 8V The clamp circuits work to limit the current command voltage signal to something less than 8V Torque Limit Pot The torque limit pot allows an adjustment of maximum allowable current When set clockwise the pot allows peak rated current of the drive to the motor Turning the pot counter clockwise clamps the maximum current to less than the drive s peak rating External Current Limit The external current limit is a user input at connector J2 Tying this input to common ac
23. arwire 1425 124 86 Spade Terminals 16 14 AWG 1 5mm Hollingsworth XSS0954S OR SS20947SF or equivalent 12 10 AWG 4 6mm Hollingsworth XSS20836 OR SS20832F or equivalent Ring Terminals 8 AWG 10mm Hollingsworth R3027BF or equiv 6 AWG 16mm Hollingsworth R4001BF or equiv 4 AWG 25mm Hollingsworth R5100BF or equiv 2 AWG 35mm Hollingsworth R7998BEN or equiv Clearance Distance Includes C1 C2 C4 C7 plus 2 of stranded bus ribbon C8 C6 Kollmorgen A 81014 002 Vendor Info PCD Mating ELFP02110 Connectors C7 Kollmorgen A 81014 004 Vendor Info PCD ELFP04110 C8 Kollmorgen A 81014 003 Vendor Info PCD ELFP03110 Connector Screw Torque 2 25 Ib in 25Nm Wire Size AWG mm System Phasing Information The SERVOSTAR SBD Series drive outputs a positive voltage Ma with respect to Mc for a clockwise command Diff High input more positive than Diff Low Input and expects to receive a positive tachometer voltage Tach High with respect to Tach Low Reference points for Kollmorgen motors Motor Armature positive lead is orange negative green Tachometer Positive Lead is white negative is black Clockwise reference is looking into the motor from the output shaft end 18 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Hardware Installation OUTLINE DIMENSIONS ST and PS Units D gt E NoteFan Sx85 WEN Inches PRODUCT a R Cc n Fr FE G u r
24. as a separate power supply module The PS Series of power supply modules are fully compatible to the SERVOSTAR SBD Series of products Fault and Safety Detection Over Voltage protection Over Current Protection Short Circuit Under Voltage Lock out Can be disabled Motor Over Speed Protection Over Temperature Protection Drive s internal temperature General Industry Standard 10 Volt command signal input External Regeneration Capability SBD2 Compensation Compatible Drive Wide Range of Power Capacity Smaller units available with integral Power Supply Units available with Modular Power Supply SERVOSTAR SBD Series ST CT Product Family 3 Danaher Motion System Description PART NUMBER DESCRIPTION Month A January Year Manufactured E February Facility Blank Radford L December C China S Israel Unit Manufactured M Spain Z Israel 5984 589 MODEL NO CT03000 SBD2 4236AA2 160 03 SERVCSTAR Amplifier Family Intended Drive S S Series Rating C C Series Compact Drive Feear intended Bus Voltage Feedback Intended Bus Voltage T Tachometer LM Tachometer Voltage Rated Current S Series 03 06 10 20 30 55 dina 3 5 5 5 5 5 M W g E C Series 03 06 10 otor Windin Hardware Variations Motor Frame 000 Standard Product SBD2 Compatible Compensation 4 SERVOSTAR SBD Series ST CT Product Family Danaher Motion System Description CT ELECTRICAL SPECIFICATIONS
25. e The second shows a technique for bonding a terminal strip for best results it is recommended not to break the shielding of the cable ST e From the drive Q D Terminal Strip 8 2 s Ololololo 0000o 9 9 o je e O e Bonded to Back Plane D CD To Motor Sx Drive Clamp Cx Drive Clamp Terminal Clamp 22 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Hardware Installation Alternative Bonding Methods Another option is to use cable bonding clamps offered by Phoenix Contact and others When using the Phoenix Contact parts make sure that a low impedance high frequency ground is connected from the ground bus bar to the back panel This can be done with a flat braid or a copper bus bar The SK parts from Phoenix SK8 SK14 amp SK20 slide onto the bus bar The cable with exposed shield is inserted through the SK piece and the thumbscrew on top of the SK piece is used to tighten the connection between the cable shield and the bus bar Phoenix Contact Part Cable Diameter Range 3025163 Shielded terminal block for SK8 Type SK8 placing the shield on bus bars up to 8mm or 0 315 inches 3025176 Shielded terminal block for SK14 TypeSK14 placing the shield on bus bars 8mm to 14mm or 0 551 inches 302518
26. ear yet the tolerance of the flashover conditions make this circuit design adequate Second Break N Kr Break VA M ONE Peak Torque SERVOSTAR S CD Product Family 35 Danaher Motion Operation Information Establishing a Single or one Break Line Limit Diode 26 sets the speed at which horsepower contouring will begin P1 D26 is calculated as Vz 8 N Nmax 1 5 Where V is the Zener Diode Voltage Rating N is the speed at which contouring begins N max Is the Maximum System Speed The first line segment P1 P2 or P1 P3 has its slope established by R25 If a single line segment approximation is suitable the resistor must have the line segment intersect at P3 and R30 is a 0 jumper The value of R25 is determined as follows R25 20 000 8 V 12 8 Tctamp Ipeak Where V is the Zener Diode Voltage Rating Tetamp 18 the Maximum current at the breakpoint Ipeak 18 the Drives Peak Current Rating 2 continuous Establishing a Two Line or Break Limit If a two line segment is required R30 is set to 2K O D26 is calculated as above and R25 is calculated for the first line segment P1 P2 with the following equation R25 20 000 S NyN V 2000 12 8 I ctamyp I peak Where the new variables N Desired Speed for second break N Motor s Rated Speed The second line segment P2 P3 is established using D20A and R31 POTENTIOMETER ADJUSTMENTS This section describes the purpose and effect
27. em Stability seems sensitive to load changes 1 Adjust Stability pot for less bandwidth 2 Reduce lead network effect Position loop pulls motor into a slightly incorrect position 1 Adjust balance pot System peak currents are erratic 1 Worn tachometer causing intermittent signal loss SERVOSTAR S CD Product Family 41 Danaher Motion SERVOSTAR Help CUSTOMER SUPPORT Kollmorgen is committed to quality customer service Our goal is to provide the customer with information and resources as soon as they are needed In order to serve in the most effective way Kollmorgen offers a one stop service center to answer our customer s product needs One number provides order status and delivery information product information and literature and application and field technical assistance Kollmorgen Customer Support Network 501 First Street Radford VA 24141 1 800 77 SERVO 73786 Email servo kollmorgen com Internet http www MotionVillage com Fax 1 540 639 1574 If you are not aware of your local sales representative please contact us at the number above Visit our website for upgrades technical articles and the most resent version of our product manuals 42 SERVOSTAR SBD Series ST CT Product Family
28. er and comparing the compensation portion of the model number to both the motor s number and the applied voltage compensation components may cause the motor to act uncontrollably It is your responsibility to be certain that damage to equipment or personnel cannot occur during startup Verify that the hardware Remote Enable input is disabled i Caution must be taken when applying power to the drive Any incorrect phasing or incorrect Power Up Sequence The SERVOSTAR is insensitive to power up sequence meaning that bus power or logic power can be applied independently Enabling the System With the input command signal at O volts enable the drive The green Enable LED should illuminate and there should be no fault LEDs red illuminated Be certain the motor does not run away If the motor does run away the phasing of the armature or tachometer must be incorrect Check the motor to see that there is applied torque by carefully commanding velocity first in one direction and then the other Drive Tuning The drive should control the motor in a proper servo stability fashion where the system is responsive yet stable When using an external position loop controller the velocity loop is to be tuned first independent of the position loop The AC Gain pot may be trimmed for best transient response for the system If the system is unstable the system is going to require tuning by someone experienced in such maters The Control Loops section of this
29. eter At higher frequencies this unwanted inductance between grounds equates to limited filter performance When connecting high frequency grounds use the shortest braid possible SERVOSTAR SBD Series ST CT Product Family 21 Danaher Motion Hardware Installation Bonding The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels of the drive system Its effect is to reduce the impedance between the cable shield and the back panel Kollmorgen recommends that all shielded cables be bonded to the back panel Power input wiring does not require shielding screening if the power is fed to the cabinet enclosure via metallized conduit If the metallized conduit is used with proper high frequency grounds bonding technology and recommended wire routing then power input wire shielding will have no affect In the event that metallized conduit is not implemented into the system shielded cable will be required on the power input wires and proper bonding technologies should be implemented The motor and feedback cables should have the shield exposed as close to the drive as possible This exposed shield can be bonded to the back panel using one of the two suggested methods below Non insulated Cable Clamp The following figures shows how cable bonding can be implemented using non insulated metallic cable clamps The first figure demonstrates clamping to the back panel in the vicinity of the driv
30. f R11 and C15 is adjusted under test to allow best transient response to a step function while keeping the decel overshoot to a maximum of 10 While a lead network adds responsiveness it can also add noise into the system and tends to tune the system for a given inertia and makes the system less tolerant to changes in the inertia It is perfectly acceptable to not use the lead network In cases with large load to motor inertia ratios or where there is changing load inertia In systems requiring a starting spot for the lead lag components the following method provides good results l Determine the value for resistor 8 With C 16 a short circuit C 15 removed and the stability pot about centered apply a 1V square wave to the input allowing the motor to rotate freely For best results the frequency of the square wave should be about 4 the desired bandwidth Start with resistor 8 at a low value 1K Raise the value of resistor 8 until the response shows good critically damped response little to no overshoot This establishes the value of resistor 8 2 Determine the value of capacitor 16 With the new value installed in R 8 replace the short circuit with a capacitor substitution box Beginning with a very high capacitance value lower the value until the response now shows some overshoot In systems not using the lead network a 10 overshoot is usually optimal In systems using a lead network 20 to 30 overshoot is usually optimal
31. inuous p NEM 2sec 50msec Line Fuses FRN LPN or 20 40 20 40 20 40 20 40 20 40 A DC BUS Voltage Nominal VDC PS20 Bus Current Main Output Amps DC 10 36 gt gt Power PS40 Bus Current Amps p NE ES Voltage 115 115 16 115 16 115 16 115 16 Logic Input e HAKI Amps AC T5 Y Supply G 7 25 8 5 7 25 8 5 7 25 8 5 7 25 8 5 m ez w n i OSIC t Ower Analog me n 25 ae 1425 mas na 143 Output Volt Range Amps 16 0 8 16 0 8 16 0 8 Internal Fusing 1 5 3 5 1 5 3 5 8V 15V Amps Turn Off Level on power up L3 89 I m m m 7 0 75 ER Protecti so Kar svac 115VAC 115VAC Fosecuon Fault Contact Closing 250 250 250 Period mSec Over Temperature trip C Internal heat dissipation 70 125 70 125 70 125 70 125 70 125 Environmental ano 2040 EE Baci cd LL 504 508 0 70 0 70 Altitude Ft 3300 3300 3300 3300 3300 Derate 5 per 1000 over EVA E eS HERE s 1030 10 90 N un o N in io 12 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Power Supplies BUS MODULE REGEN INFORMATION Product Model PS20 PS40 internal Shunt A Mas O o T j Fase Rating ampsintemal 7 SS External Shunt ___Peak eument amp rr MB Internal Regen For guidance on application sizing of Regen Kits see Application Note SERVOSTAR S C Series Regeneration Requirements on the PSP CD ROM or the Kollmorgen website www MotionVillage com Kit Parts and Models Kit Parts
32. lb in M5 201b Hardware Ground Screw M4 121b in 1 35Nm 10 32 20lb in Box Lug Size Torque 2 26Nm Control Logic AWG 18 75 MA 201b in M5 201b mm in Configurable I O wire 22 18 AWG 3 75mm gauge Ferrules recommended 18 AWG Type HI 0 14 Weidmuller 4630 0 or I equivalent Wire Size 20 AWG Type H0 75 14 Weidmuller 4629 0 or equivalent AWG Spade Terminals 16 14 AWG 1 5mm Hollingsworth XSS0954S OR SS20947SF or equivalent 12 10 AWG 4 6mm Hollingsworth XSS20836 OR SS20832F or equivalent Ring Terminals 8 AWG 10mm Hollingsworth R3027BF or equivalent 6 AWG 16mm Hollingsworth R4001BF or equivalent 4 AWG 25mm Hollingsworth R5100BF or equivalent 2 AWG 35mm Hollingsworth R7998BFN or equivalent 2 5in 63 5mm Distance Includes C1 C2 C4 C7 plus 2ft 0 25m of stranded bus ribbon C8 Se Connector Kollmorgen A 96516 Hardware Connector Screw Torque SERVOSTAR SBD Series ST CT Product Family 17 Danaher Motion Hardware Installation BUS Module Hardware Specifications BUS Module Model PA LM PS08 PS20 PS40 Mounting 10 32 M4 Hardware Applied Torque Torque 20 Ib in 2 26Nm Line Screw Size Torque 6 32 10 32 121b in 121b in 1 35Nm Connection DM Hardware BUSScrewSize Torque Screw Size T BUSScrewSize Torque Ground Screw Size Torque MAI aie in 1 35Nm Control Logic 18 75 Main Input gauge based on 90 C 14 2 5 12 4 8 6 wire BUSb
33. lly cools enough to allow reset of this condition More common causes for this fault is excessive loading on the drive and or operation in elevated ambient temperature environments Bus Over Voltage An over voltage condition shuts down the drive This fault occurs mostly during regen operation where the BUS is raised to higher values than that produced by the power supply In such a case either an external regen resistor is required or the deceleration rate must be decreased This fault also occurs if the incoming power supply voltage is excessively high Bus Under Voltage There is a Jumper internal to the drive to determine the function of this fault detection circuit If JP1 is in place normal shipping state an under voltage condition is latched and shuts down the drive This fault normally occurs when the incoming line voltage drops out or a fault occurs in the power supply If JP1 is removed the drive does not look for this fault condition A special power up circuit is provided to reset an under voltage fault after power is first applied to allow appropriate power sequencing Power Stage Fault Over Current Hardware circuitry monitors load short circuit transistor failure transistor over temperature gate drive power and instantaneous over current to latch this fault condition The most common reason for this fault is a shorted motor lead external to the drive Try removing the motor armature connections from the drive and see if
34. lts Drive Peak Current Rating Resistors 9 and 10 offer the ability to change this scaling to make the sensors more sensitive The lead network can allow for a more responsive current loop but lead networks tend to add noise This circuit features the 2 4V zener diodes to clamp noise from entering the lead network The current loop incorporates electrical isolation for protection from the high voltage BUS These current details A simple approximation can be made by simply using a single low pass filter designed to slow the rate of change of the voltage command to prevent double pulsing the PWM output Components for the tuning the current loop can be calculated with the following equation Resistor 5 lt 1x1 09 Drive s Peak Current Rating Motor inductance VAC 1 6 Capacitor 19 1 625 Resistor All other components should be open circuit Velocity Loop The purpose of the velocity loop is to regulate motor speed The velocity loop compares the commanded velocity to the actual velocity tachometer signal and generates a current command to bring the two in equilibrium The difference between actual and desired velocity is filtered through a compensator as shown in the following diagram Sazan H 680 470 Components T 47 10n H d a 10k 10K The input to the velocity loop comes from an external analog source and is scaled with the Scale potentiometer that provides the
35. m physical and environmental damage and to protect nearby personal from hazardous electrical potentials SERVOSTAR SBD Series ST CT Product Family 15 Danaher Motion Hardware Installation SERVOSTAR CT Hardware Specifications Connection Hardware BUS Screw SizefTorque SSCS Motor Serew SizefTorque OOOO J Ground Serew Size Torque OCO TT 2516 0315 Configurable I O wire gauge 22 18 AWG 3 75mm Ferrules recommended 18 AWG Type HI 0 14 Weidmuller 4630 0 or equivalent Wire Size AWG 20 AWG Type HO 75 14 Weidmuller 4629 0 or equivalent Spade Terminals 16 14 AWG 1 5mm2 Hollingsworth XSS09548 OR SS20947SF or equivalent 12 10 AWG 4 6mm2 Hollingsworth XSS20836 OR SS20832F or equivalent Ring Terminals 8 AWG 10mm2 Hollingsworth R3027BF or equivalent 6 AWG 16mm2 Hollingsworth R4001BF or equivalent 4 AWG 25mm2 Hollingsworth R5100BF or equivalent 2 AWG 35mm2 Hollingsworth R7998BEN or equivalent Clearance Distance Side to Side Sin 12 7mm Top Bottom 2 5in 63 5mm CK100 Kit Includes C1 C2 C4 C7 plus 2ft 0 69m of stranded bus Mating Connector C2 Phoenix MVSTBW 2 5 20 ST 5 08 Connector Screw Torque 2 25 Ib in 0 25m 24V Logic optional PCD ELFP02210 or equivalent 16 SERVOSTAR SBD Series ST CT Product Family Danaher Motion Hardware Installation SERVOSTAR ST Hardware Specifications Mounting Hardware 20 Ib in 2 26Nm Motor Screw Size Torque 6 32 121b in 1 35Nm 10 32 20
36. nstallation Kollmorgen AINCESINNO SH 3H MD OL COONEY E ERICA ANGELN NOVO 29 DOA COP Ow Jv EZ Svr SIV FINNM SOL li 650G AM SY DOA H SOY DO A HA SOLDI MO COME SOV 25 Bu WV ONIN NV SHE os 2100 sss EM HOOR TEEN dankans wa va mms seug omy Aue yjoeuueo ea ses eseuci eyfu s A t A ai 1 3108338 gig z LEDE 1 H3MOd LM Ke to 2100 388 INndNI NVA 1 I suas von MAPAS Q zem CT Wiring Diagram 27 SERVOSTAR S CD Product Family Danaher Motion Hardware Installation CT Wiring Diagram Notes Note 1 Note 2 Note 5 Note 6 Note 9 Note 10 Note 11 Note 12 Note 13 Note 14 Note 16 Note 17 28 FUSE 2 and contactor may not be required if input power line is neutral Also see Note 9 Allow 30 seconds after turning power off before reapplying power All AC Line wires should be twisted pair The ground of the drive and motor best minimizes ground currents and noise when connected in a star pou FORM Leka Ge ca enatt be properly SE to the Lac sin l and implemented as close to the drive side of the cable as possible for effective grounding If bonding is installed the shield on the cable end need not be connected to the star point configuration Only connect the shield on one end of the cable preferably on the drive side See Installation Practices on page 2 Ii for full details Units must be installed in an enclosure that meet the
37. oad All units have soft start capability to gradually develop the DC BUS allowing direct line connection to minimizes the effect of in rush current spikes inherent in a power up cycle An external Shunt Regulator option to dissipate regenerative energy while maintaining a safe operating voltage for the motor The logic BUS module on all units consists of a switching power supply to develop the required 5V and 8V from either the main line use L4 and Lg or a separate AC logic input Product features are Indicator PS10 PS20 40 PS50 75 85 Green LED x x x 2Yellow LED n a x x Red LED n a n a x Fault Relay n a X X SoftStart X X X Regeneration n a VE E Indicates when voltage is on the caps Indicates unit is operating in regen and may flash during aggressive accelerations 3 Indicates unit is still in SoftStart This LED is also used to indicate when an OverVoltage fault has occurred from too much power being pumped back into the system during regen 4 The relay is a normally open contact and closes after the unit is powered up and out of SoftStart The contact will open if there is an improper BUS module voltage dropping in and out of SoftStart an over heated internal regen resistor or the main heatsink becomes too hot Contains SoftStart capability E external I internal SERVOSTAR SBD Series ST CT Product Family 9 Danaher Motion Power Supplies The PA LM unit is a logic supply only and
38. oducts and systems have been successfully tested and evaluated to the limits and requirements of the EC Directive on EMC 89 336 EEC and the EC Directive on Low Voltage 72 73 EEC The product lines have been evaluated to EN50178 and EN60204 as a component of a machine and other relevant standards The Electromagnetic Compatibility EMC of a system is identified in two parts emissions and immunity Emissions are the generation of EMI electromagnetic interference and immunity is the susceptibility levels of the equipment Limits are derived from generic standards EN55081 2 and EN55082 2 for heavy industrial environment The SERVOSTAR series of drives and BUS modules have been tested for radiated emissions conducted emissions EFT ESD surge conducted immunity and radiated immunity These tests have been in accordance with EN55011 EN61000 4 2 ENV50140 IEC 1000 4 4 EN61000 4 5 and ENV50141 Installation of the equipment is critical in designing system and machine electro magnetic compatibility EMC The user must apply the installation recommendations in this manual See the installation section and CE Filtering Techniques information when mounting and installing the drive system for CE conformance iv SERVOSTAR SBD Series ST CT Product Family Danaher Motion General Information General Information This manual is designed to lead you through the proper installation and setup of a SERVOSTAR SBD Series servo system It was developed
39. ol system lives in can effect its operation Kollmorgen recommends that the SERVOSTAR system be operated and stored under the environmental conditions stated in the product specification tables The system may be operated in higher temperature ambient conditions with a derating applied Please check with the factory for derating information Attention to proper installation and field wiring are of prime importance to ensure long term and trouble free operation Users should familiarize themselves with and follow the installation and wiring instructions listed in this chapter In addition to these practices some localities and industries may require applicable electrical and safety codes laws and standards Enclosure The Kollmorgen SERVOSTAR series of electronic system components are designed for panel assembly This panel assembly should then be mounted in a metallic enclosure Enclosures are supplied by the manufacturers of the final product and must meet the environmental IP rating of the end product To ensure proper grounding and to optimize EMC the enclosure should have continuous ground continuity maintained between all metal panels This ground continuity is intended to be both a safety ground and a high frequency ground The units should be mounted on a back plane which is installed into the enclosure Ideally the back plane should be an unpainted metallic surface to optimize electrical bonding of the frame and provide the lowest p
40. on the installation requirements It is vital to ensure that all system components are connected to earth ground Electrical safety is impossible without a low resistance earth connection The SERVOSTAR product contains electrostatically sensitive components that can be damaged by incorrect handling Discharge yourself before touching the product Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface During operation keep all covers and cabinet doors shut Otherwise there are deadly hazards that could possibility cause severe damage to health or the product In operation depending on the degree of enclosure protection the product can have bare components that are live or have hot surfaces Control and power cables can carry a high voltage even when the motor is not rotating Never pull out or plug in the product while the system is live There is a danger of electric arcing and danger to persons and contacts After powering down the product wait at least 10 minutes before touching live sections of the equipment or undoing connections e g contacts screwed connections Capacitors can store dangerous voltages for long periods of time after power has been switched off To be safe measure the contact points with a meter before touching The safety alert symbols contained in this manual are Warning alerts users to potential danger or harm Failure to follow wa
41. ossible impedance path to earth ground These enclosures also provide added safety Wiring Practices Particular care should be used when layout of an enclosure is designed Efforts to separate power wires from small signal wires should be taken The following guidelines highlight some important wiring practices to implement Control and signal cables must be separated from power and motor cables A distance of 20cm 8in is sufficient in most cases Control and signal cables must be shielded to reduce the effects of radiated interference Where control cables must cross power or motor cables they should be done with an angle of 90 degrees if possible to reduce the field coupling effect Grounding System grounding is essential for proper performance of the drive system A ground bus bar may be used as a single point ground for the system Safety grounding should be provided to all pieces of the system from a star point In addition to the safety grounding a high frequency ground must be provided that connects the back panel to the enclosure and ultimately to earth ground The objective is to provide an extremely low impedance path between the filters drives power supplies and earth ground This high frequency ground can be accomplished with the use of a flat braid or copper bus bar It is important not to rely on a standard wire for the high frequency ground In general a wire has an inductance of 8nH in regardless of diam
42. potentiometer located at the top of the drive unit Under normal system phasing a positive voltage on these terminals commands the motor in a clockwise direction The analog signal wires should be a twisted shielded pair cable run free from any noise signals such as relay and solenoid wires as well as the motor armature and power line wires While a shield pin C2 pin 15 is provided it is usually best to tie the shield of this cable at the source end If it is impractical to tie this cable at the source end it is best to tie this cable directly to the drive case 30 SERVOSTAR SBD Series ST CT Product Family Kollmorgen Operation Information CONTROL LOOPS The SERVOSTAR provides high performance motor control by controlling motor current with an inner current loop which is controlled by an outer velocity loop Enable D ge Hal ley Dem Taga Hek D 1 a i 5 i 2 B 1 Armature Command Was p le gd N N A a c a d J D Ea 1 a Kal Hee Y t t E Ni V y L7 S dis T HP Contour AB 473 PES n n di EJ Tach Monitor Monitor mmm ZS T Tech Each servo loop current and velocity is subject to a compensation network as described below to allow appropriate servo loop tuning In addition the current loop is subject to clamping protection for current limiting due to input request compensation limits or commutation limits as described below Current Loop Since
43. rning notices could result in personal injury or death Caution directs attention to general precautions which if not followed could result in personal injury and or equipment damage Note highlights information critical to the users understanding or use of these products When these symbols are seen in this manual be alert to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment Failure to observe these precautions could result in serious bodily injury damage to the equipment or operational difficulty SERVOSTAR SBD Series ST CT Product Family iii Danaher Motion General Information Directives and Standards The SERVOSTAR product series has been successfully tested and evaluated to meet UL cUL 508C for U S and Canadian markets This standard outlines the minimum requirements for electrically operated power conversion equipment frequency converters and servo amplifiers which are intended to eliminate the risk of fire electric shock or injury to persons being caused by such equipmen
44. s of adjusting each of the drive s 4 adjustment potentiometers Two potentiometers DC Gain and AC Gain are located on the comp card and face the user The other two potentiometers Balance and Current limit are located at the top of the drive unit DC Gain Scale This potentiometer adjusts the velocity scaling of the drive The analog input to the drive causes a commanded velocity to the motor This potentiometer adjusts the amount of input voltage signal required to command a given motor velocity This potentiometer is typically adjusted for 10 volts rated speed for systems requiring only velocity control In systems where the drive is used inside a position loop it is common to adjust this pot so that 8 volts rated motor speed to allow servo headroom 36 SERVOSTAR SBD Series ST CT Product Family Kollmorgen Operation Information AC Gain Stability This potentiometer is used to adjust the AC gain of the velocity loop There is a low pass filter network around the velocity loop amplifier allowing the velocity loop to be bandwidth limited for stability This pot is used to modify the exiting bandwidth When the velocity loop compensator components are properly selected this pot allows some adjustment to variation in the load dynamics Adjust this potentiometer for best system response while maintaining servo loop stability Balance DC Offset This pot adds a DC offset signal into the velocity loop to null any offsets in the sy
45. stem In systems where the drive is used as a velocity controller this pot is adjusted for zero motor speed when applying a zero speed command input In systems where the drive is used inside of a position loop it is common to adjust this potentiometer when the motor is at rest for acommand of 0 000 volts input signal Current Limit This pot is used to limit the peak current to the motor to something less than the drive s peak current SERVOSTAR S CD Product Family 37 Danaher Motion System Startup System Startup Check the system wiring before applying power It is important that the proper voltages are wired to the appropriate terminals at the drive It is extremely important that the system is properly grounded The motor frame should have a ground wire back to the frame of the drive Voltage should not be applied to any of the drive s input control signals These signals are controlled by leaving them open or tying them to the drive s common The phasing of the system must be correct If either the armature or the tachometer is reverse phased the velocity loop causes a potentially unsafe run away condition allowing the motor to run uncontrolled When used inside a position loop the command signal must be phased correctly or the position loop may cause arun away condition INITIAL STARTUP Most drives are shipped from the factory already configured for a particular motor You can verify this by checking the drive s model numb
46. t Mark Conformance Servo drives are incorporated in electrical plants and machines for industrial use When the servo drives are built into machines or plants the operation of the drive is prohibited until the machine or plant meets the requirements of the EC Directive on Machines 89 392 EEC and the EC Directive on EMC 89 336 EEC EN 60204 and EN 292 must also be met In connection with the Low Voltage Directive 73 23 EEC the harmonized standards of the EN 50178 series are applied to the amplifiers together with EN 60439 1 EN 60146 and EN 60204 The manufacturer of the machine or plant is responsible for ensuring that they meet the limits which are required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding arrangement of filters treatment of connectors and the lay out of cabling can be found in this documentation Conformance with the EC Directive on EMC 89 336 EEC and the Low Voltage Directive 73 23 EEC is mandatory for the supply of servo drives within the European Community The servo drives have been tested by an authorized testing laboratory in a defined configuration with the system components described in this documentation Kollmorgen is not responsible for any divergence from the configuration and installation described in this documentation and is not responsible for the performance of new measurements or ensuring that regulatory requirements are met Kollmorgen s SERVOSTAR pr
47. tivates the limiting circuit The limit that is asserted when this input is low is a proportion of the drive s peak current limited by the Torque Limit pot and established by the value of component 23 on the comp card Component 23 is a resistor whose value is determined from the following chart 34 SERVOSTAR SBD Series ST CT Product Family Kollmorgen Operation Information External Current Limit Resistor 27 1000000 3 gt Value 2 100000 A ZS c 10000 0 10 20 30 40 50 60 70 50 90 100 Percent Torque Available The value of 23 is given on the Y axis while the percentage of available torque is given on the X axis The value of 23 should not be less than shown on the chart or the torque to the motor is asymmetrical Horse Power Contour The horse power contour circuit exists to protect the system Brush motors have a limit of how much power can be transferred from the brushes to the commutator before an arc occurs from brush to brush known as flashover Drive and motor damage can occur if flashover happens The horsepower contour circuit limits the current to the motor as a function of speed effectively creating a simulated constant horsepower curve The circuit is established as a one or two line approximation P1 P3 and P1 P2 P3 respectively as shown in the following diagram The circuit uses zener diodes which are inherently inaccurate and non lin
48. with the assumption that there is a fundamental understanding of basic electronics mechanics and proper safety practices However you do not have to be an expert in motion control to install and operate the drive system It is recommended that you read the entire manual completely before installation and operation is attempted USE AS DIRECTED The following guidelines describe the restrictions for proper use of the SERVOSTAR SBD system These amplifiers are components which are built into electrical equipment or machines and can only be commissioned as integral components of such equipment The servo amplifiers are to be used only on earthed single or three phase industrial mains supply networks TN system TT system with earthed neutral point The servo amplifiers must not be operated on power supply networks without an earth or with an asymmetrical earth If the servo amplifiers are used in residential areas or in business or commercial premises then the user must implement additional filter measures The servo amplifiers are only intended to drive specific brush type servomotors from Kollmorgen with closed loop control of torque and velocity The rated voltage of the motors must be at least as high as the DC link voltage of the servo amplifier The servo amplifiers may only be operated in a closed switch gear cabinet taking into account the ambient conditions defined in the environmental specifications WARRAN
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