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Operating Instructions 221052E, V 1.3b 09/01

1. 0 0020 Appendix C Table of faults 1 4004 vaca Ben GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 8 Operating Instructions 221052E V 1 3b Figures Fig 1 Rack mount chassis 84 units wide 2 2222 0000 eee eee Fig 2 Control signals switching towards zero interface details Fig 3 Control signals PLC compatible interface details 4 Fig 4 Encoder signals 5 volt version interface details 05 Fig 5 Encoder signals 24 volt version interface details 05 Fig 6 Connection directions 220 62 au dan san she iwc amd hend aan Fig 7 Laying of the motor cables and earthing of their shields Fig 8 Setpoint potentiometer connection for commissioning Fig 9 Motor chokes xs sense een uncan ae anee sake aaureS FIG OCR ING sc cts aeons ee ee re 80 Fig 11 Location of the jumpers on the board 000 eee ee ern Fig 12 Location of the jumpers on the customer module 055 Fig 13 Solder bridges on the Z1 module 000000 eee 86 Fig 14 Solder bridges on the Z2 module 22 nn nennen nennen 86 Fig 15 Solder bridges on the Z4 module 0 000 eee eee Fig 16 Solder bridges on the P1 and P2 modules 000 02 ee eee GEORGII KOBOLD D 70771 Leinfelden Echterdingen
2. Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted Switching output Motor standstill or Power circuit ready 12 Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A EE Analog output Current monitor Connect cable shield to the housing of the SUB D connector 4 1 2 3 Version with Z2 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable Switching input Setpoint reversing Analog input Current reduction Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted Switching output Motor standstill or Power circuit ready 12 Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A Analog output Current monitor Connect cable shield to the housing of the SUB D connector GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 22 Operating Instructions 221052E V 1 3b 4 1 2 4 Version with Z4 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E
3. EMC directive 89 336 EEC low voltage directive 73 23 EEC machinery directive 89 392 EEC CE EMC GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b VDE regulations such as DIN VDE 0100 DIN VDE 0113 lt EN 60204 gt DIN VDE 0160 lt EN 50178 gt safety rules may therefore e install e commission e maintain and e service these units They must read these operating instructions carefully beforehand and always follow the safety instructions while working 2 3 Use for the intended purpose The servo amplifiers and the power supplies have been developed manufactured tested and documented in accordance with the rele vant standards If used for the intended purpose the devices do not cause any danger to persons or property Use for the intended pur pose requires that the device should be used only in the manner described here and that the safety regulations mentioned are adhered to When using the devices use for the intended purpose includes com pliance with the relevant regulations with respect to safety machinery directive and electromagnetic compatibility EMC directive Dispose of the apparatus at the end of its useful service life in accor dance with the current regulations GEORGII KOBOLD AUGUST HEINE GmbH amp Co can accept no liability for direct or indirect damage resulting from abuse
4. 80 Operating Instructions 221052E V 1 3b 10 2 7 RFI filters 002057020Z and 002057040Z As described in section 4 4 4 a RFI filter has to be connected be tween the mains transformer and the power supply in any case The precise installation instructions can be found there The filter has to be dimensioned according to the power of the power supply or the mains trans former respectively You find the suitable filter e inthe table of the technical specifications of the mains transform ers page 73 Figure 10 shows the dimensions of the RFI filters BN 3856 2309 604 950 Fig 10 RFI filter 10 2 8 Shield connection plate 089159 To establish earthing of the motor cable shield in compliance with EMC the shields have to be connected close to the RFI filter The shield connection plate 089159 which can be supplied as acces sories simplifies this procedure It will be screwed together with the RFl filter 8 cable clamps are attached at the shield mounting side allowing the correct earthing of the shields of 6 motor cables and the shield of the connection between mains filter and power supply GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 81 Chapter 4 Notes for specialists 11 Modifications to the servo amplifier This section describes how the factory settings can be changed If you have changed the
5. Switching output Fault or Ready Input setpoint E Switching output Motor standstill or Power circuit ready Output auxiliary voltage 15 V Input 24 V if option E1 Output auxiliary voltage 15 V Switching input Reset fault 0 Volt BN 6661 0000 00A 052 Fig 2 Control signals switching towards zero interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 33 4 3 2 Connector X2 control signals PLC compatible The following figure shows the interface details internal circuit at the 15 pin SUB D male connector for the control signals section 4 1 2 2 page 21 e for the version with polarity module PLC compatible version e forthe version with Z1 add on module e viewing the connector from the front that is looking at the front panel In the version without the Z1 module section 4 2 1 1 the unassigned inputs and outputs are not connected Switching input 100ka ka u O Limit switch 2 nF Zw 47ka Analog output Current monitor One I nF 100kn 7ka 7 12V 47ka 100ka Id ate Switching input Limit switch 1 Switching output Overload Switching input Con troller enable Analog output Speed monitor Input setpoint E Switching output Fault or Ready Input setpoint E Switching outp
6. 765 255 10 2 25 5 18 0 27 0 10 8 27 0 143 475 28 19 0 855 285 11 4 28 5 1 13 3 75 2 2 15 300 _ 5 1 2 4 0 1 28 4 25 2 55 5 If the desired type of motor is given in the order the current is factory set to the permissible motor current If not the Current rotary switch is set to position 5 Current switch 10 5 ABE _ e pee ae ee Pe Pee Pe Le eee If you have changed the factory settings it is essential that you should Tip document the new switch position in the table in section 12 page 90 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 49 5 3 LEDs There are three LEDs on the front panel of the amplifier Cn o eas ONN Fault red e lights up when fault is stored rung e flashes as long as power circuit or motor is over heated flashes in the event of a resolver fault Ready green e lights up when amplifier is ready Bereit e flashes when amplifier is disabled e flashes when fault is stored E a yellow E e a up when switched from peak current to con E a tinuous current in BT event of an overload When the mains ae is switched on the amplifier remains dis abled until all voltages are stable During this time which lasts for some tenths of a second the red LED lights up GEORGII KOBOLD D 70771 Leinfelden Echterding
7. Motor standstill signal e with solder bridge Power circuit ready signal The position of the solder bridge is labeled see fig 13 or 14 e Signal End Bereit on the Z1 module Be on the Z2 module The Z4 add on module provides the Power circuit ready signal GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 88 Operating Instructions 221052E V 1 3b 11 3 4 Switching off the peak current rise To switch off the peak current rise e seta solder bridge on the add on module The position of the solder bridge is labeled see fig 13 14 or 15 e Impulsstrom Aus on the Z1 and Z4 modules e I on the Z2 module 11 3 5 Switching off active braking at controller disable If the motor should not be braked actively by reverse current when controller enable is suspended that is at controller disable e seta solder bridge on the add on module The position of the solder bridge is labeled see fig 13 14 or 15 e aktive Bremse Aus on the Z1 and Z4 modules e BR1 on the Z2 module 11 3 6 Activating the ramp function The ramp function is disabled as delivered It is activated e by setting a solder bridge on the add on module The position of the solder bridge is labeled see fig 13 or 14 e Sollwert Rampe Ein on the Z1 module e Ein on the Z2 module The Z4 add on module has no ramp function 11 3 7 Adjusti
8. e First precaution shield the setpoint lead Connect the shield on the setpoint source to the appropriate zero In particularly critical cases e to avoid sheath current install an potential equilization cable on the shield parallel to the setpoint lead with a cross section of at least 2 5 mm Or e apply only a high frequency shield on the side of the setpoint sour ce using a low induction capacitor e g 10 nF 400 V T Always use the differential input p e this prevents zero loops that is the coupling of interference via the input zero Apply the setpoint at input E Connect input E with zero at the setpoint source 4 4 10 Connection of the encoder signals Figure 6 top right shows the connection of the encoder signals to a positioning controller Please note e Choose twisted pair cables for the 5 volt version GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 45 Use a shielded cable forexample the resolver encoder connecting cable mentioned in the accessories for further details see section 10 page 75ff Connect the shield at the amplifier to the earthed amplifier hous ing using the metal plated SUB D housing Additionally earth the shield at the controller follow the recommendations of the controller manufacturer concerning earthing and shield connection 4 4 1
9. 9 3 BOWERSUDPIV else lesen lehnten 9 2 1 DESIGN sack a N a a Het ar Haare 9 2 2 SMU ME PEO MNAION are een een era 9 2 3 Connection assignment terminal blocks X5 and X6 9 2 4 LSC eee ee rere ree ee etre eC ee ee eee ee eee eee ee 9 2 5 Technical specifications of the power supply 9 2 6 External shunt resistor vs are en ee wh Grave ern era arene Mains transformers nein ee 9 3 1 General information s anaana aaa 9 3 2 CONNECHONS naar DIE DI DEM 9 3 3 Technical specifications of the mains transformers IO ACCESSOrIESe 5 rk Ss cr ec epee oh sae SCP ae a eae erregen 10 1 10 2 Available accessories and order numbers 02000 ee eee Description of accessories 26s 0 25 20th cet 21 21 each ete eae et 10 2 1 Fe coho Ao mena ara ae ONAE A IC 10 2 2 Connector sets 099066020Z and 099066010Z 10 2 3 Motor connection cables 535246 Z and 535264 Z 10 2 4 Resolver Encoder connection cable 535245 Z 10 2 5 Ferrite nng 0421030 10 2 2 tis tou ed nn 10 2 6 Motor chokes 038096010Z and 038097010Z 10 2 7 RFI filters 002057020Z and 002057040Z 10 2 8 Shield connection plate 089159 2 000 00 eee Chapter 4 Notes for specialists 11 Modifications to the servo amplifier 2 2 0000 0 eee eee 11 1 11 2 11 3 Modifying the controller circuitry zone ren ieee as 11 1 1 Speed control range 0
10. For further details see section 9 2 2 page 69 f the operating voltage is too high the fault is stored If the voltage falls below the minimum permitted operating voltage or in the case of the external supply of the control circuit module E1 if it falls below the minimum permitted supply voltage e this is reported as a fault through the Fault switching output and the Fault LED This fault is not stored e it disappears when the correct operating voltage has been reached again GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 32 Operating Instructions 221052E V 1 3b 4 3 Interface details 4 3 1 Connector X2 control signals switching towards zero The following figure shows the interface details internal circuit at the 15 pin SUB D male connector for the control signals section 4 1 2 2 page 21 e for the version without polarity module switching towards zero e for the version with Z1 add on module e viewing the connector from the front that is looking at the front panel In the version without the Z1 module section 4 2 1 1 the unassigned inputs and outputs are not connected Switching input Limit switch 2 Analog output Current monitor Switching input Limit switch 1 Switching output Overload 5 Switching input Con troller enable Analog output Speed monitor Input setpoint E
11. LED lights up As with incremental encoders the index pulse here also has the width of an increment The index pulse can be adjusted in steps of approx 1 4 with the two switches This corresponds to a resolution of 256 steps on the circumference When a pulse figure of over 256 is set then the index pulse is narrower than 1 256 of the circumference For this reason the Zero LED does not light up within the entire adjust ment window of 1 4 For it to light up the motor shaft must be rotated within the window to the exact zero point 6 5 Function module Fx Various functions including customer specific functions are imple mented on the function module So far there are the hold function and the field weakening mode which will be described in the follow ing 6 5 1 Hold function F1 Disadvantages of conventional servo drives when the motor is at a standstill e If the controller enable is canceled the motor is at a standstill without torque e Ifthe torque setpoint is made zero the motor comes to a standstill with holding torque but due to the offset drift of the speed control ler it rotates slowly in the one or the other direction These disadvantages can be avoided if the F1 Hold function module is used In many cases the magnetic brake which is otherwise neces sary is no longer required GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 58 O
12. RFI filter power supply In any case as shown in fig 6 switch in the connection between mains transformer and power supply e a RFI filter matching the chosen transformer see table Technical CE EMC specifications of the mains transformers page 73 e The mounting of the RFI filter is described above e Connect PE to earth cable cross section according to DIN VDE 0160 of min 10 mm The connections are labeled at the terminals of the RFI filter accord ing to fig 6 The connection between transformer and RF I filter e must have an adequate cross section for the chosen mains trans former see the table on page 73 e Shielding is not required The connection between RFI filter and power supply CE EMC e must not be longer than 50 cm e must have an adequate cross section for the chosen mains trans former see the table on page 73 e has to be shielded the shield is large area earthed with a cable clamp of the shield connection plate on the RFI filter e Unshielded cable ends must not be longer than 5 cm Therefore the shield must not end at the earthing clamp but has to continue 4 4 4 3 Connection power supply servo amplifier The power supply has terminals to connect the amplifiers installed in CE EMC the chassis section 9 2 3 page 69 Connect e the positive and negative operating voltage as well as the corre sponding earth PE from the power supply to the amplifier e inside the wiring d
13. connections on the amplifier There are three fuses for the operating voltage on the board For dimensions and value of the fuse links see section 9 2 5 Technical specifications of the power supply GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 71 9 2 4 LEDs The three LEDs have the following meanings Check Marking Color Display Fault e lights up when input voltage is too low St rung e lights up when power supply is overheated e lights up when fuse is defective lights up when shunt circuit is short circuited Ready e lights up when output voltage gt 160 V and Bereit there is no fault Shunt yellow lights up when the shunt circuit for accepting Ballast the energy returned when the motor is brak ed is switched on 9 2 5 Technical specifications of the power supply Climatic category DIN EN 50178 operation stora 3K3 1K4 2K3 ge transport Power suppl Mains connection via isolating transformer 3 x 230 V AC 10 Minimum mains voltage S Nominal bus voltage 320 V DC Min bus voltage ae Response threshold of shunt regulator 380 V DC Load factor ooo Maximum continuous braking power 100 W Peak braking power 2 switching cycle 2 sec Fuse link mains input 6 x 32 mm 3x 20AT Fuse link shunt circuit 6 x 32 mm Dimensions Width Height De
14. ee 11 1 2 Number of motor pole pairs 00002 20 eee 11 1 3 Current control instead of speed control 11 1 4 Changing the direction of rotation 00005 Modifications to the feedback 0 000 eee ees 11 2 1 Resettime rc ee pe tebe ee Pa Gee eee ee baa geen ae Vie DCU scape dece beau eta bel bere oe ol oak ike ue eek eked Modifications to the Z1 Z2 and Z4 add on modules 11 3 1 Location of the solder bridges 2 00000 ce eee 11 3 2 Former versions of modules Z1 and Z2 11 3 3 Power circuit ready signal instead of Motor standstill signal 11 3 4 Switching off the peak current rise 2 000005 11 3 5 Switching off active braking at controller disable Fe Fea ed ed ea Bead GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 7 11 3 6 Activating the ramp function 022000 0c eee eee 11 3 7 Adjusting and limiting the component of the speed controller 11 4 Modifications to the polarity module 000 cee eee eee 89 89 11 4 1 Ready signal instead of Fault signal 12 Documentation of the settings 0 00 ee ee Appendix Appendix A EC Declaration of Conformity 20000005 Appendix B Terms of warranty
15. phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 9 Chapter 1 General information 1 Preliminary remarks 1 1 About this description These operating instructions explain the characteristics connection installation and setting up of e the KSV 6HE servo amplifiers designed as 19 plug in modules 6 units height e the associated power supplies 19 plug in module design 6 units height for the connection to 3 x 230 V three phase current e the mains transformers for the connection to 3 x 400 V three phase current and the RFI filter e accessories e and provides notes for specialists The operation instructions are divided up into 4 chapters and 12 sections After the safety instructions and the technical specifications the connection of the servo amplifier is described In some cases you will require details which are not explained more fully until later It is therefore important that you should read the sections important for your application in a sequence commensurate with your previous knowledge The chapter Notes for the specialist describes changes which can be carried out on site by specially qualified electronics experts at their own risk providing that all precautions have been taken 1 2 KSV 6HE Servo Drive Packages KSV 6HE servo drive packages in 19 design consist of e the brushless motor with coupled resolver as a speed and position sensor e the an
16. 1 1 Motor and power supply Combicon connector X1 Marking Assignment Motor connection U o Q am Motor V Motor connection V Motor connection W PE PE for motor cable Negative pole of bus voltage from power supply PE from power supply Us Positive pole of bus voltage from power suppl 4 1 2 Control signals Steuersignale SUB D fem connector X2 15 pin 4 1 2 1 Version without add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable not assigned not assigned Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted not assigned Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A EEE Analog output Current monitor Connect cable shield to the housing of the SUB D connector GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 _ Operating Instructions 221052E V 1 3b 2 4 1 2 2 Version with Z1 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable Switching input Limit switch 1 Switching input Limit switch 2
17. 2 Index pulse adjustment lt ses veseseteeeu eset eet desta 8 3 Function module FX serrera gy Soe tai ed de Lee Ne ein elie a neal Oy Sees ce 6 5 1 Hold function Ei sans teaser es ig res Gas eS 6 5 2 Field weakening mode F2 202 eee eee eee eee 6 6 Option E1 external supply of control circuit 000005 7 Shutting down the motor and safety shutdown 7 1 SMUTINGIOOWRMODIOMSH ur ee ie Meare tated Soares 7 2 Estimating the braking distance 00 ce eee 7 3 Emergency stop and safety regulations 2000005 8 GOMMISSIONIAG ze 0er rien Bed HPF SCAUUOMG ts ine AA a 8 2 Switching on for the first time Saas er De ie See ees 8 3 Setting the speed uses ee ee reg 8 4 Setting the feedback normal case 000 cee cece cease 8 5 Setting the feedback critical applications a nn a annaa 8 6 Setting the feedback with Z4 add on module 2 22 22 8 7 Setting the current MMI bests nnana anaana aa 8 8 Setting the offset es Fass irn 8 9 Setting the holding control loop amplification a a aoaaa aaaea Chapter 3 Power supply and accessories 9 Power supply of the servo amplifiers aana aaan 9 1 Load TaclOR Stern Are ak te se E cay ek a EE cae dG E al a tea GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 9 2
18. F R BURSTENLOSE MOTOREN Motortyp z J w i J wei ms 077 3 Motor type p Ca TDA E EDA geay ee BEREE CREE x27 2 Polpaare 6 6 6 a 2228 2 pole pairs Jizz sm FAS BIDET ves P s 7 3 Polpaare aoao 3 pole pairs Lesy 2 4 Polpaare aofe 4 pole pairs Gebermodul Synchronisation Encoder module Synchronization BN 6661 0000 00B 059 Fig 11 Location of the jumpers on the board 11 1 3 Current control instead of speed control Whether the servo amplifier is set for speed control or for current control is implemented on the customer module module K3 for 2 pole pair or K6 for 3 pole pair motors GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 84 Operating Instructions 221052E V 1 3b To switch the servo amplifier from speed control as supplied to current control e insert a jumper in the Moment torque position Figure 12 shows the location of the jumper The following then applies e 10 V setpoint corresponds to the peak current set at the Current rotary switch S1 pf a tal Eye Drehrichtungsumschaltung Haltekreis Verst rkung Carat g ks 3 Change direction of rotation nur bei Option F1 gt Hold circuit amplification S a only with option F1 EA z 7 ur i B i D Anteil nicht best ckt care D Adjustment not assembled R ckf hr Zeitkonstante z Steckbr cken t1 und t2 2 v Feedbac
19. Switching input Controller enable Switching input Limit switch 1 Switching input Limit switch 2 Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted Switching output Power circuit ready Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A EE Analog output Current monitor Connect cable shield to the housing of the SUB D connector 4 1 3 Position sensor Lagegeber SUB D female connector X3 9 pin Pin Assignment 0 volt connect only in special cases 0 volt for motor temperature sensor Sine S 2 Cosine S 3 Excitation R 2 Motor temperature sensor if there is no sensor connect to 2 Sine S 4 Cosine S 1 Excitation R 1 Connect cable shield to the housing of the SUB D connector Ta Housin If the motors has no temperature sensor then connect pins 2 and 6 in the 9 pin connector GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 23 4 1 4 Encoder signals Gebersignale SUB D male connector X4 9 pin The 9 pin SUB D connector Encoder signals is only fitted when one of the encoder modules options G1 to G4 is installed Pin Assignment Switching input Hold only with option F1 Holding cont
20. not active as delivered To activate it a solder bridge must be installed e for further details see section 11 3 page 85 The ramp rise can be set with a potentiometer on the add on module The potentiometer is marked with two ramp symbols e Left hand limit slope of 7 ms per 1 V of setpoint voltage e right hand limit slope of 70 ms per 1 V of setpoint voltage that means a setpoint jump of 10 volts leads to a linear rise of the internally effective setpoint within 0 7 seconds GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 52 Operating Instructions 221052E V 1 3b 6 2 2 Tip The ramp function is effective in all 4 quadrants It is also effective e when actuating a limit switch and e when actuating the controller enable Please note the Z1 add on module is practical only for speed con trolled drives In a KSV 6HE amplifier configured for current control the functions Limit switch and Controller enable do not have a braking effect It is essential that you should document all changes in the table in section 12 page 90 Add on module Z2 Additional characteristics when Z2 add on module is fitted e externally adjustable current reduction e externally switchable setpoint reversing for PLC with single pole analog output e controller enable braking in case of shutdown can be switched to non braking using a solder bridge e switching
21. of the de vices 2 4 Protective earthing On account of leakage current from the RFI filter to be built in the protective earth conductor in accordance with DIN VDE 0160 must e either be run double to the amplifier or e have a cable cross section of at least 10 mm Cu Operation using an earth leakage circuit breaker is not possible e due to the leakage current of the RFI filter and GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 13 e since in case of earth leakage a part of the direct current flows in the protective earth conductor 2 5 Hazard warnings i Due to their design and connection system the servo amplifiers and Caution the power supplies e may only be operated in closed housings control cabinet e may only be operated with a fixed connection to the mains Do not introduce any objects screwdrivers wires into the interior of the device through the ventilation holes Before you remove a device from the chassis and before you discon nect or reconnect a connector e switch off mains voltage Power off The charging capacitor of the power supply retains the voltage even after it has been switched off Before working at or in the device wait gt 2 min e wait at least two minutes after switching off Electronic devices are generally not fail safe The user must make Danger sure e that when a device b
22. plate where the RF I filter is installed as described above in the context of figures 6 and 7 e Establish a large area connection between the shield and earth at the motor in a suitable manner At all places avoid earthing the shield using twirled strands pigtails of the shield e Connect the machine earth to the central zero point of the control cabinet using an potential equilization cable with an adequate cross section GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 43 The shield of the motor cable must not be interrupted e If you have to install contactors switches or chokes in the motor cable then install these in a metallic housing and establish a large area connection between the shield and the housing using a cable clamp as described above The motor cables e have to leave the control cabinet at shortest possible distance e must not be laid parallel to sensible control leads or unshielded mains cables lf parallel arrangement cannot be avoided ensure a distance of min 25 cm to the other cables 4 4 6 Motor choke Longer motor cables can overload the device and lead to intolerable CE EMC high emission e If the motor cable is longer than 7 m install the appropriate motor choke supplied by us in the motor cable at the amplifier side For cable lengths order numbers and technical s
23. potentiometer inside the device which is marked n OFFSET It is located at the very top behind the front panel see fig 11 There are two options for offset adjustment e With measuring device Switch off the controller enable GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 82 Operating Instructions 221052E V 1 3b measure the voltage at the analog output Speed monitor and then make this voltage zero using the potentiometer n OFF SET e Without measuring device Make the setpoint zero before changing the jumpers adjust the offset with the trim po tentiometer on the front panel so that the motor comes to a standstill as good as possible Switch off the mains only then change the jumpers switch on again Then adjust the offset again but this time using the potentiome ter n OFFSET inside the device Note If this adjustment is not carried out in this way when the Z mod ule is in position the tacho window could not be switched on when the motor is at a standstill and therefore the amplifier would not be en abled at a standstill 11 1 2 Number of motor pole pairs The adaptation of the number of motor pole pairs is determined by the option K K1 K2 K3 K4 K5 K6 KA and KB It is realized by jump ers on the board Modify by relocating the jumpers on the field X 13 There are 4 positions for each
24. resistor e second block 7 terminals connected in parallel for the positive pole of the bus voltage labeled U e third block 7 terminals connected in parallel for the negative pole of the bus voltage labeled U e fourth block 7 terminals connected in parallel for the PE connec tion of the amplifiers e lower terminal block with larger terminals connection of mains transformer GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 70 Operating Instructions 221052E V 1 3b Terminal assignment Terminal block X5 Either connect external shunt resistor between R and R or install jumper from Rim to R Jumper is factory set 7 terminals connected in parallel for positive pole of bus volt 3 age This allows a separate line to be laid to each of 7 con nected amplifiers 7 terminals connected in parallel for negative pole of bus volt age This allows a separate line to be laid to each of 7 con nected amplifiers 7 terminals connected in parallel for PE This allows a sepa rate line to be laid to each of 7 connected amplifiers borin block X62 block X6 Power safety ground a Phase 1 secondary side transformer Phase 2 secondary side transformer Phase 3 secondary side transformer vu m For details on the laying of cables see fig 6 and section 4 4 4 pa ge 40 Please note that the terminals are in reverse order compared with the
25. rotation is re versed The Controller enable input e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 85 An additional switching output supplies e the Motor standstill signal or e the signal Power circuit ready as a special version For conversion to the version with the Power circuit ready signal see section 11 3 page 85 The ramp function is not effective as delivered To activate it a solder bridge must be installed e for further details see section 11 3 page 85 The ramp rise can be set with a potentiometer on the add on module The potentiometer is marked with two ramp symbols e Left hand limit slope of 7 ms per 1 V of setpoint voltage e right hand limit slope of 70 ms per 1 V of setpoint voltage that means a setpoint jump of 10 volts leads to a linear rise of the internally effective setpoint within 0 7 seconds 6 2 3 Add on module Z4 The customer module labeled P I l lim has to be installed when using the Z4 add on module Additional characteristics when fitted with the Z1 add on module e speed control with limitation of the component e 2 limit switch inputs directional braked e controller enable braking in case of shutdown can be switched to non braking using a solder bridge e switching output Power circuit ready e peak current can be switched off by means of a s
26. setpoint Speed standardization incorrect Set to desired speed using Speed potentiometer adjust speed control range if necessary section 11 1 1 Speed adjustment also influences feedback Adjust feedback setting Feedback too hard Motor runs rough or soft after speed adjustment at speed potentiometer Motor runs roughly or vibrates Turn Feedback potentiometer to the left until motor runs smoothly Motor shaft can be moved out of posi Feedback too soft Turn Feedback potentiometer to the tion by hand at standstill right until motor runs roughly vibrates then to the left until motor runs smoothly Motor Bee to turn slowly at setpoint Zero loop e g between amplifier zero and Use differential input see section zero Bee increasing load control zero 4 4 9 page 44 Supplement for KSV 6HE with F1 option Holding control loop Motor is at a standstill with power with Holding control loop accidentally activated Check Hold signal connection out drift cannot be regulated Motor shaft can be moved by hand at If holding control loop is activated Holding Adjust Hold potentiometer standstill control loop too soft End of Operating Instructions 221052E GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
27. the peak current rise is to be switched off a solder bridge must be installed e for further details see section 11 3 page 85 It is essential that you should document all changes in the table in section 12 page 90 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 55 6 2 4 Further add on modules Further add on modules are available as e customer specific solutions specially adapted to the application 6 3 Polarity module Px The function of the polarity module has already been described in section 4 2 3 1 on page 24 it ensures that the switching inputs and outputs are PLC compatible that is that they switch towards 24 V If it is not implemented these inputs and outputs switch towards zero 6 4 Encoder modules G1 to G4 Application of the encoder signals e Connection of positioning controls e Connection of a digital speed counter for monitoring the motor speed For all encoder modules 16 different pulse numbers can be set Encoder signals are available only if the encoder module is fitted For the various encoder modules see type code section 3 1 on page 15 e Standard G1 encoder module outputs like standard incremental encoder 5 volt push pull RS 422 interface with SN 75114 line driver phase 1 phase 2 index pulse and corresponding complement that is 6 lines outputs electrically connected to
28. value 1 5A 3A en Maximum peak current crest value 10A 20A 30A 30A Current limiting adjustable from to 0 4 1 5A 0 8 3 A 1 5 6 A 2 3 9 A 3 12 A Load factor in conjunction with mains 4 8 transformer Integration time of the I t circuit at max peak current approx 2 s Setpoint value 10 V at 20 KQ 1 7 3500 r p m 2 V 1000 r p m Output speed monitor 1 V 1000 r p m Ra 10 KQ at speed range 10 500 r p m 0 67 V 1000 r p m 0 5 V 1000 r p m Output current monitor RA 10 kQ 10 V for maximum pulse current ee ee Frequency of current ripple 32 kHz Ce a a Load capacity of auxiliary voltages 10 mA each via 125 Q PTC en E1 external control circuit 24 V DC 15 20 approx 400 mA at 24 V Climatic category DIN EN 50178 opera 3K3 1K4 2K3 tion storage transport Permissible ambient without fan not permissible temperature in contin Recommended Wiring to Combicon Cross section u Minimum cross 1 0 mm 1 5 mm 1 5 mm section f 1 The load factor given is for calculating the number of amplifiers that can be operated by one common power supply For further details see Section 9 1 page 68 Fan of the 089100010Z or 089100020Z chassis see section 10 page 75 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 17 Sewo amifer Sewo a
29. warnings and instructions in the margin Danger for life and limb through electrical shock or motion of the Danger drive system e Caution Disregard can lead to personal injury or death or damage Caution of property e Prohibition Disregard is a violation of safety regulations or statu Do not tory provisions Power off Disconnect the device from the mains and wait at least Power off 2 minutes until the DC bus capacitors have discharged before wait gt 2 min carrying out the measures described CE EMC e The CE marking presumes compliance with the EMC limits in accordance with EN 55011 A and B emissions and EN 50082 1 and 2 immunity The specifications marked with this symbol must be complied with Otherwise the installation in which the amplifier is being run must be checked for compliance with the EMC limits at the discretion of the customer Other instructions given in the margin e Check First check these positions if the drive system does not work as required or if you cannot proceed working with the device for other reasons e Tip Useful hint Check Tip N N Technical staff The servo amplifiers and the power supplies work with voltages which are dangerous in case of contact Touching live parts can cause serious injury or death Danger Only trained technical staff with special knowledge in the fields of e automation e dealing with dangerous voltages e standards and regulations such as
30. 1 Connecting the position sensor resolver The connection cable to the position sensor resolver must e be laid separate from the motor cable be connected exactly according to the instructions otherwise Check the motor blocks the motor runs roughly the motor runs uncontrolled at full speed or the servo amplifier reports a fault This causes no damage either to the motor or to the amplifier but there is a risk for the machine and the installation person nel Danger the motor runs with a low torque To connect up the resolver as shown in fig 6 e use twisted pairs of leads for channel 1 channel 2 and excitation for example the resolver encoder connection cable mentioned in the accessories for further details see section 10 2 4 page 77 e connect the shield using the strain relief of the metal plated SUB D housing this allows you to achieve the necessary large area earth con nection for the shield and to avoid earthing the shield using twirled strands pigtails of the shield e Do not connect the shield at the motor side GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 46 Operating Instructions 221052E V 1 3b 4 4 12 Connection of the motor temperature sensor The motor temperature sensor is connected via the cable for the position sensor and its connector e If the motor has no temperature sensor the two
31. 1 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b Tip e if the installation follows the connection directions given on pa ge 36ff The CE marking is valid only when the EMC limits are complied with If you install the amplifier in a different way e itis your responsibility to check the installation for complying with the EMC limits The air must be able to flow through the chassis undisturbed If you install additional chassis above or below they must not obstruct the air flow Note that the air leaving the chassis is heated up e this may disturb devices sensitive to heat Figure 1 shows a rack mount chassis 84 units wide fully equipped with one power supply and 7 amplifiers GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 19 Operating Instructions 221052E V 1 3b Kabelkanal 40 x 40 mm gt Wiring duct BN 9128 0000 00B 050 330 4325 84 TE SSH IN FHUUUMOO GTA NENNEN AULA Z EE S O6L Fig 1 Rack mount chassis 84 units wide GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 20 Operating Instructions 221052E V 1 3b 4 Connection Assignment of connectors and details 4 1 Connector assignments For details concerning connections and the optional modules please refer to the later sections 4
32. 2 pole pair motor speed control 7 000 min K3 2 pole pair motor current control K4 3 pole pair motor speed control 3 500 min Additional equipment through add on modules ZO none standard Zi limit switch ramp controller inhibit braking Z2 external current limiting rotation reversal input output polarity polarity module PO switching towards zero standard P1 PLC compatible fault output Additional equipment through encoder modules incremental encoder emulation GO no pulse outputs standard G1 pulse outputs 5 V push pull signals RS 422 G2 pulse outputs 24 V push pull signals Additional equipment through function modules FO none standard F1 holding control loop Supply of control circuit cannot be refitted EO internal supply from DC bus standard Special equipment customization so none standard S2 reinforced terminals 20 A Front panel WO standard For further details on the modular expansion options please refer to section 6 page 50 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 16 Operating Instructions 221052E V 1 3b 3 Technical specifications 2 Servo amplifier KSV 1 5 5 Ksvar o KSv6 20 Ksvarso KSY 12 8 Mains connection via isolat transformer 3 x 120 230 V AC 10 Bus voltage 320 V DC Minimum bus voltage 160 VDC Maximum permissible bus voltage 420 V DC Maximum continuous current rms
33. 3 4 Switching output Fault or Ready 4 2 3 5 Switching output Overload 222 22220 4 2 3 6 Switching output Motor standstill or Power circuit en 4 2 44 Analog outputs 2h 2a ace aie ea Keen ee 4 2 5 Encoder signals holding function ssassn ease 02 es 4 2 6 Position Sensor s c5 8 0 8 8 rusiaed eneraia nnen he 4 2 7 Motor temperature sensor 0 eee eee eee 4 2 8 Sensor fault detection 0 ccc eee ASO Block protection cisco an ae ee ae ee area 4 2 10 Fault Memory Areas 4 3 Interface details unuunu ee ea pet aaencas tee 4 3 1 Connector X2 control signals switching towards zero 4 3 2 Connector X2 control signals PLC compatible 4 3 3 Connector X4 encoder signals 5 volt version 4 3 4 Connector X4 encoder signals 24 volt version 4 4 Connection directions s oe toia Giese ae ee hae a Pear ees 4 4 1 Installation on the mounting plate anann a naaa 4 4 2 Installation in a 19 rack system annua ns nennen 4 4 3 Potential equilization cables 00000 nennen AAA Mains connection n c22crchanckonmehchekue nek chekbhek abe 4 4 4 1 Connection mains mains transformer 4 4 4 2 Connections mains transformer RFI filter power suppl a 4 4 4 3 Connection power supply servo amplifier 4 4 5 Motor connection general informat
34. 5903 53 Operating Instructions 221052E V 1 3b 75 10 Accessories 10 1 Available accessories and order numbers Chassis 84 units empty for up to 7 KSV 6HE servo amplifiers and 1 power supply 089100010Z with fan units for installation in 19 racks or in the control cabinet Accessories Order number 0891000202 Chassis 54 units empty for up to 4 KSV 6HE servo amplifiers and 1 power supply with fan units for installation in the control cabinet Connector set for KSV 6HE servo amplifier without encoder module option 0990660202 Connector set for KSV 6HE servo amplifier with encoder module option 099066010Z Synchronization unit see separate operating instructions 086047010Z 099070010Z Motor connection cable 4 cores cross section 1 5 mm shield 535246 Z 535264 Z Resolver Encoder connection cable 8 cores twisted pair shield 535245 Z Connector set for 2 KSV 6HE amplifiers and one synchronization unit Motor connection cable 4 cores cross section 2 5 mm shield Ferrite ring for interference suppression of supply cables 042103010 Motor choke with terminals and enclosure for medium length cables up to 25 m 038096010Z Motor choke with terminals and enclosure for longer cables more than 25 m 038097010Z RFl filter 16 A 0020570202 RFI filter 36 A 002057040Z Shield connection plate 089159 10 2 Description of accessories 10 2 1 Chassis All are 7 height units high 6 heigh
35. 8 Commissioning For the initial commissioning proceed as described below Deviate Tip from this procedure only when you have gained enough experience with the devices 8 1 Precautions For commissioning you must always Danger e disengage the motor from the machine part to be driven so that its operation can be observed without endangering the machine e switch off the mains voltage when carrying out connections and Power off disconnections or replacing components in the amplifier or when wait gt 2 min working on the motor If you wish to proceed particularly cautiously because a high risk can be expected with a particular machine in the event of operating error e you should allow a small current only and thus a low torque Make a note of the actual setting of the rotary switch for current limiting see section 5 2 page 47 Set the rotary switch to a low value near the 0 position After commissioning restore the original setting of the rotary switch 8 2 Switching on for the first time Before switching on carefully check Check e to see whether all connections have been correctly established e to ensure that the controller enable input does not block the con troller to ensure that the limit switches are closed if the Z1 or Z4 add on module is being used Supply the setpoint using a potentiometer You can do this as shown in fig 8 using the auxiliary voltage outputs section 4 2 1 pa
36. I Funk Entst rfilter RFI Filter Trafo 2 PE Transformer Netz Mains PE Zentraler Nullpunkt im Schaltschrank Centrai zero point inthe control cabinet BN 6670 0000 004 056 Fig 6 Connection directions GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 38 Operating Instructions 221052E V 1 3b plug in module plug in module P filter shield con nection plate I motor cable Le shield connection plate filter wiring duct BN 6670 0000 004 057 Installation on a mounting plate Installation in a 19 rack system Fig 7 Laying of the motor cables and earthing of their shields e be connected to the central zero point via a shortest possible potential equilization cable of cross section 10 mm or more or better using a wide copper braiding earth strip To ensure a well conducting connection for high frequencies between the housing of the RFI filter the mounting plate and the chassis e install the RFI filter directly on the bare mounting plate below the chassis Establish the earthing of the motor cable shields at the shield connec tion plate where the RFI filter is installed by e removing a ring shaped part of the isolating cable sheath and e clamping the bare shield on the shield connection plate The length of the remaining cable between the earthing point of the shield and the con
37. KSV 6HE Servo Amplifier for Brushless Motors KSV 1 5 5 to KSV 12 30 19 inch 6 height units front connection Operating Instructions 221052E V 1 3b 09 01 These operating instructions apply to e KSV 6HE KSV 1 5 5 to KSV 12 30 servo amplifiers 19 plug in module even numbers e 2800140000 power supply 19 plug in module e 038100050Z 038100070Z 038100090Z and 038100130Z mains transformers e accessories GEORGII KOBOLD AUGUST HEINE GmbH amp Co Fasanenweg 6 8 D 70771 Leinfelden Echterdingen Federal Republic of Germany Tel 49 0 711 7 59 03 0 E mail service georgii kobold de Fax 49 0 711 7 59 03 53 www georgii kobold de 2 Operating Instructions 221052E V 1 3b Versions of the document 30 11 99 V 1 3 MH First English version based on 221059 V 1 3 and 221055E V 1 5a similar to German version 1 3 12 01 00 V 1 3a MH values for time constant on Z4 add on module ad justed figure 11 new corrections document styles similar to German version V 1 3a 24 09 01 V 1 3b MH OEM preparation corrections similar to German version V 1 3b 0 pdf Vorlagen GK 221052E_15a wpd Copyright by GEORGII KOBOLD AUGUST HEINE GmbH amp Co D 70771 Leinfelden Echterdingen Germany All rights reserved including those of translation No part of these operating instructions may be copied reproduced stored or processed in an information system or transmitted in any other form without prior written permission by GEO
38. P1 and P2 modules GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 90 Operating Instructions 221052E V 1 3b 12 Documentation of the settings Copy this page and enter into the following tables the nameplate Tip information and all of the settings and modifications you have carried out Keep these sheets with your documentation If you should later require a similarly configured or modified device send us a copy of these tables Nameplate information In case of multiple devices Device No Current setting the switch setting is marked with a cross Lol 2 3 al 5 e 7 e 9 af el cl oJ ef F Encoder pulse setting the switch setting is marked with a cross 1 F231 al sl sl 7 81 of a B cf oJ E Speed control range the range set is marked with a cross 3 500 min open 7 000 min 1 10 500 min 2 14 000 min 1 2 No of pole pairs set number of pole pairs is marked with a cross 2 pole pairs 2PP 3 pole pairs open 4 pole pairs 4PP Current control instead of speed control marked with a cross if jumper is set Jumper in position torque Moment Standard direction of rotation set direction of rotation is marked with a cross SHE Reset time the set time constant is marked with a cross 3 3 ms open 6 6 ms t1 10 ms t2 14 ms t1 12 Modifications to Z1 Z2 add on module closed solder bridges marked with a cross P
39. PI Aktives Bremsen aus as Active braking off e Fig 14 Solder bridges on the Z2 module GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 87 Zusatzmodul Z4 Z4 add on module O Oo Z4 Modul EEE EN N l Zeitkonstante ol time constant Peak current off gt jea laele 1 rile g ktiv gt I Aktives Bremsen aus P s Brense Aus H Sp Active braking off SF m Begrenzungsschwelle VIENNA Limitation threshold A i i un ine ojo ll n Kiil 1 7 ral e e a n X Potentiometer nur auf Sondermodul BN 6661 0000 00A 064 Potentiometer on special module only Fig 15 Solder bridges on the Z4 module 11 3 2 Former versions of modules Z1 and Z2 The following description of the Z1 and Z2 add on modules applies to the devices delivered now Former versions of the add on modules have other jumpers or fewer functions They have other layouts as the modules shown in fig 13 and 14 If your amplifier is fitted with other modules please contact us so that we can send you matching docu mentation 11 3 3 Power circuit ready signal instead of Motor standstill signal If one of the Z1 or Z2 add on modules is fitted the switching output provides the signal Motor standstill factory setting Modify by setting a solder bridge on the add on module e without solder bridge
40. RGII KOBOLD AUGUST HEINE GmbH amp Co These operating instructions have been prepared with care However GEORGII KOBOLD AUGUST HEINE GmbH amp Co can accept no liability for any errors in these operating instructions or possible consequences Neither can any liability be accepted for direct or indirect damage resulting from abuse of the device The relevant regulations concerning safety technology and electromagnetic compatibility must be complied with when using the device Subject to alteration GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 3 Contents Chapter 1 General information T Preliminary remarks 2 2 Seta eu retusa ea wee gates eke ee lo 1 1 About this description ses een 1 2 KSV 6HE Servo Drive Packages 20 s gt 00s 2404 main denen 2 Safety InsiEUcHONns nn ans rer 2 1 Type of instruction Ss eeeeeeeinlelatsr 22 Technical staff sesei ere ee tiee taani ea Se hs n hE de na a Re Maaa 2 3 Use for the intended purpose 0 naana 2 4 Protective earthing stars astra ec eh ieee ee te a ee Ei 2 5 Hazard warnings 4J 25 eee sssaaa aeaea 2 6 01 gt 10 41 8 Renee r E E E ee 2 7 Preconditions for commissioning gt c0 lt eudbondesue ende endend 2 8 Working with the amplifier or the power supply 5 Chapter 2 Servo amplifier 3 Technical specifications 2 us Ju ar Dur O
41. Since the phase shift results in a weakening of the torque forming part of the magnetic rotary field this operating mode is also called Field weakening mode by analogy with the terms used for DC drives The F2 function module Field weakening mode shifts the phase of the motor current in the desired direction from a predefined speed depending on the direction of rotation This predefined speed is fac tory set on a trim potentiometer on the module This setting must not be changed GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 59 6 6 Option E1 external supply of control circuit In the standard version the E1 module External supply of control circuit module is not fitted When the supply voltage is switched off e the position information disappears The version with the E1 module External supply of control circuit has an input for the separate feeding of a supply voltage of 24 V see table Technical specifications page 16 for connection see section 4 1 2 page 20 When the supply voltage is switched off e the position information is saved as long as the external supply voltage is connected This module is used e when for example in case of an emergency stop the supply volt age of the amplifier is switched off and e the position information must be saved The External supply of control circu
42. abled the fault is reported through the Fault output and displayed by the Fault LED flashing With this fault the fault memory cannot be reset through the Reset fault input but only by switching the operating voltage off and on again or the supply voltage in the case of the external supply of the control circuit module E1 4 2 9 Block protection If the motor is blocked this is not a case of normal operation e If the motor is at a standstill for longer than about 4 seconds at maximum current the drive is shut down and the fault is reported through the Fault output and through the Fault LED flashing GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 30 Operating Instructions 221052E V 1 3b 4 2 10 Fault memory The following faults do not lead to damage but to a machine shut down and to a fault signal e overheating of the power circuit e overheating of the motor if it is fitted with a temperature sensor e short circuit between one or more motor leads and earth or protec tive earth conductor e short circuit between the motor leads e faulty internal auxiliary voltage e operating voltage too high or too low e customer module absent e fault in resolver or its supply leads e motor blocked for longer than about 4 seconds External fault signal except in the case of overheating see below e Fault
43. ables can overload the device and cause unacceptably CE EMC high interference emission For this reason a motor choke must be fitted in the motor cable if Check the cable is longer than 7 m For the correct choke please refer to the following table Both motor chokes are supplied in a steel plate housing ready for installation and connection They are supplied with terminals and with cable clamps Figure 9 shows the mounting dimensions the connection please note the connection of the shield and the marking of the terminals GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 79 During operation under full load the chokes can reach a temperature Caution of over 100 C To ensure adequate heat dissipation they must be screwed to a sufficiently large metal plate Technical specifications Motor choke 038096010Z 038097010Z Permissible current 10A 12A For cable lengths when using 7to25m more than 25 m KSV 6HE amplifiers Internal design partially compensated 3 single chokes triple choke um Motor o the motor N vom Verst rker from the amplifier BN 3845 0000 00A 050 Dimensions Distance X Housing height _ Internal choke choke a 038096010Z mm 038097010Z mm Fig 9 Motor neo GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
44. alog servo amplifier as 19 plug in module 6 units height e the 19 plug in module power supply 6 units height with mains transformer connected in series The series described here comprises to12A e amplifiers with different specifications optional e amplifiers for 5 different currents 1 5 A rms ne I GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 10 Operating Instructions 221052E V 1 3b e power supplies for 19 rack system plug in power supplies e mains transformers for the plug in power supplies e RFl filters e 19 chassis We construct the multi axis servo amplifier matched to your applica tion using chassis Use these operating instructions for connecting and commissioning We evaluate the servo drive matched to your application and e deliver the matching servo motor They have separate operating instructions and terminal connec tion diagrams As well as the series in 19 plug in module design there is also a series in compact design for installation on the mounting plate of a control cabinet KSV 1 5 5 compact design to KSV 12 30 compact design amplifiers with separate operating instructions GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 11 2 Safety instructions 2 1 Type of instruction It is essential that you should note the
45. and at standstill if the feedback is set too hard the motor runs loud and rough if itis set too soft you can move the motor back and forwards a little by hand This soft behavior can cause inaccuracies later when the drive is operated with a higher level controller GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 65 e Turn the feedback trimmer Verst rkung clockwise until the motor runs loud and rough then turn back the trimmer approx one turn 8 5 Setting the feedback critical applications How to proceed with critical applications e check limit switch connect motor to load as above e apply setpoint to amplifier input via a switch so that a setpoint jump can be generated e generate a setpoint jump e record the step reply at the Speed monitor output with a memory oscilloscope e evaluate the step reply and correct the feedback setting for most applications the speed should reach its final value as fast as possible but only with a slight overshoot Under extreme conditions the adjustment range of the feedback may be insufficient In this case the reset time must be changed For further details see section 11 2 1 page 85 8 6 Setting the feedback with Z4 add on module Tip For the purpose of commissioning a special module is available on which e potentiometers for the time con
46. connecting points provided for this purpose in the 9 pin male connector of the position sensor are connected to each other GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 47 5 Adjustment and display elements The adjustment and display elements contained in all KSV 6HE ver sions are described here Special information for the versions with expansion modules is given with the appropriate options 5 1 Trim potentiometers 3 trim potentiometers are accessible on the front panel of the ampli fier Their significance is in the sequence from top to bottom Schematic en Effect with clockwise Feedback P Amplification speed Verst rkung control circuit Speed Offset If the module F1 for activating the holding control loop is fitted the trim potentiometer Hold Halten is located on the customer mod ule P4 gain holding control loop The trim potentiometer setpoint gain Sollwertverst rkung can be installed on the customer module as an option Amplification rises 5 2 Current limiting and Current rotary switch A current limiting device with I t function protects the motor and the amplifier From the unloaded state a maximum current equivalent to the preset peak current is possible If the square of this exceeds a certain given threshold value for a certain time then the curre
47. cretion of the customer Figure 6 shows for one axis of the KSV 6HE drive package e the prescribed connection e the design of the plug in module and of the RFI filter e the laying of the cables and of the potential equilization cables e the prescribed earthing of the cable shields using the shield con nection plate For the two ways of installation installation on the mounting plate and Installation in a 19 rack system fig 7 shows the arrangement of e the chassis e the RFI filter with mounted shield connection plate for further details on the shield connection plate 089159 see section 10 2 7 page 80 4 4 1 Installation on the mounting plate If you install the chassis on a mounting plate in the control cabinet screw the chassis onto the bare metal e g zinc plated mounting plate e with the bare metal rear panel of the chassis CE EMC The mounting plate has to e be earthed and therefore e either carry the central zero point on its own or GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 37 Positioniersteuerung Position controller Sollwertquelle Setpoint source Steuer signale Control signals Option ext Ballastwiderstand ext shunt resistor A Dp BE L Geber Position sensor kR RTE Achse II Achse III Axis I Axis
48. d When the servo amplifier is being operated within the set continuous current limits or when peak current is only drawn briefly then e the output is 0 If the current limiting circuit has switched back from peak current to continuous current due to an overload then e the output switches to 1 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 27 4 2 3 6 Switching output Motor standstill or Power circuit ready The Motor standstill output is available only e if the standard version of the Z1 or Z2 add on module is used If the servo motor is operated at a speed greater than 1 of the maximum possible speed e the Motor standstill output is set to 0 If the servo motor runs more slowly or is at a standstill then e the Motor standstill output is set to 1 On request the Power circuit ready output can be switched instead of the Motor standstill output Since the same connector pin on the control signal male connector is used for both options the two outputs cannot be present at the same time The Power circuit ready output reports that the power circuit is ready that is functional It is only available e if the standard version of the Z4 add on module or if the appropriate special version of the Z1 or Z2 add on module is used The Z1 or Z2 add on
49. duction defects In quality assurance measured values are recorded in the final inspection and testing The warranty period begins with delivery It lasts for 12 months Delivery is based on the General Terms of Delivery for Products and Services of the Electrical Industry green terms of ZVEI German electrical and electronic manufacturers association In the event of a defect or in case of absence of a guaranteed property the device is to be returned It is repaired in the works of the manufacturer free of charge or replaced at our discretion No other claims for damage which has not occurred in our device can be accepted No claims for indirect damage resulting from a malfunction of or defect in our device may be put forward Appendix C Table of faults If the drive does not work as desired the following table of faults can help you to detect and eliminate the cause of the fault No LED lights up No operating voltage for amplifier Check input voltage Green Ready LED flashes Controller enable or limit switch open Check cables connections limit swit ches No supply voltage this display only in case of Switch on operating voltage check option E1 emergency stop circuit Operating voltage too low Measure operating voltage must be gt 160 V With option E1 only External control circuit Measure voltage must be gt 19 V supply voltage too low or has dips from poor check for dips below 19 V ly filtered r
50. e Current rotary switch see section 5 2 page 47 It is essential that you should document the new switch position in the table in section 12 page 90 if you have changed the factory settings Never set the continuous current higher than permissible for the motor Otherwise may damage the motor Should the motor require a higher current in order to work properly then it has not been dimen sioned adequately and a more powerful motor must be selected 8 8 Setting the offset Set the offset only when the device has reached operating tempera ture How to proceed e make setpoint zero the best way is to disconnect the setpoint cable from the source directly at the setpoint source and short circuit it e observe motor shaft e or observe pulse output if an encoder module is fitted e set offset trimmer so that the motor comes to a standstill as well as possible GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 67 8 9 Setting the holding control loop amplification Applicable only if the F1 function module Hold function for the hold ing control loop is fitted How to proceed e set the Hold trim potentiometer in accordance with the applica tion Excessive amplification leads to unevenness or vibrations in the drive To adjust the Hold trim potentiometer e remove the mains voltage The servo amplifier mu
51. ectification Faulty auxiliary voltage Measure auxiliary voltage at connector for control signals 15 V and 15 V 10 Red Fault LED lights up and green Ready LED flashes Short circuit or earth fault in motor cables or Check wiring and motor for short circuit in motor and earth fault Customer module missing or incorrectly in Customer module forgotten or incor serted rectly inserted after amplifier replace ment Blocking protection device triggered Electrical fault motor or resolver ca bles transposed Mechanical fault mechanism jammed or faulty Operating voltage increases excessively due Check shunt circuit shunt resistor to fault in shunt circuit missing or defective many axes brak ing at the same time GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 93 Red and green LEDs pen alternately Sensor not connected one or more leads not connected one or more leads Check sensor wiring when device is cold or at operating interrupted one or more leads short circuited temperature This fault can be reset only by switch ing the operating voltage off and on again with E1 of the external 24 V supply Red and green LEDs flash alternately after some period of operation Amplifier has switched off due to overtemperature of its heat sink or due to motor overhea
52. ector with screwable housing The housings of the connectors are metallized and therefore shielded 10 2 3 Motor connection cables 535246 Z and 535264 Z The motor must be connected with a shielded cable Characteristics of our motor connection cable e 4 core shielded e cross section 1 5 mm in the case of 535246 Z e cross section 2 5 mm in the case of 535264 Z e suitable as trailing cable Choose the appropriate cable according to the required cross sec tions given in table Technical specifications on page 16 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 77 Technical specifications Motor connection cable 535246 Z 535264 Z Cable code KWLifPETPC11Y JZ KWLifPETPC11Y JZ 4 x 1 5mm 4 x 2 5 mm Single core 1 5 mm Cu litz 2 5 mm Cu litz bare 192 x 0 1 mm bare 320 x 0 1 mm Structure 4 cores stranded with optimized length of twist Color coding 1 x green yellow PE cond 3 x black Z1 Z3 Total shield Cu braiding tin coated 0 1 mm single wire diameter Total sheath Polyurethane orange RAL 2003 Bending radius for single min 65 mm bend fixed installation Rolling radius for continuous min 95 mm min 120 mm altern bending trailing use Operating temperature 50 to 90 C fixed installation 30 to 80 C trailing use 10 2 4 Resolver Encoder connection cable 535245 Z The re
53. en phone 49 0 711 75903 0 fax 49 0 711 75903 53 50 Operating Instructions 221052E V 1 3b 6 Modular fittings and expansions This section describes the functions of the modules The modules of a special KSV 6HE servo amplifier are given in a special type code as initials For further details on the type code see section 3 1 page 15 The modules are called e Customer module Kundenmodul e Add on module Zusatzmodul e Polarity module Polaritatsmodul e Encoder module Gebermodul e Function module Funktionsmodul e External supply for control circuit Not all modules are real boards variants that have been implemen ted differently are also possible 6 1 Customer module Kx Tip The pluggable customer module contains e all assemblies to be set during installation e assemblies for special features such as current control or speed control When an amplifier is replaced the customer module can be trans ferred to the new amplifier Readjustment is therefore not necessary The customer module is fitted in all versions To replace the customer module e remove fixing bolt and take out the module The customer module is located on the left Amplifiers equipped with different customer modules differ also in the arrangement of the jumpers on the amplifier board 6 2 Add on modules Zx Many additional characteristics can be implemented by means of add on modules The mode of op
54. eration of the Z1 Z2 and Z4 add on modules is described in the following further add on modules are available on request GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 51 6 2 1 Add on module Z1 Additional characteristics when fitted with the Z1 add on module e 2 limit switch inputs directional braked e controller enable braking in case of shutdown can be switched to non braking using a solder bridge e switching output internally selectable Motor standstill or Power circuit ready e peak current can be switched off by means of a solder bridge e ramp function can be switched on by means of a solder bridge Using the limit switch inputs the motor is e shut down depending on the direction of rotation and is actively braked by reversal The Controller enable input also e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 85 An additional switching output supplies e the Motor standstill signal or e the Power circuit ready signal as a special version For conversion to the version with the Power circuit ready signal see section 11 3 page 85 If the peak current rise is to be switched off a solder bridge must be installed e for further details see section 11 3 page 85 The ramp function is
55. erived from the machinery directive do Do not not allow safety functions to be carried out by electronic circuits since the risk of failure cannot be fully ruled out e An emergency stop or any other safety circuit must not only be effected by zeroing the setpoint or by using the controller enable With emergency stop switches or other functions important for the safety of persons or property it must therefore be ensured that the shutdown e is effected directly by positively driven contacts which shut down either the motor supply line or the power supply to the amplifier For further details see the relevant regulations including DIN VDE Do not Caution 0113 EN 60204 Safety of machines electrical equipment in ma chines e The operating voltage must not be switched off and on on the DC side because the charging capacitor of the power supply would be switched directly onto the input capacitor of the amplifier GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 62 Operating Instructions 221052E V 1 3b this would result in current peaks of more than 1000 A which would destroy the relay contacts and overload the capacitors e Therefore switch the operating voltage off and on before the power Tip supply GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 63
56. factory settings it is essential that you should Tip document the new settings in the table in section 12 page 90 11 1 Modifying the controller circuitry The controller circuit is defined by the name of the customer module see type code section 3 1 page 15 In some cases it is implemented on the customer module itself in some cases through jumpers on the board Electronics specialists can change the controller circuitry on site if required 11 1 1 Speed control range The speed control range is determined using the option K K1 K2 K4 K5 KA and KB However it is not implemented on the customer module but by means of jumpers on the board Modify by relocating the jumpers on the X 14 field labeled DREHZAHL speed 2 jumpers must always be placed at the same time The positions are marked 1 and 2 Figure 11 shows the location of the jumpers and the locating options The speed control range is factory set for the used motor if Known see type code page 15 Kx option To obtain good speed resolution the lowest possible range for the application should be selected Relocating the jumpers changes the offset of the amplifier e If no add on module is fitted the offset can be reset using the offset trimmer on the front panel If the amplifier is fitted with an add on module the offset must be readjusted in the manner described below To do this the offset trimmer on the front panel is required as well as the
57. first disconnect the device from the mains e pull off the connector and remove cables from the terminals and e remove the device from the chassis after loosening the front panel screws Never operate the device when it is removed from hte chassis Danger GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 15 Chapter 2 Servo amplifier 3 Technical specifications 3 1 Type code The type code clearly identifies a servo amplifier equipped in a certain way The type code also applies for devices of the series in compact design Example gt KSV 3 10 NO K4 Z0 P2 G1 FO E1 S0O WO U 3 10 NO K4 ZO P2 G1 FO E1 So wo Design Power no text 19 plug in module 1 5 5 compact design compact device 3 10 6 20 9 30 12 30 Power supply 320 V DC bus output 1 5 Ams rated current 5 A peak current 320 V DC bus output 3 Ams rated current 10 A peak current 320 V DC bus output 6 Ams rated current 20 A peak current 320 V DC bus output 9 Ams rated current 30 A peak current 320 V DC bus output 12 A rated current 30 A peak current NO no power supply external power supply KSN 8 M1 280014000 needed standard N2 power supply 3 phase 3 x 230 V Controller switching customer module and jumpers KO none device not ready for operation K1 2 pole pair motor speed control 3 500 min K2
58. g Instructions 221052E V 1 3b 35 4 3 4 Connector X4 encoder signals 24 volt version The following figure shows the interface details internal circuit at the 9 pin SUB D connector for the encoder signals section 4 1 4 on page 23 e for the 24 volt version e viewing the connector from the front that is looking at the front panel If the option F1 Holding control loop is missing connection point 1 is not connected Please note e the separate voltage supply of the output Pulse output index pulse Pulse output phase 2 Pulse output phase 1 Supply 0 V schaltend SPS kompatibel switching towards PLC compatible Voltage supply 24 V Switching input Hold only with option F1 Holding control loop BN 6661 0000 00A 055 Fig 5 Encoder signals 24 volt version interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 36 Operating Instructions 221052E V 1 3b 4 4 Connection directions The EMC limits in accordance with EN 55011 A and B emission as CE EMC well as EN 50082 1 and 2 immunity are complied with e if the KSV 6HE drive package is connected in accordance with the directions given here e Only then is the CE marking valid If the connection directions are not complied with e the installation in which the amplifiers are being operated must be checked for compliance with the EMC limits at the dis
59. ge 23 Recommended value 5 to 10 kQ If the supply voltage is now applied while the motor is connected e the green LED must light up e andthe motor must rotate at a speed corresponding to the setpoint applied GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 64 Operating Instructions 221052E V 1 3b If this is not the case please check the connection once more Con sult the fault chart in the appendix as well Pins of the connector X2 encoder signals Steuersignale BN 6646 0000 00A 057 Fig 8 Setpoint potentiometer connection for commissioning 8 3 Setting the speed During commissioning the speed is set with the trimmer Speed Drehzahl for the given setpoint The speed control range is factory set for the used motor if Known see type code page 15 Kx option To obtain good speed resolution the lowest possible range for the application should be selected For conversion on site see section 11 1 1 page 81 8 4 Setting the feedback normal case How to proceed with a speed controller e for drives with limited paths e g carriage drives check the correct Caution functioning of the limit switches e engage the motor with the load to be driven e disconnect the higher level controller apply the setpoint using the setpoint potentiometer Be careful with drives with limited paths e Observe motor behavior at different speeds
60. ion 4 4 6 Motor choke u a au aww tdesdsanebaeesaw ees 4 4 7 Shield connection of the external shunt resistor cable 4 4 8 Connection shielding and laying of the control leads 449 Selpoiit connection 2 24 csench ancrdhehehekaberemek amu 4 4 10 Connection of the encoder signals 000005 4 4 11 Connecting the position sensor resolver 4 4 4 12 Connection of the motor temperature sensor GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 5 5 Adjustment and display elements 00022ceeeeeeee 5 1 Trim potentiometers 2 246 cuesd ous ee ee ee eh 5 2 Current limiting and Current rotary switch 0 BS WEDS sca Val una a a ULE Gna a Ate E ale AiG ie he 6 Modular fittings and expansions 0 000 eee G61 GUSIOMermodlile Kx zitiere a sud Rene poate E 5 2 Add on MOdUIES ZX 224225 fete Bee Meee eee ed 6 2 1 Add on module ZT ur ee een 6 2 2 Add mmod le Z2 rear eee eae ae wok oe eae pore eae get 6 2 3 Add on module ZA 000 cece 6 2 4 Further add on modules 000 cee eee eee eee 8 3 Polarity mod le PX a 22222 ees erga ee eee eee ee eee ee eee eas 6 4 Encoder modules G1 to G4 os 2 222 See en See ee nn 6 4 1 PUG Se MING ars ey tee ese eae eo hae eee mere E eee 6 4
61. it module is not a pluggable module but a modular variation which cannot be retrofitted on site GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 60 Operating Instructions 221052E V 1 3b 7 Shutting down the motor and safety shutdown 7 1 Shutting down options Options for shutting down the motor Disabling through the Controller enable input without Z1 Z2 or Z4 module the motor decelerates brakeless with Z1 Z2 or Z4 module the motor is actively braked by rever sal Switch off via limit switch only with Z1 or Z4 module directional motor is actively braked by reversal Switch off the speed setpoint set setpoint to 0 volts motor is actively braked by reversal Switch off the supply voltage motor decelerates brakeless the position information is lost When switching off the supply voltage please note the tip on page 62 Switch off in the motor supply line without braking resistors motor decelerates brakeless with braking resistors motor is braked by withdrawal of kinetic energy less effective than active braking by reversal Braking resistors effect increases as their resistance value falls the maximum permissible peak current given in the data sheet for the motor may not be exceeded by that If no value is given assume that the limit is three times the continuous current Switching sequence
62. jumper The positions are labeled 2PP 4PP Seli and Sel2 Figure 11 shows the location of the jumpers and the locating options Jumper in position 2PP motor with 2 pole pairs no jumper plugged in motor with 3 pole pairs e jumper in position 4PP motor with 4 pole pairs e jumper in position Seli or Sel2 special motor further details on request The number of pole pairs is factory set for the used motor see type code page 15 Kx option GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 83 Kundenmodul Polarit tsmodul Zusatzmodul Funktionsmodul 1 P3 Customer module Polarity module Add on module Function module strom n offset Current x 14 S gene Q O ZUSATZMOD Drehzahlbereich 50 bei 10 V Sollwert B Set SY GR ERAS Speed range aoe ea at 10 V setpoint EEEIEE HAHN g a ERBEABERBEBE T 500 3500 min oe BE Beal LHL BErFERE P 5 2 11 ATRE alB Fra IE 1000 7000 min eb JE DERBBE T 1500 10500 min JRE a nun 2000 14000 min Zia ERE TEL Tti OW OW OEA D LEISTUNGSVERST RKER 7 Ka z
63. k time constant noge T Jumpers t1 and t2 Steckbr cke Stromregelung Moment BN 6661 0000 00C 060 Jumper current control torque Fig 12 Location of the jumpers on the customer module Current control is not provided with the customer module belonging to the Z4 add on module 11 1 4 Changing the direction of rotation The assignment of the direction of rotation to the polarity of the set points is described in section 4 2 2 page 23 If it is to be changed so that it corresponds to the direction of rotation assignment of the Georgii Kobold 3 units high servo amplifiers e then relocate the jumpers on the customer module from position 6 HE to position 3 HE GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 85 11 2 Modifications to the feedback As standard the speed control is realized as Pl controller 11 2 1 Reset time The customer module has two additional capacitors with which the reset time of the speed controller can be increased These capacitors can be connected to the existing capacitor by means of the jumpers ti and 22 Figure 12 shows the location of the jumpers The following applies Solder bridge Reset time 6 6 ms 10 ms t1 12 standard factory setting With the Z4 add on module the time constant can be adjusted on the add on module itself 11 2 2 D circuit If a D circuit
64. l Typ code See ae Pee eet ee thee Eh a EL FREE 3 2 Technical specifications r serssensee essen 83 Detalls esena Sk Gok ea een rer ee nk 3 3 1 DESIGN wacecke deme sce dees eee ee ens eee ee tee ee ee 3 3 2 CASSIS oa nn A ahaa aah rene ated ergo che eee er GA cea 4 Connection Assignment of connectors and details 4 1 Connector assignments rss 4 1 1 Motor and power supply Combicon connector X1 4 1 2 Control signals Steuersignale SUB D fem connector X2 15 pin 4 1 2 1 Version without add on module 4 1 2 2 Version with Z1 add on module 4 1 2 3 Version with Z2 add on module 4 1 2 4 Version with Z4 add on module 4 1 3 Position sensor Lagegeber SUB D female connector X3 9 pin 4 1 4 Encoder signals Gebersignale SUB D male connector X4 nz 4 2 Details about the signals tat arena GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 4 Operating Instructions 221052E V 1 3b 4 2 1 Auxiliary voltage outputs 2 2 22 00000 cee eee 4 2 2 Setpoint through differential amplifier 2222222200 4 2 3 Switching inputs and switching outputs 222222220 4 2 3 1 Properties of the switching inputs and outputs 4 2 3 2 Switching input Controller enable 4 2 3 3 Switching input Reset fault 2 2 2222 4 2
65. lding function Encoder signals are available e only when a encoder module is in position Encoder modules are available e with 5 volt outputs and e with 24 volt outputs For further details see section 6 4 page 55 The Hold switching input is only available e when the Holding function module is in position The motor can then be shut down with holding torque without the motor shaft continuing to turn slowly For further details see section 6 5 1 page 57 4 2 6 Position sensor The input for the position sensor is dimensioned for the common servo drive type e 2 pin resolver 1 pole pair with a gear ratio of 1 0 5 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 29 4 2 7 Motor temperature sensor At the Position sensor connector the e motor temperature sensor is also connected e Ifthe motor has no temperature sensor the two connections 2 and 6 in the male connector must be jumpered The following are suitable as temperature sensors e Thermo switch which opens in case of overheating or e PTC resistor which raises its value to over 2 KQ in case of over heating 4 2 8 Sensor fault detection The position sensor resolver and its supply leads are monitored e If the resolver breaks down or e if one or more resolver leads are interrupted the drive is shut down immediately the fault memory is en
66. mifer KSV 1 5 5 KSV 3 10 KSV e20 6 20 KSva0 Sa win 40 units 50 8 mm Height 6 height units 262 mm Weight 1 3 k 3 3 Details 3 3 1 Design KSV 6HE servo amplifiers in 19 design are manufactured as plug in modules They consist of a printed circuit assembly PCA with heat sink arranged in parallel the customer module and the front panel The PCA has slots for the modules explained later All connections trim potentiometers and LEDs are located at the front panel e control signals 15 pin SUB D female connector e motor and operating voltage input 7 pin Combicon connector e position sensor resolver 9 pin SUB D female connector e output for encoder signals 15 pin SUB D male connector present only if encoder module is mounted The devices for continuous currents up to 3 A e work with natural convection The devices for continuous currents above 3 A need fans like the ones included in our chassis 089100010Z and For currents and temperatures see table Technical specifications page 16 for chassis see section 10 page 75 3 3 2 Chassis Use chassis to combine multiple KSV 6HE amplifier plug in modules with the power supply or several power supplies For further details refer to section 10 2 1 page 75 The requirements of the EMC directive are fulfilled CE EMC a er 4 e if the KSV 6HE servo amplifiers are built into an Georgii Kobold chassis and GEORGII KOBOLD D 7077
67. mm 002057040Z 340 x 194 x Wiring Recomm cross section Minimum cross section Necessary RFI filter Dimensions L x W x Hin mm The following applies for combinations of several amplifiers with one transformer e The load factors of the amplifiers working simultaneously on one power supply at full load are added and the proportionally reduced load factors of the amplifiers working under part load are added The total load factor thus calculated determines the transformer required e Check to make sure that the load factor of the power supply is not exceeded If it is exceeded several power supplies and possibly several transformers must be used If more than one power supply is connected to one mains transformer e the bus voltages i e the outputs of these power supplies must not be connected GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 74 Operating Instructions 221052E V 1 3b lf this cannot be ensured a separate mains transformer has to be used for each power supply or a common transformer with separate secondary windings A RFI filter has to be switched behind the secondary winding of the CE EMC mains transformer and therefore before the power supply input see sections 4 4 4 page 40 and 10 2 7 page 80 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 7
68. module can be converted from the standard version Motor standstill into the special version Power circuit ready by means of a solder bridge For further information please refer to section 11 Notes for specialists on page 81 ff When the servo amplifier e is working correctly and e is not disabled either by the controller enable or by means of a limit switch then the Power circuit ready output is set to 1 When the servo amplifier e is faulty or e disabled then the Power circuit ready output switches to O For further details on fault monitoring please refer to section 4 2 10 Fault memory page 30 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 28 Operating Instructions 221052E V 1 3b 4 2 4 Analog outputs The analog output Speed monitor supplies a e voltage proportional to the motor speed the polarity corresponds to the direction of rotation for example to connect a measuring instrument to display the speed The analog output Current monitor supplies a e voltage proportional to the current flowing in the motor the polarity corresponds to the direction of the torque Preconditions e Motor correctly connected Motor operating within the voltage limits of the amplifier For values of both outputs see table Technical specifications on page 16 4 2 5 Encoder signals ho
69. n Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 26 Operating Instructions 221052E V 1 3b 4 2 3 4 Switching output Fault or Ready The Fault output is present e when no polarity module PO or polarity module P1 is used When the servo amplifier is working correctly then e the Fault output is set to 0 If there is a fault then e the Fault output switches to 1 For further details on the fault signal and on the fault memory see section 4 2 10 page 30 On request the Ready output can be switched instead of the Fault output Since the same connector pin on the control signal male connector is used for both options the two outputs cannot be present at the same time The Ready output is inverse to the Fault output It is present e when the polarity module P2 is used When the servo amplifier is working correctly then e the Ready output is set to 1 If there is a fault then e the Ready output is set to 0 For further details on the fault signal and on the fault memory see section 4 2 10 Fault memory page 30 If the amplifier is off circuit then e the output is disabled that is it is at O V The polarity module P1 can be converted into the polarity module P2 using a solder bridge For further information please refer to section 11 Notes for specialists on page 81ff 4 2 3 5 Switching output Overloa
70. ncreases during braking until the connected amplifiers switch off due to overvoltage e the red LED of the amplifiers indicates the fault the Fault St rung output switches on This fault can only be reset e by switching the mains voltage off and on again 9 3 Mains transformers 9 3 1 General information The mains transformers are laid out for three phase connection As well as the standard transformers shown in the following table we can also supply special versions further details on request GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 7 wo In accordance with the data given the transformers can also be ordered by the user from a local manufacturer in order to save the comparatively high costs of post and packaging The transformers have separate primary and secondary windings CE EMC Autotransformers are not permissible 9 3 2 Connections The connections are clearly labeled on the terminals of the trans formers 9 3 3 Technical specifications of the mains transformers transformer 038100050Z 038100070Z 038100090Z 038100130Z Mains connection primary 3 x 400 V Output voltage 3 x 230 V Load factor power supply dimensioning 15 25 40 80 Rated output 1 2 kVA 2 5 kVA 3 5 kVA 7 5 kVA Primary side back up fuses 3x4AT 3x6AT 3x10AT 3x16AT 1 5 mm 2 5 mm 4 0 mm 1 0 mm 1 5 mm 2 5
71. nd cabling given in the operating instructions are observed Operating instructions 22 10 52E The products are developed constructed and produced in accordance to EC Directive EMC directive 89 336 EWG amended by 91 263 EWG 92 31 EWG 93 68 EWG Low voltage directive 73 23 EWG amended by 93 68 EWG of exclusive responsibility of company GEORGII KOBOLD Postfach 10 01 54 D 70745 Leinfelden Echterdingen Fasanenweg 6 8 D 70771 Leinfelden Echterdingen AUGUST HEINE GmbH amp Co Telefon 0711 75903 0 gt Fax 0711 7590353 The signers are Schilhab head of quality department Schramm technical director The following harmonised Standards are used EN 55011 1991 class A and B DIN VDE 0875 part 11 DIN EN 50082 1 1994 DIN EN 50082 2 1995 DIN pr EN 50178 1994 Cede A technical documentation is completely available An operation instruction is available in the original version O in the native language of the user ueensessessnnsssnnnenennnesnnsensnnnenannennensenennensnnnennnnsnnnsnnsnnnennannnnnnene Dok Nr Ausgabestand ersteilt ge ndert Seite Schilhab Datum Signum 9977 10 4 31 4 18 Januar 2000 1 Mrika Datum Signum 18 Januar 2000 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 92 Operating Instructions 221052E V 1 3b Appendix B Terms of warranty warrants that the device is free of material and pro
72. ne 49 0 711 75903 0 fax 49 0 711 75903 53 24 Operating Instructions 221052E V 1 3b i A positive setpoint E positive against E results in a clockwise Tip rotation of the motor shaft when looking towards the bearing plate This applies if e the costumer module has not been modified 4 2 3 Switching inputs and switching outputs Through the switching inputs and switching outputs the servo ampli fier works together with e with external switches e with the primary controller 4 2 3 1 Properties of the switching inputs and outputs Two possible polarities by means of polarity module P module see also type code e Switching towards zero when no polarity module is used PO in type code e Switching towards positive PLC compatible when polarity module is used P1 in type code Positive is either the externally supplied PLC operating voltage 15 35 V preferably 24 V or the internal auxiliary voltage of 15 V The outputs are applied via PTC resistors and are thus short circuit proof Each output can operate a miniature relay max 30 mA at max 35 V e The coil must be cleared by a diode The specifications are shown in the following table GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 25 Technical data of the Switching PLC compatible version switching inputs and towards switching outpu
73. nector at the amplifier has to be no longer than 50 cm It remains shielded The shield is not connected at the cable s end e If you cannot use the shield connection plate install cable clamps on the mounting plate as close as possible to the RFI filter GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 39 4 4 2 Installation in a 19 rack system If you install the chassis in a 19 control cabinet screw the chassis e with its bare metal mounting flanges on the bare metal rack CE EMC made of chromated aluminum or made of zinc plated sheet steel with low resistance earthing i e connected to the central zero point via a shortest possible potential equilization cable of cross section 10 mm or more or better using a wide copper braiding earth strip e Do not use varnished or anodized racks To ensure a well conducting connection for high frequencies between the housing of the RFI filter see section 4 4 4 and the chassis e install the RFI filter directly on the rear wall of the chassis Suitable mounting holes are located there Establish the earthing of the motor cable shields at the shield connec tion plate where the RFI filter is installed by removing a ring shaped part of the isolating cable sheath and e clamping the bare shield on the shield connection plate The length of the remaining cable between
74. ng and limiting the component of the speed controller Using the t0 t1 and t2 solder bridges the time constant of the speed controller component can be adjusted on the Z4 add on module GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 89 Figure 15 shows the location of the solder bridges The following applies Solder bridge time constant no component 25 ms 2 5 ms 2 1 25 ms t1 12 0 8 ms Potentiometer 1 25 25 ms only on special module for commissioning aid none Using the lim1 to lim3 solder bridges the component can be limited on the Z4 add on module The limitation threshold is given in percent of the maximum permissible pulse current The following applies Solder bridge Limitation threshold none 100 lim1 10 lim3 30 Potentiometer 0 55 only on special module for commissioning aid 11 4 Modifications to the polarity module 11 4 1 Ready signal instead of Fault signal The P1 polarity module supplies among other things the Fault signal while the P2 polarity module supplies the Ready signal To convert from P1 to P2 connect the two soldering areas labeled Be on the polarity mod ule see fig 16 453 GHG H X ACCELERERA meere TEE EEBB BSS eeue BN 6661 0000 00B 063 INGOW d Fig 16 Solder bridges on the
75. nt is reduced to the value of the preset continuous current and an external Overload signal is given The amplifier can be operated for any length of time in this state If the current is reduced the Overload state is canceled after some time The 16 position rotary switch Current Strom for setting the cur rent limit is located at the top of the PCA approximately 100 mm behind the customer module It is not accessible from outside so that it cannot be adjusted unintentionally The assignment of the switch positions to the values for the motor current limit continuous current GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 48 Operating Instructions 221052E V 1 3b l as rms value and peak current as crest value is shown in the following table Servo amplifier KSV 1 5 5 KSV 3 10 KSV 6 20 KSV 9 30 KSV 12 30 Cont Peak Cont Peak Cont Peak Cont Peak Cont Peak current current current current current current current current current current Ip A th A b A IA b A L A b A h A Io A l A 0 38 Ea 0 75 2 5 2 25 7 5 3 0 75 3 0 9 0 0 53 BEE 1 05 35 3 15 10 5 2 0 4 0 12 0 12 0 0 68 225 1 35 4 05 13 5 13 5 075 25 10 0 15 0 15 0 0 83 2 75 1 65 11 0 495 165 66 16 5 3 0 1 8 12 0 18 0 18 0 0 98 3 25 1 95 13 0 585 195 19 5 1 05 14 0 21 0 21 0 150 6 75 225 22 5 16 0 24 0 24 0 17 0
76. older bridge GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 54 Operating Instructions 221052E V 1 3b Tip Tip The speed control loop is divided e inthe P component P controller adjustable with the Feedback Verst rkung potentiometer on the front panel e and the component I controller The time constant can be selected by solder bridges on the Z4 add on module for further details see section 11 3 7 page 88 For overshoot suppression in the speed control loop e the component can be limited The limitation threshold can be selected by solder bridges on the Z4 add on module for further details see section 11 3 7 pa ge 88 For the purpose of commissioning a special module is available on which e potentiometers for time constant and limitation threshold are mounted The special module is not suitable for normal operation because the potentiometers e can only be adjusted when the device is open Using the limit switch inputs the motor is e shut down depending on the direction of rotation and is actively braked by reversal PLC compatible The Controller enable input also e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 85 An additional switching output supplies e the Power circuit ready signal PLC compatible If
77. output Motor standstill or Power circuit ready internally selectable e peak current can be switched off using a solder bridge e ramp function can be switched off using a solder bridge The external analog input Current reduction proportionally reduces the current limit set with the Current selector switch e If the input is open or if it is set to 10 V the current limit has the effect which has been set at the Cur rent selector switch e If there is a voltage of less than 10 V at the input the current limit is reduced proportionally First only the peak current is reduced Only when the current limit is lowered by the external setpoint below the peak current value the continuous current is also reduced e Values of over 10 V do not cause a higher current than 100 and values of less than 0 1 V do not cause a lower current than 1 of the set value The peak current rise can be switched off e for conversion by the specialist see section 11 3 page 85 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 53 The additional switching input Setpoint reversing e reverses the polarity of the setpoint internally Ifitis open or set to 0 the setpoint leads to the same direction of motor rotation as without the module If it is switched to 1 the direction of the motor
78. ower circuit ready Signal End Bereit Be Peak current off Impulsstrom Aus I Active braking off aktive Bremse Aus BR1 Ramp function on Sollwer Rrampe Ein Ein Modifications to Z4 add on module Feedback time constant the set time constant is marked with a cross Limitation of the speed controller component the set limitation is marked with a cross 100 open 10 lim 20 lim2 30 lim3 Modification to polarity module marked with a cross when solder bridge closed pe ee GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 91 Appendix Appendix A EC Declaration of Conformity GEORGII KOBOLD Form AUGUST HEINE GmbH amp Co Certificate of Conformity Total Quality Certificate of Conformity in the sense of EC Directive Here with we confirm that the products Product GEORGII KOBOLD Type KSV 6HE front connection Series KSV Servo Amplifier correspond to the EC directives standards and regulations below and are designed for installation in a ma chine According to EC directive Machines commissioning is prohibited until it has been ascertained that the machine in which the above product is installed meets the provisions of the EC directive The requirements of the EC directives standards and regulations will only be met if the directions for instal lation a
79. pecifications of the chokes please refer to section 10 2 6 page 78 4 4 7 Shield connection of the external shunt resistor cable If an external shunt resistor is connected see section 9 2 6 page 71 for further details e use a shielded cable e connect the shield with the earthed housing of the shunt resistor using a cable clamp at the housing as shown in fig 6 4 4 8 Connection shielding and laying of the control leads These notes on connection shielding and laying of the control leads CE EMC apply for the following three sections e Use only shielded leads GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 44 Operating Instructions 221052E V 1 3b e The SUB D connectors must have metal plated housings like the connectors supplied by us There the shield is connected with a low resistance to the hous ing via the strain relief e This allows you to achieve the necessary large area earth connec tion for the shield and to avoid earthing the shield using twirled strands pigtails of the shield Do not lay control leads parallel to motor cables or to connections between power supply and amplifier in the wiring duct 4 4 9 Setpoint connection When connecting the setpoint source top in fig 6 e ensure that earthing and shielding have been correctly carried out to avoid faults at the amplifier input to prevent faults at the setpoint source
80. perating Instructions 221052E V 1 3b Mode of operation of the hold function when the hold command is entered at the Hold input through logical 1 then e the external setpoint is switched off internally e The internal holding control loop digitally saves the position of the motor at the moment the command was given e The holding control loop returns the motor to this position and holds the motor in this position with its full torque The holding control loop monitors the position within one revolution If the motor has required more than one revolution to come to a standstill from a higher speed due to inertia these revolutions are not recalled Example of a simple positioning solution e A pre sensor reduces the speed of the motor in good time before the position so that later no more than a single revolution will be needed to brake the motor e a sensor gives the hold command at the position e the motor brakes and the internal holding control loop recalls it to the switching point of the position sensor In many cases the holding control loop makes a magnetic brake on the motor superfluous If the safety aspects derived from the machine directive require the brake however it cannot be replaced by the holding control loop 6 5 2 Field weakening mode F2 In AC servo drives the maximum speed that can be reached can be increased at reduced torque by shifting the phase of the motor current at higher speeds
81. pth without connector 14 units 71 mm 6 height units 262 mm 195 mm 9 2 6 External shunt resistor Operating the unit as a braking controller where the motors mainly have to work against an external torque in braking mode requires an external shunt resistor dimensioned for the required power The internal resistor is insufficient for this GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 72 Operating Instructions 221052E V 1 3b The resistance of the external shunt resistor should lie between 27 Q and 33 Q The load capability has to be dimensioned according to the required braking power If you would like to use an external shunt resistor instead of the inter nal one then e remove the jumper between Rin and R e connect the external resistor to the connections R and Rp The external shunt resistor e must be installed in an earthed metal housing to avoid emission and CE EMC ae as a protection against contact with live parts and with the hot resistor The cable e must have a cross section of 1 5 mm and must be shielded CE EMC ere ee Note the connection directions section 4 4 7 Shield connection of the external shunt resistor cable The output for the shunt resistor is short circuit proof In case of a short circuit e the shunt circuit will be switched off The red LED indicates the fault As a consequence the bus voltage i
82. reaks down the drive is switched to a safe state 2 6 CE marking The KSV 6HE servo amplifiers meet the requirements of e the EMC directive 89 336 EEC and e the low voltage directive 73 23 EEC C They thus conform to the currently valid EU regulations and bear the CE marking The CE marking only applies CE EMC e when all installation and connection requirements of these operat ing instructions have been exactly complied with and e when the requirements in the notes next to the CE EMC marks have been met GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 14 Operating Instructions 221052E V 1 3b If this is not possible then e you must have the installation in which the amplifiers are being operated tested at your own discretion for compliance with the EMC limits 2 7 Preconditions for commissioning In addition to the low voltage and EMC directives applicable to the servo amplifiers the e machinery directive 89 392 EEC applies to machines The machinery directive 89 392 EEC applies to the final product that is the machine containing the servo amplifier The machine manufacturer must comply with the machinery directive 89 392 EEC Commissioning is forbidden until the requirements of the machinery Do not directive have been met 2 8 Working with the amplifier or the power supply To replace modules or to carry out matching or other work e
83. rol loop 0 Volt Pulse output phase 1 U Pulse output phase 2 U Pulse output index pulse Ua Voltage supply encoder module 24 V only with 24 V version Pulse output phase 1 inverse U for 24 V vers not assigned Pulse output phase 2 inverse U for 24 V vers not assigned Pulse output index pulse inverse U for 24 V vers not assigned Housing Connect cable shield to the housing of the SUB D connector cE 4 2 Details about the signals This section describes details about the signals named in the connec tion assignments The sequence corresponds to the sequence of connectors given above 4 2 1 Auxiliary voltage outputs The two auxiliary voltage outputs are primarily for connecting an external setpoint potentiometer for initial tests see fig 8 page 64 The auxiliary voltage outputs are led via PTC resistors and therefore short circuit proof For further details see the table Technical specifi cations page 16 The auxiliary voltages are only roughly stabilized their voltage values vary within the given tolerances when the ampli fier output is placed under load 4 2 2 Setpoint through differential amplifier The setpoint input is applied to a internal differential amplifier with the two inputs E and E When correctly connected see section 4 4 9 page 44 you avoid faults caused by neutral loops with the differential input GEORGII KOBOLD D 70771 Leinfelden Echterdingen pho
84. ry is to be connected to the speed feedback PID con troller the components C 2 and R 10 must be installed on the custo mer module Their locations are printed on the board see fig 12 The values must be determined by experiment 100 nF and 100 kQ can be regarded as guide values D circuitry connection is not provided with the customer module be longing to the Z4 add on module 11 3 Modifications to the Z1 Z2 and Z4 add on modules 11 3 1 Location of the solder bridges The following figures show the position of the solder bridges on the Z1 Z2 and Z4 add on modules GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 86 Operating Instructions 221052E V 1 3b Zusatzmodul Z1 Z1 add on module O Impulsstrom aus Peak current off aa Inpuls strom Aus aktiv Aktives Bremsen aus Ly Brense Aus Active braking off BN 6661 0000 00B 061 Z1 Modul ren FO er Rampenfunktion ein o weri Ramps Ea 4 Ramp function on Endcderei 198 Endstufe bereit an statt Motor steht Power circuit ready instead of Motor standstill Fig 13 Solder bridges on the Z1 module Z2 add on module Zusatzmodul Z2 O ar Impulsstrom aus I T Ip Peak current off Endstufe bereit an ti statt Motor steht Power circuit ready instead of Motor standstill BN 6661 0000 00C 062 O Fa Rampenfunktion ein Eis 4 Ramp function on B
85. solver encoder connection cable is suitable for connecting the position sensor resolver as well as for connecting a positioning controller to the sensor signals output Characteristics of our resol ver encoder connection cable 535245 Z e 8 core shielded e twisted pair e suitable as trailing cable GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 78 Operating Instructions 221052E V 1 3b Technical specifications Res Enc connection cable 535245 Z Cable code KWLiFPETP C 11YP OB 2 x 4 x 0 25 mm Single core 0 25 mm C Litz bare 19 x 0 127 mm Structure 4 pairs stranded with short length of twist Color coding white brown green yellow grey pink blue red Total shield Cu mixed braiding tin coated coverage 85 Total sheath Polyurethane orange RAL 2003 Diameter 6 4 0 3 mm Bending radius for single min 80 mm bend fixed installation Rolling radius for continuous min 150 mm altern bending trailing use Operating temperature 40 bis 80 C fixed installation 30 bis 70 C trailing use 10 2 5 Ferrite ring 042103010 The ferrite ring damps the high frequency interference immediately at the terminal For application see connection directions in section 4 4 on page 36ff Dimensions ferrite ring 042103010 Outer diameter 16 mm Inner diameter 8 5 10 mm 10 2 6 Motor chokes 038096010Z and 038097010Z Longer motor c
86. st not be operated when it is open e pull the servo amplifier out of the chassis for about 40 mm The trim potentiometer on the customer module is now accessible GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 68 Operating Instructions 221052E V 1 3b Chapter 3 Power supply and accessories 9 Power supply of the servo amplifiers 9 1 9 2 9 2 1 Load factor The load factor gives the number of amplifiers that can be connected You will find it in the technical specifications for the amplifiers the power supplies and the mains transformers The following applies When all amplifiers are being operated simultaneously at full load the sum of their load factors must not exceed the load factor of the power supply and the one of the mains transformer When not all amplifiers are being operated simultaneously at full load which is frequently the case with servo drives the total load factor is the sum of the load factors of the amplifiers being oper ated simultaneously When amplifiers are operated under part load only their load fac tors are reduced for purposes of the calculation in proportion to the part load Example The KSV 6 20 KSV 6HE amplifier has a load factor of 16 the 2800140000 power supply has a load factor of 75 this means that this power supply can run 4 of these amplifiers simultaneously at full load and still has plenty of reserve For 4 of
87. stant and limitation threshold are mounted The special module is not suitable for normal operation because the potentiometers e jut out of the amplifier and e can only be adjusted when the device is open The locations of the solder bridges on the Z4 add on module are indicated in section 11 3 page 85ff How to proceed with a speed controller with component limitation e check limit switch connect motor to load as above e switch off component close t0 solder bridge e adjust P controller turn the feedback trimmer Verst rkung clockwise until the motor runs loud and rough then turn back the trimmer approx one turn GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 66 Operating Instructions 221052E V 1 3b e set limitation threshold to 20 close lim2 solder bridge e switch on component open t0 solder bridge e apply reversing motion by position control optimize step response by reducing the time constant t1 and t2 solder bridges e select limitation threshold disturbing overshoot decrease limitation lim1 following error increase limitation lim3 optimize time constant again if necessary 8 7 Setting the current limit Tip Factory setting for delivery of drive packages amplifier and motor Current limit is set to the rated current of the motor For changing the current limit atthe open device through th
88. switching output switches to 1 and e Fault LED lights up The fault is stored exception Operating voltage too low A fault signal can only be reset when the cause of the fault has been elimi nated To reset e the switching input Reset fault is switched briefly from 0 to 1 This does not reset resolver faults Or e the operating voltage is switched off and then on again or the supply voltage in the case of the external supply of the control circuit module E1 This also resets resolver faults Before switching back on wait until the Fault LED has gone out In the case of the external supply of the control circuit mod ule E1 if the supply voltage is switched off and then on again to reset the fault the position information stored in the control circuit is deleted External fault signal in the case of overheating power circuit or mo tor e Fault switching output switches to 1 and e Fault LED flashes as long as the temperature limited is exceeded GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 31 lights up constantly when it has cooled down below the tempera ture limit Only then can the fault memory be reset The operating voltage may reach an excessively high value e ifthe motor is braked and the shunt regulator is missing
89. t units for the plug in modules 1 height unit for the fan unit e 84 units wide in common 19 design mounting flanges and han dles at the front for installation in 19 racks or on a mounting plate order number 089100010Z e 54 unites wide for installation on mounting plate mounting flanges at the rear without handles order number The chassis 84 units wide can accommodate 7 amplifiers and 1 power supply The chassis 54 units wide can accommodate 4 amplifi ers and 1 power supply The chassis with fan units provide at the lower part of the front e wiring duct to accommodate the DC bus connections between power supply and servo amplifiers GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 76 Operating Instructions 221052E V 1 3b At the same location there is a 3 pin Combicon connector for supply of the fans e Supply 230 V mains voltage Assignment from left to right Le In ee 10 2 2 Connector sets 099066020Z and 099066010Z The amplifiers are supplied without mating connectors The connector set comprises all necessary connectors e The connector set 099066020Z includes connectors for the version without encoder module GO two SUB D connectors with screwable housings and one 7 pole Combicon female connector e The connector set 099066010Z for the version with one of the encoder module options G1 to G4 includes one additional SUB D conn
90. the amplifier circuit e G3 encoder module characteristics like G1 but in addition with adjustable index pulse The index pulse can be shifted in 256 steps within one motor revolution For further details see section 6 4 2 page 56 e G2 encoder module pulse output for 24 volts interface push pull outputs actively switching towards zero and towards 24 volts phase 1 phase 2 and index pulse without complement over 3 lines outputs electrically connected to the amplifier circuit outputs short circuit proof GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 56 Operating Instructions 221052E V 1 3b external supply as with incremental encoders with 24 V 20 e G4 encoder module characteristics like G2 but in addition with adjustable index pulse The index pulse can be shifted in 256 steps within one motor revolution For further details see section 6 4 2 page 56 Ti The following applies for all encoder modules p e When the motor shaft rotates clockwise looking towards the bear ing plate phase 2 lags behind phase 1 This corresponds to the definition with the output impulses of an incremental encoder e With all pulse figures the index pulse like standard incremental encoders has half the width of the pulses from phase 1 and phase 2 6 4 1 Pulse setting A rotary switch with 16 positions on the encoder module is for set
91. the earthing point of the shield and the connector at the amplifier has to be no longer than 50 cm It remains shielded The shield is not connected at the cable s end Leave a gap below the chassis e Under the chassis lay the cable from the power supply to the filter via the shield connection plate to the back e Lead the motor cables under the plug in module to the back via the shield connection plate into the general control cabinet cabling 4 4 3 Potential equilization cables Figure 6 shows potential equilization cables They come from the central zero point of the control cabinet Their tasks are e they form alow resistance connection between various zero points e they reduce compensating current on the cable shield and thus prevent electrical faults GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 40 Operating Instructions 221052E V 1 3b The central zero point of the control cabinet is connected to the PE protective earth conductor This connection e ensures protection of the operating and maintenance personnel in Danger case of electrical faults Due to leakage current from the RFI filter the potential equilization cable from the central zero point to the PE bolt of the RFI filter must in accordance with DIN VDE 0160 like the protective earth conductor have a cable cross section of at least 10 mm Cu The other potential equilization cables must ha
92. these amplifiers the transformer 038100130Z with a load factor of 80 has to be used as mains transformer Power supply Design The servo amplifiers the power supply and the mains transformers are well matched Design of the power supply order number 2800140000 19 plug in module designed in the same way as the servo ampli fier for installation into the 19 chassis together with servo amplifi ers The power supply contains the mains rectifier GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 69 e the charging capacitors e the monitoring circuit and e the shunt regulator with a shunt resistor sufficient for common servo applications For the plug in power supply various mains transformers are avail able 9 2 2 Shunt regulator During braking the kinetic energy of a rotating servo motor is fed back into the power supply as electrical energy e this causes the bus voltage to rise A shunt regulator also called shunt circuit built into the power supply e prevents that the power transistors are destroyed by that For higher shunt performance an external shunt resistor can be used For further details see section 9 2 6 page 71 9 2 3 Connection assignment terminal blocks X5 and X6 28 terminals in 5 blocks are located on the front panel of the power supply e Upper block connection for the external shunt
93. ting Amplifier or motor cooling inade quate temperature sensor has not yet switched back fault reset not possible now After some time the display changes to the following condition see next row Current limit set too high Set to the current given for the motor Red LED lights up continuously green LED flashes Amplifier motor has cooled down temperature sensor has switched back fault can now be reset Yellow Overload LED lights up Motor is overloaded or blocked Check mechanical system Current limit set too low Compare nominal motor data with set ting Motor is not connected or a motor lead is Check motor wiring interrupted Motor is at a standstill with power Setpoint missing setpoint lead interrupted or Check setpoint lead connection TA drifts slowly but cannot be controlled short circuited Offset adjustment incorrect Adjust offset potentiometer One setpoint lead is open shield is not cor Check setpoint lead It must be con rect motor is not earthed transformer neutral nected on one side to setpoint source point is not earthed zero volts Check shield check zero Motor runs slowly at setpoint zero Disturbing noise when motor is run ning humming whistling chirping Motor runs in the wrong direction Setpoint inputs transposed Transpose E and E or set jumper on customer module Motor runs too slowly or too fast at given
94. ting the pulse number The following applies Switch setting Pusespr per Switch setting setting Pulses ee m B N a as a ee ee el BEA factory setting HH errr specially intended for speed display with frequency meter Gives direct revolutions per minute if the display is set to Hz It is essential that you should document the switch position in the Tip table in section 12 page 90 if you have changed the factory settings 6 4 2 Index pulse adjustment With the G3 and G4 encoder modules adjustable index pulse the position of the index pulse can be shifted within a motor revolution For this purpose the encoder module has two rotary switches Rough and Fine and three LEDs GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 57 Tip e The Rough switch shifts the pulses by 22 5 per step e the Fine switch shifts them by approx 1 4 per step e The Zero LED indicates the index pulse that is the moment when the output level is High e The Rough and Fine LEDs light up when the index pulse is within the setting range of the appropriate switch Adjustment instructions 1 Turn the motor shaft to where the index pulse should be 2 Turn Fine switch until the Fine LED lights up 3 Turn Rough switch until the Rough
95. ts zero version With internal With externally auxiliary voltage supplied PLC voltage Input resistor switching 22 KQ to 2 2 kQ 2 2 KQ towards input wards 15 V towards 0 V oV Output resistor switching 125 Q to 1250 125 Q towards output wards 0 V towards 14 V PLC voltage Maximum permissible load current Logic level for logical 0 open or open or lt 2 V gt 13 V Logic level for logical 1 lt 2 V Permissible PLC signal 15 35 V voltage 4 2 3 2 Switching input Controller enable At the switching input Controller enable the logic level for e 1 leads to amplifier enabled motor can run the green Ready LED lights up e 0 leads to amplifier disabled the motor decelerates brakeless the green Ready LED flashes Disabling through the Controller enable switching input does not meet the safety requirements of the machine directive e if an en stop or a safety shutdown of the machine is re quired the instructions given in section 7 3 concerning the safety re quirements of the machine directive must be followed strictly 4 2 3 3 Switching input Reset fault The logic level at the Reset fault condition input e must be set to 0 at rest e is briefly switched to 1 when a stored fault is to be reset For further details on the fault signal and on the fault memory see section 4 2 10 page 30 GEORGII KOBOLD D 70771 Leinfelde
96. uct as shown in fig 6 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 42 Operating Instructions 221052E V 1 3b e via short three core wiring connections for the necessary cable cross section see table Technical specifications page 16 e Do not lay other cables motor cables control cables parallel to this connection in the wiring duct e Lead the two wires for the operating voltage but not the PE lead through a ferrite ring 042103010 section 10 2 5 page 78 directly at the amplifier input as shown in fig 6 4 4 5 Motor connection general information Check Danger CE EMC For the motors supplied by Georgii Kobold the connection is given in the motor connection sheet shipped with each motor To connect other motors not supplied by us please contact us The 3 motor phases must be connected with the correct assignments otherwise e the motor blocks e the motor runs roughly e the motor runs with a low torque or e the motor runs uncontrolled at full speed This causes no damage either to the motor or to the amplifier but there is a risk for the machine and the installation personnel un in fig 6 the motor is connected using a 4 pin shielded cable e Use the motor supply cable described in the accessories for fur ther details see section 10 2 3 on page 76 e Establish the earthing of the motor cable shields at the shield connection
97. ut Motor standstill or Power circuit ready Output auxiliary voltage 15 V Input 24 V for polarity module and if option E1 Output auxiliary voltage 15 V Switching input Reset fault 100ka paa fod 10nF 0 Volt BN 6661 0000 00A 053 Fig 3 Control signals PLC compatible interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 34 Operating Instructions 221052E V 1 3b 4 3 3 Connector X4 encoder signals 5 volt version The following figure shows the interface details internal circuit at the 9 pin SUB D connector for the encoder signals section 4 1 4 on page 23 for the 5 volt version e viewing the connector from the front that is looking at the front panel If the option F1 Holding control loop is missing connection point 1 is not connected Pulse output index pulse Pulse output index pulse inverse Pulse output phase 2 Pulse output phase 2 inverse Pulse output phase 1 Pulse output phase 1 inverse OV schaitend 4 SPS kompatibel switching towards PLC compatible frei 6 Voltage supply 5 V Switching input Hold only with option F1 Holding control loop BN 6661 0000 00A 054 Fig 4 Encoder signals 5 volt version interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operatin
98. ve e a cross section of at least 2 5 mm or preferably 4 mm It is true that drives can run without potential equilization cables without shielded cables and without compliance with safety regula tions However this e is contrary to elementary safety requirements Do not e violates statutory regulations and endangers the safety of persons endangers the operational safety of the system and may lead to faults from and in other parts of the system 4 4 4 Mains connection 4 4 4 1 Connection mains mains transformer The mains transformer e is chosen corresponding to the technical specifications of the trans formers in section 9 3 3 page 73 The connections are clearly labeled at the terminals of the transform ers The cable between mains and the transformer e is led through line side fuses see the table on page 73 for values e must have an adequate cross section for the chosen mains trans former given in the same table e must have a fixed connection e Shielding is not required e Connect PE to earth e The secondary neutral point has to be earthed GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 41 If more than one power supply is connected to one mains transformer e the bus voltages i e the outputs of these power supplies must not be connected 4 4 4 2 Connections mains transformer
99. when switching off in the motor supply line first disable the amplifier using controller enable then open the motor line no delay is required between the two operations since the power contactor is slower than the disabling operation To switch on again first close the motor line then enable the controller Delay necessary depending on the power contactor for example 20 ms or more GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221052E V 1 3b 61 If the braking time is too long with the selected manner of shutting down the motor the motor can be fitted with a magnetic brake which acts using spring power when the current is switched off 7 2 Estimating the braking distance The braking distance of the connected machine part depends on the moment of inertia of the drive and on the mass of the part to be moved e g of the machine carriage Example assumed values e Braking time for active braking limit switch or zeroing of setpoint 0 1 seconds e linear braking from a velocity of 10 meters per minute e results in a braking distance of approx 8 millimeters This means that with the values of this example the setpoint must be set to zero at least 8 millimeters before the mechanical limit stop if the stop is not to be struck hard 7 3 Emergency stop and safety regulations The safety regulations to be d

Operating Instructions 221052E, V 1.3b 09/01

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