Home

Operating Instructions 221072E, V 7.5a

1. GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 36 Operating Instructions 221072E V 7 5a 08 05 4 8 Input EnDat Encoder Option R4 X11 R4 15 pin SUB D female connector X11 on the bottom side assignment for de vices equipped with option R4 Pin r pao oe 3 4 5 digital serial cycle incremental signals SS digital serial data 9 DATA 5 V supply voltage for EnDat encoder 11 A incremental signals e A 13 5 V input measuring lead for regulating the supply voltage for the EnDat OV encoder 15 OV for supply voltage EnDat encoder The EnDat encoder input is designed for EnDat encoder EQN 1325 or ECN 1313 produced by Heidenhain Motors with built in EnDat encoder are available from Georgii Kobold Kaes To keep the supply voltage of the encoder at constant 5 V it is fed back to the amplifier via the measuring lead and the output voltage is re adjusted in the range between 5 V and 8 V For the differences between the types of motor position sensors option Rx please see section 3 4 2 page 22 For connecting an EnDat encoder see sections 5 13 page 63 and 5 13 4 page 64 With option R4 the motor temperature sensor must be connected to Combicon connector X7 see section 5 10 page 61 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5
2. 324 Environmental Conditions Servo Amplifier KDV 2 400 KDV 4 400 KDV 8 400 KDV 12 400 KDV 20 400 Degree of protection IP20 according to EN 60529 Degree of pollution 2 according to EN 50178 Mounting height without current derating lt 1000 m above sea level Mounting height with current derating lt 2000 m above sea level 1 5 per 100 m above 1000 m Climatic category acc to DIN EN 50178 operation 3K3 storage 1K4 transport 2K3 Permissible ambient temperature 45 440 C 25 455 C 25 470 C en EE E E A EE ue 3 2 5 Analog and Digital Inputs and Outputs Interfaces KDV 2 400 KDV 8 400 Analog I O 10 mA each via PTC 125 Q short circuit proof setpoint speed default setting assignment speed current default setting resolution 10 Bit Digital UO opto isolated switching towards positive PLC compatible Voltage supply from outside 24 V DC at 24 V I O 0 V I O 18 32 V DC Digital inputs 16 freely configurable depending on the option for an exemplary assignment see section 4 3 page 30 assignment voltage level 0 5 V for 0 low 12 30 V for 1 high Digital outputs 8 freely configurable 1 assigned NET depending on the option 9 for an exemplary assignment see section 4 3 page 30 output resistance 125 Q PTC GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 539
3. GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 4 3 3 Motor Temperature Sensor SS SE SS SS ees 37 44 Shunt Resistor and DC Bus X9 nannan anaana anae 32 4 4 1 Shunt EEN 4 4 2 DE TEE 33 4 5 Input Resolver Option R1 GOIN 33 4 6 Input Sincos Hiperface Encoder Option R2 X11 R2 34 4 7 Input High Resolution Incremental Encoder Option R3 X11 R3 4 8 Input EnDat Encoder Option R4 GIRA 36 4 9 Input Encoder Signals 5 V Option L1 X12 L1 0 4 10 Input Encoder Signals 24 V Option L2 X12 L2 38 4 11 Output Encoder Signals 5 V Option G1 X13 G1 4 12 Output Encoder Signals 24 V Option G2 X13 G2 22 0 40 4 13 Interbus Option F1 and F3 X14 F1 X15 F1 EE Se ee ee 40 4 14 CANopen Option F2 X14 F2 IF 43 4 15 Serial Interface COM1 for PC Gi 4 16 Serial Interface COM2 X2 0 0 es 46 4 17 Control Signals X3 EEN 4 17 1 24 V Supply of Digital Inputs and Outputs 48 4 17 2 Digital Input Frei Enable SS naaa 4 17 3 Digital Output St rung Fault SES EES ES ee 49 4 17 4 Relay Contact BTB Ready 0220 eee nn 49 4 17 5 Auxiliary Voltage Outputs 15 V 2DN ee 4 17 6 Analog Input Setpoint 4 17 7 Analog Outputs Actual1
4. Appendix A EC Declaration of Conformity 82 Appendix B Terms of Warranty 222 000000 eee GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 6 Operating Instructions 221072E V 7 5a 08 05 Appendix C Firmware Versions Relating to the Connection 84 Appendix D Hardware Versions 86 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 7 Figures Figure 1 Mounting Dimensions Location of Connectors KDV 2 400 to KDV 8 400 16 Figure 2 Mounting Dimensions Location of Connectors KDV 12 400 KDV 20 400 17 Figure 3 X7 Connection Example and Internal Circuitry 30 Figure 4 X3 Connection Example and Internal Circuitry 48 Figure 5 X4 and X5 Connection Example and Internal Circuitry 53 Figure 6 X6 to X9 Connection Directions 56 Figure 7 Mounting Set 086230 Side View Standard Mounting 67 Figure 8 Mounting Set 086230 Side View Special Mounting 68 Eigure 9 Line CHOKE Sir ers teed EE 69 Figure TOY Motor CHOKE cas EE 72 Figure 11 External Shunt Resistor Dimensions and Permissible Mounting Positions 74 Note Names and brand labels of software and hardware used in these operating instructions are generally governed by tradem
5. This section deals with the installation of the servo amplifier in a control cabinet and the establishment of the electrical connections Section 7 page 77ff describes how to proceed with the installation information on the various connectors can be found in section 4 page 28ff The values according to EN 55011 A and B emission and EN 50082 1 and 2 immunity are kept within the EMC limits if the KDV drive package is con nected according to the instructions given herein Only in this case the CE marking is valid If the connection instructions are not observed the facility in which the amplifier is operated has to be checked for compliance with the EMC limits at the cus tomer s own responsibility The connectors must not be plugged or unplugged while under voltage The current rush might destroy the contacts of the connector The connectors are intended for fixed connection only Figure 6 shows the connection instructions for connectors X6 to X9 How to Open the Terminal Compartment Proceed as follows to get to the terminal compartment e If the servo amplifier is already connected disconnect the device from the mains and switch off the control supply voltage e Remove the cover of the terminal compartment after having loosened 2 screws on the upper side Installation in the Control Cabinet Mounting in the control cabinet e At the top of the rear side there are two straps with an opening for hooking into two
6. A A 2 6 EMC 2 7 A Hazard Warnings Due to their design and connection system the servo amplifiers may be oper ated e only in a closed housing control cabinet e only with a fixed mains connection Do not insert objects screwdrivers wires etc through the ventilation holes into the inside of the device Before connecting or disconnecting a connector e switch off the mains voltage The charging capacitor of the power supply unit maintains the voltage after switch off Before working at the device e wait for at least 2 minutes after having switched off Electronic devices are generally not fail safe The user has to make sure that e the drive is switched to a safe state in case of a break down of the device CE Marking The KDV servo amplifiers meet the requirements of e EMC Directive 89 336 EEC and e Low Voltage Directive 73 23 EEC Thus they conform to the current EU regulations and have a CE marking The CE marking is only valid if e all installation and connection instructions have been observed exactly and e the requirements marked with the EMC symbol have been met If this is not possible you must have checked the facility in which the amplifiers are operated for compliance with the EMC limits on your own responsibility Preconditions for Commissioning In addition to the low voltage and EMC directives applicable to the servo ampli fier the machine directive 89 392 EEC applies as well
7. off fond rotating approc04s If these times are observed the mains can be switched off and on arbitrarily In rare cases a non observance of these times may lead to a damage at the rectifier Relay contact BTB Ready can be used for checking whether or not the DC bus voltage has fallen below the threshold value if this contact is open the current limiting circuit is activated For connecting the amplifier to the mains see section 5 5 page 58 The recommended line side fuses and cable cross sections are listed in the table in section 3 2 2 page 15 4 2 Motor X8 3 pin Combicon connector X8 RM 7 62 in the terminal compartment Pin 1 Designation Belegung Motor U Meier W PE bolt M6 in the terminal compartment PE ofthe motor supply cable Strain relief connect the cable shield using the strain relief The motor connector is earth fault and short circuit proof Only the AC servo motors with permanent magnets in the rotor synchronous servo motors supplied by Georgii Kobold can be connected Other motors can only be used after consultation with Georgii Kobold The adaptation of the control to other motors can only be carried out by Georgii Kobold at extra charge For connecting the motor to the amplifier see section 5 6 page 59 Recom mended cable cross sections are listed in the table in section 3 2 2 page 15 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www
8. 5 18 PC C nneelion artnet EE EE ERG 6 ACCES SOMES oo GR DE DR EE DE N t ege 66 6 1 Available Accessories and Order Numbers 66 6 2 Mounting Set NEE 66 6 2 1 Standard Mounting on the Rear Wall of the Control Cabinet 6 2 2 Special Mounting on Mounting Plate 6 2 3 General Notes for Both Mounting Types 68 6 3 Connector Set 0990840107 EE EE eee 69 64 Line Choke 0380980102 nasser DER ER EE een eee eet EE GER ELE SAS 69 6 5 Motor Supply Cables 535246 535262 535271 535269 535273 and 09027 Ole Sashes EE a ee oe eee eed 6 6 Motor Choke 0380970102 su VERSE SE DE EED SEA EE SEED DRS 6 7 Encoder Connection Cables 535254 535270 and 535265 6 8 External Shunt Resistor 021058010 or 021060010 6 9 Command and Commissioning Software SPP Windows 6 10 Drivers DLL Libraries and Example Programs 005 1 COMMISSIONING os drehe bela BEDE DERE DE saree whens 7 1 How to Proceed for Commissioning 7 2 Connecting the Control Supply Voltage First Test 7 3 Connecting the Motor Position Sensor 7 4 Connecting the Motor Power 80 7 5 Connecting the Amplifier to the Mains 80 7 6 Setting the Machine Data iss 256 22 25 BERE ESE Rea Ee 7 7 Connecting Other Peripheral Devices 0 0 0 0 eee eee 81 7 8 Writing and Testing Part Programs 81 Appendix
9. Operating Instructions 221071E Functions and Parameters Short description see section 4 17 6 page 50 of these Operating Instruc tions e Assignment of analog outputs Ist1 Ist2 at X3 can now be selected also see Operating Instructions 221071E Functions and Parameters Short description see section 4 17 7 page 50 of these Operating Instruc tions Changes from V 3 3b on e Monitoring for leaving target position implemented also see Operating Instructions 221071E Functions and Parameters section 4 18 table on page 51 O 1 2 at X4 assigned drive specifically with function Position monitoring Changes from V 3 2 on e Function for measuring position via input implemented also see Operating Instructions 221071E Functions and Parameters section 4 18 table on page 51 I 1 6 at X4 assigned drive specifically with function Measure position GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 86 Operating Instructions 221072E V 7 5a 08 05 Appendix D Hardware Versions This section summarizes notes on changes in the hardware with references to the corresponding sections in the text The latest modifications are listed first The character identifying the hardware version is stated on the nameplate behind the serial number SN Changes in version compared with G and H e Extended memory 256 kB Ram Changes in v
10. 0 Fax 49 0 7451 5394 30 www georgii kobold de 72 Operating Instructions 221072E V 7 5a 08 05 Technical Specifications Motor Choke Triple Choke 0380970107 Permissible current crest value Design 3 single chokes in sheet metal housing with terminals and shield connection clamps Degree of protection IP20 Dimensions with straps and terminals 125 x 130 x 45 mm H x W x D Geh useh he housing height 45mm zum Motor to the motor 130 60 ENE al vom Verst rker W aa EE _trom the amplifier py Et BN 3857 2311 00A 050 Internal Choke Input Output The pins PE are connected to each other and to the housing Figure 10 Motor Choke GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 73 6 7 Encoder Connection Cables 535254 535270 and 535265 Encoder connection cable 535254 is suitable for connecting resolver and incremental encoder signals to X12 X13 input encoder signals output en coder signals For connecting the Sincos Hiperface encoder 535270 should be used Encoder connection cable 535265 is suitable for connecting the high resolution incremental encoder Heidenhain ERN 1185 or ERN 1387 and the EnDat encoder Characteristics of the encoder connection cables 535254 535270 and 535265 by Georgii Kobold e 8 core twisted pair shielded 53525
11. 22 2 1 Type of Instructions AE IE OE ER ee 10 2 2 Qualified Personnel EE 2 3 Use forthe Intended Purpose SE EE Es ss eee AN 24 Protective Earle ses os os Wee En ns wese EE DE ei 11 2 5 Hazard Warnings Zar sus SDA ED Da a a ee ae 12 2 6 EE MaKIG OR 2 7 Preconditions tor Commissioning 24a 0 RE ebay eb eee AR N 12 3 Description of the Device gett BEES ee 13 Ol TYPE GCOdE uses EE E een 13 3 2 Technical Specifications ee eet ra 14 3 2 1 Electrical Specifications ti er sled rare 14 3 2 2 Line Side Fuses Cable Cross Sections and Lengths 3 2 3 Mounting Dimensions and Weight 3 2 4 Environmental Conditions 18 3 2 5 Analog and Digital Inputs and Outputs Interfaces 18 3 2 6 Control and Operating Modes Oo DESIGN Ziele ie ed DA DA aes 19 3 3 1 General Information NEE 19 3 3 2 DEE EE 20 3 3 3 Operating Modes EE EEN 3 4 Modular Equipment EE are Ee d EN 3 4 1 Mains Connection and DC Bus Voltage 21 3 4 2 Motor Position Sensor Options Rx 22 3 4 3 Output Encoder Signals Options Gx 222200 3 4 4 Input Encoder Signals Options vi 26 3 4 5 Fieldbus Options Ee ste ce Rss en 4 Assignment of Connectors EE EE EE EE EE EE EE Ee Ee ee ee nenn 28 4 1 Mains Connection X6 an Meat EE Ae 28 AZ Motor EEN 29 4 3 Control Supply Voltage Brake Motor Temperature Sensor X7 4 3 1 Control Supply Voltage 37 4 3 2 EG EN
12. 600 W 1 5 KW Internal fuse shunt circuit soldered fuse at the resistor 8AT Pulse braking power 2 switch on dura 1 2 kW 25kW tion 2 s Switch in threshold shunt resistor 670 V DC Shutdown threshold shunt resistor Usable shunt resistor external 62 220 Q 62 120Q 62 70Q 30 33 Q Control supply protected against polarity reversal Control supply voltage 24 V DC 20 Maximum interruption time 10 ms without amplifier reset EE LEAN without Tan 560 mA 780 mA 410 depending on motor position sensor Fan starting current for approx 2 s 200 mA 260 mA Fan current consumption switched on 100 mA 180 mA Additional current consumption due to up to 70 mA 10 modular equipment plus position sensor power supply for option Lx GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 15 3 2 2 Line Side Fuses Cable Cross Sections and Lengths Servo Amplifier KDV 2 400 KDV 4 400 KDV 8 400 KDV 12 400 KDV 20 400 Line side fuses mains 3 pieces GAT 10AT 16AT Line side fuse control supply 2 AT plus current for brake if connected Mains supply cable shield not required Motor supply cable shielded Maximum length without motor choke Connection external shunt resistor shielded Cable cross section Connection cable encoder shielded twisted pair Cable cross section others depending on the encoder type Cables
13. CANopen interface is installed in the KDV servo amplifiers as a module option F2 It consists of two 9 pin SUB D connectors located on the bottom side of the device Connection X15 F2 CAN IN 9 pin SUB D male connector at the top side X14 F2 CAN OUT 9 pin SUB D female connector at the top side CAN_L bus line dominant low CAN ground Shield connection for special applications use only after consul tation with on Kobold Connect cable shield via the SUB D housing Use metallized connector housings and install the cable shield over a large sur face After having plugged the connector housing on X15 X14 screw the connector housing onto the male or female SUB D con nector The two 9 pin SUB D connectors are assigned according to CANopen CiA DR 303 1 Cabling and Connector Pin Assignment The signals correspond to standard ISO 11898 The bus connection is galvanically isolated from the CAN controller by means of optocouplers With the CAN IN and CAN OUT connectors the device can be connected to the bus without T connectors and stub lines Bus Lines Max permissible bus lengths total of all bus lengths AL m To Tele Ta To Cables corresponding to the following specifications must be used e shielded e twisted pair CAN L and CAN_H twisted with one another e wave impedance 120 Q GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 44 Operating Instruc
14. Purpose The servo amplifiers have been developed manufactured tested and docu mented in accordance with the relevant standards If used for the intended purpose the devices do not cause any danger to persons or property Use for the intended purpose requires that the device should be used only in the man ner described here and that the safety regulations mentioned should be ad hered to IN When using the devices use for the intended purpose includes compliance with the relevant regulations with respect to safety machinery directive and electromagnetic compatibility EMC directive At the end of its service life dispose of the device according to the regulations to be applied then GEORGII KOBOLD GmbH amp Co KG does not accept any liability for direct or indirect damage resulting from an abuse of the devices 2 4 Protective Earthing Due to the leakage currents of the built in RFI filter the protective earth conduc tor in accordance with DIN VDE 0160 must e either be routed double or e have a cable cross section of at least 10 mm Cu Operation via earth leakage circuit breaker is not possible e due to the leakage currents of the RFI filter and e since in case of an earth leakage a part of the direct current flows in the protective earth conductor GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 2 5 A
15. Under full load the motor choke can reach an operating temperature of more than 100 C For an adequate heat dissipation it must be screwed on a metal plate GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 60 Operating Instructions 221072E V 7 5a 08 05 A 5 7 EMC 5 8 AN The 3 motor phases must be connected with the correct assignments otherwise e the motor blocks e the motor runs unsmoothly e the motor runs with a lower torque or e the motor runs uncontrolled at full speed This does not damage motor or amplifier but may endanger machine and commissioning personnel Shield Connection Motor Supply Cable A cable clamp for the shielded motor supply cable is provided on the amplifier e Use this to establish a large area connection between shield and housing by folding back the strands of the shield over the cable insulation and securing the strands using the cable clamp e Establish a large area connection between shield and earth at the motor in a suitable manner e At that avoid earthing the shield using twirled strands pigtails of the shield braiding at all places The shields of the motor supply cable must not be interrupted If you have to install contactors switches or chokes in the motor supply cable e install them in a metal housing and e connect a large area of the shield via the cable clamp as described above The motor c
16. amplifier 60 BN 3857 2407 00B 003 Figure 9 Line Choke GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 70 Operating Instructions 221072E V 7 5a 08 05 Technical Specifications Line Choke Triple Choke 0380980107 Permissible current crest value 12A Inductance 3 x 0 9 mH 3 single chokes in sheet metal housing with terminals Degree of protection IP20 Design Dimensions with straps and terminals 125 x 130 x 45 mm HxWxD For higher currents line choke is available If required please contact Georgii Kobold 6 5 Motor Supply Cables 535246 535262 535271 535269 535273 and 535276 As explained in section 5 6 page 59 the motor must be connected with a shielded cable Characteristics of the Georgii Kobold motor supply cables e 4 core shielded 535246 535271 535273 additionally 2 core shielded 535262 535269 535276 e cross section 1 5 mm 535246 535262 2 5 mm 535271 535269 4 0 mm 535273 535276 e suitable as trailing cable The two additional cores of cables 535262 535269 and 535276 can be used e g for connecting a brake see section 4 3 2 page 31 or a motor temperature sensor see section 4 3 3 page 31 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 71 Technical Specifications
17. and Services of the Electrical Industry green terms of ZVEI German electrical and electronic manufacturers association In case of a defect as to quality 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 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 84 Operating Instructions 221072E V 7 5a 08 05 Appendix C Firmware Versions Relating to the Connection This section summarizes notes on changes in the firmware with references to the corresponding sections in the text The latest modifications are listed first If you have worked with a KDV servo amplifier with an older firmware before and have obtained a new KDV servo amplifier with a new firmware please observe all sections referring to changes between the two version numbers This appendix lists all firmware changes regarding the connection described in these operating instructions For further firmware modifications also see the respective appendices of the other operating instructions for KDV servo amplifi ers Changes from V 7 2 on e Flying shear digital output synchronous point e Input fast position measurement with stop e Out
18. connection motor temperature sensor can be found in sections 4 3 and 4 3 3 page 30ff GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 62 Operating Instructions 221072E V 7 5a 08 05 5 11 EMC External Shunt Resistor If you would like to connect an external shunt resistor to Combicon connector X9 instead of an internal one and R e connect the external resistor to connections R and R e remove the jumper between R int e connect the PE of the shunt resistor cable to the corresponding PE bolt in the terminal compartment see figure 6 page 56 The external shunt resistor must be installed in an earthed metal housing e in order to avoid emissions and e asa protection against contact with live parts and the hot resistor Use e g shunt resistor 021058010 or 021060010 described in the accessories see section 6 8 page 74 The external shunt resistor becomes very hot during operation Therefore it should be mounted outside the control cabinet Pay attention to the degree of protection of the resistor Recommended cross sections for the shunt resistor cables are listed in the table in section 3 2 2 page 15 A cable clamp for the shielded cable is provided on the amplifier e Use this to establish a large area connection between shield and housing by folding back the strands of the shield over the cable insulation and securing the st
19. georgii kobold de 30 Operating Instructions 221072E V 7 5a 08 05 4 3 Control Supply Voltage Brake Motor Temperature Sensor X7 6 pin Combicon connector X7 RM 5 in the terminal compartment Control supply voltage 24 V DC Control supply voltage 0 V Brake control 24 V DC O 3 0 from control supply voltage via contact in KDV zz Motor temp The drive specific assignment Brake control can be switched on and off for this output by means of the machine data When the drive specific assignment is switched off this output can be used freely as output O 3 0 For option R1 resolver this input is connected in parallel internally with the corresponding pins at connector X11 R1 Figure 3 shows the internal circuitry of connector X7 together with an example of a connection Anschluss beispiel externe Beschaltung Servoverstarker interne Schaltung Connection example external wiring Servo amplifier interior circuitry X 7 ext Netzgerat ext power supply DC DC Wandler converter Temp Sensor Auswertung evalution BN 6710 0000 00B 053 Figure 3 X7 Connection Example and Internal Circuitry GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 31 4 3 1 Control Supply Voltage The control supply voltage of 24 V DC powers the electronics and if installed the fan s o
20. of the protective earth conductor in accordance with EN 50178 e either be routed double at PE bolt and mains connector or e have a cable cross section of at least 10 mm Cu connect to PE bolt GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 58 Operating Instructions 221072E V 7 5a 08 05 The other potential equalization cables must have a cross section of at least 2 5 mm or if possible 4 mm It is true Drives can be run without potential equalization cables without shielded cables and without compliance with safety regulations However this AN e is contradictory to elementary safety requirements e violates statutory regulations e endangers the safety of persons e endangers the operational safety of the system e may lead to disturbances in the devices caused by other parts of the system may lead to disturbances in other parts of the system caused by the devices 5 5 Mains Connection The mains is connected directly at the servo amplifier via Combicon connector X6 in the terminal compartment see figure 6 page 56 AN The cable to the servo amplifier must have e a sufficient cross section and e a fixed connection also applies to transformers if installed Shield is not required The recommended line side fuse and cable cross sections are listed in the table in section 3 2 2 page 15 bg The mains connector must not be plugged or unplugged
21. sensor the pins must be jumpered at one of the connectors Otherwise the amplifier would constantly report a motor overtemperature fault GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 32 Operating Instructions 221072E V 7 5a 08 05 The motor temperature sensor is connected via Combicon connector X7 or the input of the motor position sensor X11 The connection is described in section 5 10 page 61 4 4 Shunt Resistor and DC Bus X9 5 pin Combicon connector X9 RM 7 62 in the terminal compartment Pin Designation Assignment Rex Either connect external shunt resistor between R and R or in 4 Rint stall jumper from Rin to R Manufacturer default with jumper in Eu R stalled 2 U Positive connection of the bus voltage from the power supply unit Loi U Negative connection of the bus voltage from the power supply unit 4 4 1 Shunt Resistor The servo amplifier is equipped with a shunt resistor that takes up energy returned by the motor The shunt resistor internal or external is protected against overload by hard and software e Under normal conditions a software monitoring protects the shunt resistor against overheating the amplifier signals fault overtemperature shunt resis tor e In case of a failure of the control system the internal overload fuse protects the shunt resistor from overheating Attention If the overl
22. system 7 8 Writing and Testing Part Programs Part programs should not be written and tested until all above mentioned steps have been carried out Part programs cannot run correctly unless the drive system is running in command mode and the machine data have been set correctly Further information can be found in Operating Instructions 221117E Part Program GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 82 Operating Instructions 221072E V 7 5a 08 05 Appendix Appendix A EC Declaration of Conformity GEORGII KOBOLD AN SS GmbH A Co KG som Certificate of Conformity Total Quality Certificate of Conformity In the sense of EC Directives Here with we confirm that the products Product GEORGII KOBOLD Type KDV X Series Digital Servo Amplifier KDV corresponds to the EC directives standards and regulations below and are designed for installation in a machine 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 installation and cabling given in the operating instructions are observed Operating instructions 221072E The products are developed constructed and produced in accordance to EC Directives 89 336 EEC
23. via menu item Communication Connect A fault should be displayed in the device control and the fault window The fault is described more detailed in the fault window and the status line GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 79 As a motor position sensor has not been connected yet it must either be an encoder fault or a resolver fault When the SPP Windows command and commissioning software is working together with the KDV servo amplifier you can continue with the next steps of commissioning 7 3 Connecting the Motor Position Sensor 0 Four types of motor position sensors can be used First of all check which version of the KDV servo amplifiers you are using e R1 for connecting a resolver e R2 for connecting a Sincos Hiperface encoder single or multi turn e R3 for connecting a high resolution incremental encoder e R4 for connecting an EnDat encoder single or multi turn bg Then check whether or not the motor position sensor installed in the motor matches using your documents or the nameplate In case of a motor in special design please ensure also that the signal assignment of the encoder connec tion cable matches the signal assignment of the encoder connector at the motor If the equipment of the KDV servo amplifier or the signal assignment does not match the connected encoder parts
24. while under voltage The current rush might destroy the contacts of the connector The connectors are intended for fixed connection only EMC The EMC limits for power supply systems in an industrial environment according to e EN 55011 A emission e EN 50082 1 immunity are complied with without additional measures for mains connection The limits according to above standards are not exceeded with the filters installed in the servo amplifier if all connections are made in accordance with section 5 For compliance with the stricter EMC limits for power supply systems in a residential commercial and light industry environment according to e EN 55011 A emission e EN 50082 1 immunity GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 59 an additional line choke triple choke is required in the mains cable To this line choke applies e a line choke according to section 6 4 page 69 must be used e the line choke has to be mounted near the servo amplifier e the connecting cable between line choke and servo amplifier must not be longer than 1 m shield is not required For compliance with these stricter limits the additional use of the line choke is sufficient if all connections are carried out in accordance with section 5 5 6 Motor Connection Power The motor is connected at Combicon connector X8 in the terminal
25. www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 67 With mounting set 086230 mounting can be carried out in two different ways which are described in the following as standard mounting and special mount ing 6 2 1 Standard Mounting on the Rear Wall of the Control Cabinet ad ee re Interior control cabinet Rear wall control cabinet Mounting plate KDV servo amplifier Cutout in rear wall control cabinet 322 x 85 mm Mounting hole distance 4 x M4 in rear wall sym metrical with the cutout 346 x 60 mm Cutout in the mounting plate 370 x 90 mm BN 6710 0000 00B 057 Figure 7 Mounting Set 086230 Side View Standard Mounting GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 68 Operating Instructions 221072E V 7 5a 08 05 6 2 2 Special Mounting on Mounting Plate EI zg E e E mm eg o Interior control cabinet Rear wall control cabinet Mounting plate KDV servo amplifier Cutout in rear wall control cabinet 322 x 85 mm Cutout in mounting plate 330 x 90 mm Mounting hole distance 4 x M4 in mounting plate symmetrical with the cut out 346 x 60 mm BN 6710 0000 00B 058 Figure 8 Mounting Set 086230 Side View Special Mounting For this special mounting the two mounting brackets at the top and at the bottom of the KDV servo amplifier must be turned by 180 compared t
26. 4 additionally 2 core 535270 additionally 8 core 4 of them with extra shield 535265 suitable as trailing cable Technical Specifications Encoder Connection Cable 535254 535270 535265 Structure 4 pairs of cores 4 pairs of cores and 2 4 pairs of cores and 8 4 x 2 x 0 25 mm single cores single cores 4 x 2 x 0 25 4x2x0 14 2 x 0 5 mm 4 x 0 14 4 x 0 5 mm Color coding RD BU GY PK GN GN BN GY PK BU RD BK GY PK YE YE WH BN VT RD BK WH BN VT BN GN BU BK GN BK RD BK YE BK WH BU WH GN BN GN Conductor Cu braiding stranded according to DIN VDE 0295 Cu tin coated class 6 or IEC 228 class 6 Total shield coverage approx 85 CuSn 216 x 0 10 mm braiding coverage approx 85 Outer sheath Polyurethane Operating temperature fixed installation 50 to 90 C 50 to 90 C 40 to 80 C trailing use 30 to 80 C 30 to 80 C 10 to 80 C Min bending radius for single 40 5 mm 42 5 mm 40 mm bending fixed installation approx Min bending radius for cont 60 8 mm 63 8 mm 100 mm altern bending trailing use approx We also offer ready assembled cables If required please contact Georgii Kobold GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 74 Operating Instructions 221072E V 7 5a 08 05 6 8 External Shunt Resistor 021058010 or 021060010 According to section 4 4 1 page 32
27. 4 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 19 Servo Amplifier KDV 2 400 KDV 4 400 KDV 8 400 KDV 12 400 KDV 20 400 Relay output Ready potential free BTB Ready Permissible switching voltage 36 V AC DC Relay output Brake not short circuit proof Output voltage from control supply voltage 24 V and 24 V Permissible load current resolver standard Sincos Hiperface encoder high resolution RE incremental encoder or EnDat encoder options Encoder signals UO option 5 V push pull signals RS 422 or 24 V single ended COM1 RS 232C COM2 RS 232C or RS 485 SE not galvanically isolated max 9600 Baud Interbus local bus optical fiber local bus CANopen Field ou open according to DRIVECOM profile 22 Profibus DP in preparation 3 2 6 Control and Operating Modes KDV 2 400 KDV 81400 Cycle time current control loop Cycle time speed control loop 62 5 us Operating modes with torque speed or position control with positioning control 500 blocks 2 axis synchronization electronic gearing flying shear Ramp functions 3 3 Design 3 3 1 General Information The KDV servo amplifiers are manufactured in a compact design for being screwed on a mounting plate They have a metal housing Figure 1 page 16 shows the mounting dimension of amplifiers KDV 2 400 to KDV 8 400 figure 2 page 17 shows the
28. 6710 0000 00C 054 Figure 4 X3 Connection Example and Internal Circuitry Section 3 2 5 page 18 includes general information on the technical data of the inputs and outputs 4 17 1 24 V Supply of Digital Inputs and Outputs Through pins 24 V VO and 0 V I O the supply voltage 18 V DC to 32 V DC preferably 24 V DC for the digital inputs and outputs and the connected consumers is applied from outside This power supply may be e an independent power supply or e the power supply for the control supply voltage at X7 Since in this case the 0 V of the control supply voltage are connected to the O V of the digital inputs and outputs the opto isolation of the digital inputs and outputs becomes ineffective When dimensioning the corresponding power supplies take into account the current consumption of the consumers connected to the digital inputs and outputs GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 49 4 17 2 Digital Input Frei Enable At digital input Frei Enable the logic level for e 1 leads to enabled e 0 leads to disabled The meaning of enabled e g ready to accept a setpoint or start part pro gram and disabled can be set via the machine data Action enable inactive active AN Disabling via digital input Frei Enable does not m
29. According to the resolution of the motor position sensor Gx steps revolution 512 or 2048 per track Zero pulse output en e signals option Current consumption of 560 mA 10 770 mA 10 740 mA 10 740 mA 10 the amplifier Higher speeds on request 2 Prerequisite resolver has an accuracy of at least 10 3 Before having passed the reference signal for the first time the position accuracy is 5 After the first revolution of the rotor at the latest the stated accuracy will be reached From the control voltage supply at full load without connected consumers and other options The current consumption can be considerably lower e g when the power circuit is disabled Also see the table in section 3 2 1 page 14 Motor position sensor connector X11 is described in sections 4 5 resolver 4 6 Sincos Hiperface encoder 4 7 high resolution incremental encoder and 4 6 EnDat encoder from page 33 on For connecting a motor position sensor see section 5 13 page 63ff 3 4 3 Output Encoder Signals Options Gx Encoder signals actually incremental encoder signals are either generated by the KDV servo amplifier output encoder signals option G1 or G2 or can be processed with it input encoder signals option L1 or L2 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 25 Via output encod
30. Actual2 4 18 Digital Inputs and Outputs X4 bi 4 18 1 Digital Inputs I 1 0 to 2 7 ER RE 0222 4 18 2 Digital Outputs O 1 0 to O 1 3 and O 2 0 to O 2 3 5 Installation and Connection Instructions 5 1 How to Open the Terminal Compartment iS EE EE Ee ee 5 2 Installation in the Control Cabinet EE EE EE ee 5 3 Installation on a Mounting Plate 54 Potential Equalization Cables se EE de sen Dee ae or 9 5 Mans Connection ersteren 5 6 Motor Connection Power zur terre 5 7 Shield Connection Motor Supply Cable 60 5 8 Connection of Control Supply Voltage 24 V SESSE eee 60 5 9 Connection of a Brake oor sla ee reihen red A 5 10 Connection of the Motor Temperature Sensor 61 5411 Extemal Shunt Resistor Ee 282 E ie eter etree ees 62 5 12 Shield Connection SUB D Connectors EE EE SEE EE EE Ee 62 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 5 5 13 Connection of a Motor Position Sensor 0 0 0 cece eee 63 5 13 1 Connection of the Resolver EE ER eGo dil es 63 5 13 2 Connection of the Sincos Hiperface Encoder 5 13 3 Connection of the High Resolution Incremental Encoder 64 5 13 4 Connection of the EnDat Encoder 64 5 14 Connection of Encoder Signals iese EE EE EE ES EE Ee Se ee ee 64 515 EERSTEN
31. Due to that it is also applicable to the final product the machine in which the servo amplifier is operated That means it must be fulfilled by the machine manufacturer Commissioning is prohibited until the requirements of the machine directive have been met GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 3 Description of the Device 3 1 Type Code The type code clearly identifies amplifiers equipped in a certain way It is also applicable to device variants not described in these operating instructions Example gt KDV A14R1 1G1 L4 F1V sx U Continuous output current 2 output current 2 As 12 output current 12 Asr 4 output current 4 A 20 output current 20 Ay 8 output current 8 Ay Mains connection and DC bus voltage 000 no mains connection supply via DC bus from other device in preparation 400 mains connection 400 V 3 phase corresponds to 560 V DC bus voltage Digital inputs outputs A1 16 inputs 8 outputs 24 V standard AK customer specific Motor position sensor R1 resolver standard R2 sincos encoder available for Motor KSY 3 or larger single or multi turn R3 high resolution incremental encoder Heidenhain R4 EnDat encoder single or multi turn RK customer specific Output encoder signals encoder emulation G1 incremental encoder output 5 V push pull signals RS 422 G2 incremental encoder ou
32. GEORGII KOBOLD GmbH amp Co KG KDV Digital Servo Amplifier for Direct Mains Connection KDV 2 400 to KDV 20 400 Connection and Commissioning Operating Instructions 221072E V 7 5a 08 05 These operating instructions apply to e KDV servo amplifiers compact design KDV 2 400 to KDV 20 400 with built in power supply unit for AC power connection e Operation via personal computer with SPP Windows software e Access to device functions via communication interfaces e Accessories These operating instructions are applicable together with e Operating Instructions 221071E Functions and Parameters e Operating Instructions 221102E SPP Windows Command and Commissioning Software and other operating instructions according to the equipment GEORGII KOBOLD GmbH amp Co KG Ihlinger Stra e 57 72160 Horb Federal Republic of Germany Phone 49 0 7451 5394 0 e Mail service georgii kobold de Fax 49 0 7451 5394 30 www georgii kobold de 2 Operating Instructions 221072E V 7 5a 08 05 Versions of the Document 2000 08 28 V 5 5 MH for KDV Firmware V 5 5 hardware version G Remarks concerning system accuracy with resolver p 24 impulse current resistance against mains off on p 29 voltage ripple of analog outputs Ist1 Ist2 p 51 line choke for higher currents p 70 references to SPP Windows references to ready assembled cables docu ment styles 2004 02 02 V 7 5 KS MH for KDV firmware V 7 5 hardware versio
33. Instructions 221071 Func tions and Parameters Continuous illumination indicates a drive fault flashing indicates a programming or parameterization error Bereit green Lit when the power circuit is ready state operation enabled and the bus voltage is in the permissible range see p 49 Flashing in all other cases berlast yellow Lit when switched from peak current to continuous current in the event of an overload Ballast yellow Lit when the shunt circuit is switched on to receive the energy returned when the motor is braked 11 01012 7 Lit when 24 V are applied at the corresponding digital output ed i i O 1 0 to O 2 3 r Lit when the digital output is set no matter whether or not a con sumer is connected 3 3 3 Operating Modes The KDV servo amplifier permits the following operating modes e Command mode with torque speed or position control for direct control of axis motions via single commands of a higher level controller PLC PC electronic gearing the axis follows an externally specified position GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 21 homing mode establishes a reference between actual axis position value and coordinate system of the machine e Program mode with positioning control 500 blocks For running special programs so called part programs on the KDV
34. M 4 bolts e At the bottom of the rear side there is another strap with two slots for addi tional fixing see figure 1 page 16 and figure 2 page 17 For mounting on a bare metal mounting plate see section 5 3 To ensure that the air can flow through housing and heat sink leave a clear ance of e at least 80 mm above and below the devices GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 56 Operating Instructions 221072E V 7 5a 08 05 PE Steuerung Controller Zentraler Nullpunkt im Schaltschrank Central zero point in control cabinet Motor Lagegeber motor Heu viw position sensor Netz Mains 2LVDC 3x400V j LK AAN Ae III em X 11 gi oxt Ballastwiderstand ext shunt resistor Option OOK KK AN KR ER S N AALS AR Netz Mains rleislels e Lal N IN e DC iF 5 E 5 s oun X7 Er EE SE 4 Be Bremse 3 4 a oo Brake ra oe aee ee E N Motor 5 a J temp 6 2 BN 6710 0000 008 056 Figure 6 X6 to X9 Connection Directions GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 57 Several of those devices can be installed directly next to each other without lateral gaps between the devices Some millimeters of space facilitate installa tion and subsequent disassembly and assemb
35. Motor Supply Cable 535246 535271 535273 535262 535269 535276 Structure 4 cores stranded with optimized 6 cores stranded with optimized length of twist length of twist Color coding GN YE GN YE 3 x BK U VV WWW 3 x BK 1 2 3 2 x BK BR1 BR2 Element shield Rm coverage approx 90 Total shield coverage approx 85 Outer sheath Polyurethane orange low adhesion 11YM1 acc to DIN VDE 0250 part 818 imprint black Operating temperature 50 to 90 C fixed Do 30 to 80 C trailing use Min bending radius for single 47 mm 48 mm 67 5 mm 58 mm 62 5 mm 74 5 mm bending fixed installation Min bending radius cont 70 5 mm 72 mm 101 2 mm 87 mm 93 8 mm 111 7 mm altern bending use We also offer ready assembled cables If required please contact Georgii Kobold 6 6 Motor Choke 038097010Z According to section 5 6 page 59 a motor choke triple choke is required depending on the cable length This is motor choke 038097010Z which is supplied ready for installation and connection in a zinc plated sheet metal housing IP20 with terminals and shield connection clamps AN Under full load the motor choke can reach an operating temperature of more than 100 C For an adequate heat dissipation it must be screwed on a metal plate Figure 10 shows the mounting dimensions the connection note the connection of the shield and the marking of the terminals GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394
36. R3 as motor position sensor Depending on the resolution of the motor position sensor the resolution of the encoder signals is 512 or 2048 pulses per revolution The index pulse is given once per motor revolution Output encoder signals is designed as a module It can be installed by Georgii Kobold only subsequent installation on site is not possible The current consumption from the control voltage supply of the amplifier in creases by approximately 20 mA when equipped with option G1 or G2 Connector X13 for output encoder signals is described in sections 4 11 and 4 12 page 39ff For connecting the encoder signals see section 5 14 page 64 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 26 Operating Instructions 221072E V 7 5a 08 05 344 Input Encoder Signals Options Lx Encoder signals actually incremental encoder signals are either generated by the KDV servo amplifier output encoder signals option G1 or G2 or can be processed with it input encoder signals option L1 or L2 Input encoder signals can be used for axis coupling synchronization electronic gearing the connection of an external position sensor or pilot frequency setting The encoder signals can be processed either as incremental encoder or as pulse direction signals The maximally permissible signal frequency is 200 kHz higher frequencies only after consultation with Ge
37. a 08 05 3 NJ 4 9 Input Encoder Signals 5 V Option L1 X12 L1 15 pin SUB D female connector X12 at the bottom side assignment for devices equipped with option L1 Pin Assignment Ua1 channel A 2 4 5 V output power supply for external position sensor 6 8 BE 12 0 V reference voltage for encoder signals and for power supply for external position sensor Ua1 channel A 14 Ua2 channel B Ua0 index pulse Connect cable shield via the SUB D housing Input X12 L1 is equipped with an internal RS 422 compatible line receiver for 5 V push pull signals With it the KDV servo amplifier can process encoder signals An incremental encoder can be supplied with current via pin 5 and 12 The maximally permissible current consumption is 200 mA Attention This 5 V output is not short circuit proof For connecting the encoder signals see section 5 14 page 64 Details on input encoder signals can be found in section 3 4 4 page 26 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 38 Operating Instructions 221072E V 7 5a 08 05 4 10 Input Encoder Signals 24 V Option L2 X12 L2 15 pin SUB D female connector X12 on the bottom side assignment for de vices equipped with option L2 Pin Assignment OV reference voltage for encoder signals and for input power supply for 2 24 V external position sensor internally connected to pin 12
38. alog signals SIN REFSIN COS and REFCOS are not affected by interferences For connecting the motor temperature sensor please see section 5 10 page 61 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 35 4 7 Input High Resolution Incremental Encoder Option R3 X11 R3 15 pin SUB D female connector X11on the bottom side assignment for devices equipped with option R3 Pin Assignment SSCS reference signal Z1 track mental encoder 15 OV for supply voltage incremental encoder Connect cable shield via the SUB D housing The high resolution incremental encoder input is designed for incremental encoder ERN 1185 or ERN 1387 produced by Heidenhain Motors with built in high resolution incremental encoder are available from Georgii Kobold input measuring lead for regulating the supply voltage for the incre To keep the supply voltage of the encoder at constant 5 V it is fed back to the amplifier via the measuring lead and the output voltage is re adjusted in the range between 5 V and 8 V For the differences between the types of motor position sensors option Rx please see section 3 4 2 page 22 For connecting a high resolution incremental encoder see sections 5 13 page 63 and 5 13 3 page 64 With option R3 the motor temperature sensor must be connected to Combicon connector X7 see section 5 10 page 61
39. als can be assigned to the individual inputs and outputs by means of machine data Digital inputs signal and Digital outputs signal Alternatively inputs as well as outputs can be used freely GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 52 Operating Instructions 221072E V 7 5a 08 05 12 pin Combicon connector X5 RM 3 81 on the front panel 120 022 digital output O 2 2 O 2 3 digital output O 2 3 Drive specific functions and signals can be assigned to the individual inputs and outputs by means of machine data Digital inputs signal and Digital outputs signal Alternatively inputs as well as outputs can be used freely Via digital inputs and outputs the servo amplifier communicates with e sensors in the machine e g switches e actuators in the machine e g relays e other controllers The digital inputs and outputs of connectors X3 X4 and X5 e are opto isolated and e switch towards positive PLC compatible Plus is the externally supplied voltage 24 V VO at X3 see section 4 17 1 page 48 The outputs are channeled via PTC resistors and thus short circuit proof The logic levels are listed in the table in section 3 2 5 page 18 The delay times are e 3 ms typical at the inputs e 1 ms maximum at inputs 01 0 01 1 and 01 3 e 3 ms typical sporadically up to 10 ms at output O1 2 and A2x If an output oper
40. amended by 91 263 ECC 92 31 ECC 93 68 ECC EMC Directive and 72 23 ECC amended by 93 68 ECC Low Voltage Directive of exclusive responsibility of company GEORGII KOBOLD Ihlinger Strasse 57 D 72160 Horb Tel 49 07451 53 94 0 GmbH amp Co KG Fax 49 07451 53 94 30 The signers are Krychevskyy application Schramm technical director The following harmonized standards are used X EN 55011 1991 Classes A and B DIN VDE 0875 Part 11 X DIN EN 50082 1 1994 X DIN EN 50082 2 1995 x DINEN 50178 1994 A technical documentation is completely available An operation instruction for the machinery is available x in the original version in the native language Of the user ee ee ee ee ek ee ee ee ee ese ee ee ee ee ee ee EE aa aaau Leg Edition made changed release checked Page Krychevskyy Schra Date Signum Date Signum Q8 2 4 52 2 27 Mai 2005 s 27 Mai 2005 Ke 1of1 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 83 Appendix B Terms of Warranty GEORGII KOBOLD GmbH amp Co KG warrants that the device is free of material and production defects In quality assurance measured values are recorded in the final inspec tion and testing The warranty period begins with delivery It lasts for 12 months Delivery is based on the General Terms of Delivery for Products
41. an external shunt resistor might be re quired under certain circumstances For that you can use the external shunt resistor 021058010 or 021060010 by Georgii Kobold which is supplied ready for installation and connection in a zinc plated sheet metal housing IP20 with terminals and shield connection clamps The shield is connected via the metallic PG gland Figure 11 shows the mounting dimensions and the permissible mounting positions of the external shunt resistor 4xLangloch oblong hole 6 5x 12 Zul ssige Einbaulagen permissible mounting positions senkrecht Klemmenkasten unten Vertical terminal box below waagerecht horizontal a E 7 EW 1000 0033 00A 002 Binensions OE at 18 u I m 021058070 Figure 11 External Shunt Resistor Dimensions and Permissible Mounting Positions GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 75 6 9 Technical Specifications Deg dist eta housing wth terminals Degree of protection IP20 Dimensions with straps and terminals 120 x 486 x 92 mm 120 x 646 x 92 mm HxWxD Please note that the machine data have to be adapted when using an external shunt resistor Detailed information can be found in Operating Instructions 221071 Functions and Parameters Command and Commissioning Software SPP Windows The command and commissioning sof
42. and the above men tioned operating instructions are available GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 9 12 KDV Servo Drive Packages KDV servo drive packages consist of e an AC servo motor with integrated resolver Sincos Hiperface encoder high resolution incremental encoder or EnDat encoder as motor position sensor and e a digital servo amplifier with built in power supply unit These operating instructions describe e the servo amplifiers e the connection e the accessories and e the commissioning The series described here includes e amplifiers for 5 different currents 2 A to 20 A options with different equipment rms rms GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 2 Safety Instructions 2 1 Type of Instructions The warnings instructions and hints in the margin must be observed under any circumstances IN AN EMC e e Danger to health and life due to electrical shock or motion of the drive When disconnecting the device from the mains wait for at least 2 minutes until the DC bus capacitors have discharged before carrying out the measure de scribed Caution Noncompliance violates the safety regulations or statutory provi sions and can lead to pers
43. ark registered trademark or patent GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 8 Operating Instructions 221072E V 7 5a 08 05 1 Preliminary Remarks 1 1 About this Description These Operating Instructions 221072E explain the connection and commission ing of KDV servo drives with built in power supply unit for direct connection to 3 x 400 V AC They are applicable together with e Operating Instructions 221071E Functions and Parameters included in the scope of delivery of the KDV servo amplifier e Operating Instructions 221102E SPP Windows Command and Commissioning Software supplied with command and commissioning software SPP Windows e Operating Instructions 221117E Part Program running motion sequences independent of a higher level controller included in the scope of delivery of the KDV servo amplifier as well as according to the equipment e Operating Instructions 221074E Communication Functions Interbus access to device functions via com munication interfaces COM1 and or Interbus supplied with the optional Interbus interface e Operating Instructions 221086E CANopen Interface supplied with the optional CANopen interface O For the commissioning of the functions described in these operating instruc tions a PC with command and commissioning software SPP Windows is required Please make sure that this requirement is met
44. ates a miniature relay the relay has to be e connected with the 0 V of the control supply 0 V I O at X3 see section 4 17 1 page 48 or GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 53 e shunted by a diode Figure 5 shows the internal circuitry of connectors X4 and X5 together with an example of a connection Anschlussbeispiele externe Beschaltung Connection example external wiring SPS PLC Transistor Schalter Switch ext Netzger t ext power supply X 3 erh AN 24V 1 0 OV LIG a Sai vue E A Ree 1 A email ZE 9 29 1 11 2 112 22 113 23 8 Eing nge Inputs 114 24 CS 115 25 116 26 11727 e 010 20 ES gt 011 2 1 4 Ausg nge Outputs 012 22 SPS PLC LED Bene Eingang rm Relay 013 23 Input Ee ele Ge z 12 l h i ze Fr Di 3 l I r 4 Mex 2 BS ku ext Netzger t eme ext power supply Servoverst rker Interne Schaltung Servo amplifier interior circuitry LED 11 0 m LE Lieft a GEE SEN BN 6710 0000 00B 055 Figure 5 X4 and X5 Connection Example and Internal Circuitry GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 54 Operating Instructions 221072E V 7 5a 08 05 Section 3 2 5 page 18 includes general information on the technical specifica tions of t
45. available from Georgii Kobold are described in detail in section 6 page 66ff 3 2 3 Mounting Dimensions and Weight Servo Amplifier KDV 2 400 KO 4 400 KOV 8 400 KDV 12 400 KDV 20 409 in control cabinet only vertical wall mounting Width S O Height without mounting straps Height with mounting straps Depth without connectors Figure 1 shows the mounting dimensions of amplifiers KDV 2 400 to KDV 8 400 fig 2 shows the mounting dimensions of amplifiers KDV 12 400 and KDV 20 400 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 16 Operating Instructions 221072E V 7 5a 08 05 Ben Bea x a x I IT 000000000000 00000 000900000000 Steckverbinder Connectors X11 X15 BN 6710 1959 00B 005 Figure 1 Mounting Dimensions Location of Connectors KDV 2 400 to KDV 8 400 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 17 E d es e SE X11 X15 m 32 oO o N 8 Se 8 3 8 B 3 o sd X3 o S 8 p D Oo i t Steckverbinder Connectors Figure 2 Mounting Dimensions Location of Connectors KDV 12 400 KDV 20 400 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 18 Operating Instructions 221072E V 7 5a 08 05
46. choke see section 5 6 page 59 e connect the motor supply cable to the motor shield PE motor phases U V W e connect the machine earth to the central zero point of the control cabinet e lay the motor supply cable separate from the encoder connection cable For motor supply cables of a length of more than 5 m a motor choke is required see section 6 6 page 71 Install the motor choke near the amplifier and connect the motor supply cable shield PE motor phases U V W e Connect shield and leads of the connection cable to the amplifier in the same way shielded max 1 m long Connection to the amplifier e Connect the motor supply cable to Combicon connector X8 of the KDV servo amplifier shield PE motor phases U V W Pay attention to the correct assignment of the motor phases Connect the cable shield to the cable clamp and the PE line to the PE bolt in the terminal compartment Connecting the Amplifier to the Mains Connect the device to the central zero point of the control cabinet using a suitable potential equalization cable see section 5 4 page 57 Connect the amplifier to the mains as follows for information on the connection see section 5 5 page 58 For an installation of the device in a residential commercial and light industry environment the following is required for compliance with the EMC limits e an additional line choke see section 6 4 page 69 Install this line choke near
47. compartment by means of a 4 core see figure 6 page 56 e Connect the shield as described in the following section e Connect the machine earth to the central zero point of the control cabinet using a potential equalization cable with a cross section of 10 mm e Connect the PE of the motor supply cable with the PE bolt in the terminal compartment e Use the motor supply cable specified in the accessories for further details see section 6 5 page 70 The cable cross section must be in accordance with the mains connection cable for that please refer to the table in section 3 2 2 page 15 AN The motor connector must not be plugged or unplugged while under voltage The current rush might destroy the contacts of the connector The connectors are intended for fixed connection only The capacitive load caused by the motor supply cable is an additional load for the amplifier This load is reduced by means of a choke 0 For motor supply cable lengths of more than 5 m a motor choke triple choke must be installed in the motor supply cable For that the following applies e A motor choke according to section 6 6 page 71 must be used e The motor choke must be mounted near the servo amplifier e The connecting cable between motor choke and servo amplifier must not be longer than 1 m and must also be shielded e The shield must be connected according to section 5 7 Note the maximum cable lengths in section 3 2 2 page 15 bg
48. cribed there as well 4 17 7 Analog Outputs Actual1 Actual2 Actual values such as speed or current can be output as analog currents via outputs Ist1 and Ist2 Which signal is given at which output can be set with the machine data for further details see Operating Instructions 221071 Functions and Parameters Connection 0 V at SUB D female connector X3 is the related zero point GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 51 Technical specifications of the analog outputs Analog Output actual current 1 48 V max cont current ofthe amplifier actual speed Signal und scaling delivery state 5 V 8 200 r p m Output voltage range 1 248 steps corresponding to 8 mV per step Output resistance R Voltage ripple 5 mV 8 kHz 40 mV 8 kHz 4 18 Digital Inputs and Outputs X4 X5 12 pin Combicon connector X4 RM 3 81 on the front panel Pin Designation Assignment Delivery State Standard 11 0 digital input I 1 0 Clear fault I 11 1 digital input 1 1 Pre pulse 11 2 digital input 1 2 for free use NI Go 5 11 4 digital input 1 4 i Enable saw 7 11 6 digital input 1 6 i Measure position 9 O 1 0 digital output O 1 0 i Overload 11 O 1 2 digital output O1 2 i Position monitoring 013 Drive specific functions and sign
49. d please observe the following e Connect the shield of the encoder connection cable at the amplifier side only via the SUB D housings Thus you achieve the necessary large area earth connection of the shield and avoid earthing the shield using twirled strands pigtails of the shield braiding e Do not connect the shield at the motor end of the cable 5 13 1 Connection of the Resolver For connecting the resolver option R1 to the corresponding connector X11 R1 use e a shielded cable with twisted pair leads for sine cosine and excitation e g encoder connection cable 535254 specified in the accessories for further details see section 6 7 page 73 5 13 2 Connection of the Sincos Hiperface Encoder For connecting the Sincos Hiperface encoder option R2 to the corresponding connector X11 R2 use e a shielded cable with twisted pair leads for the signals SIN REFSIN COS REFCOS and 485 485 e g encoder connection cable 535270 specified in the accessories for further details see section 6 7 page 73 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 64 Operating Instructions 221072E V 7 5a 08 05 5 13 3 Connection of the High Resolution Incremental Encoder For connecting the high resolution incremental encoder option R3 to the corresponding connector X11 R3 use e a shielded cable with twisted pair leads for the signals At A and B B Al
50. e 55ff 34 1 Mains Connection and DC Bus Voltage The following options for mains connection are available e without mains connection supply via DC bus from another device up to 560 V on request e Mains connection 400 V 3 phase corresponds to 560 V in the DC bus other voltages on request KDV 400 The power supply unit is installed by Georgii Kobold refitting by the customer is not possible GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de ER Operating Instructions 221072E V 7 5a 08 05 Connector X6 for mains connection is described in section 4 1 page 28 For connecting the amplifier to the mains see section 5 5 page 58 3 4 2 Motor Position Sensor Options Rx KDV servo amplifiers support servo motors with four types of position sensors e R1 resolver standard e R2 Sincos Hiperface encoder single or multi turn e R3 high resolution incremental encoder and e R4 EnDat encoder single or multi turn The servo drive is adjusted to the used encoder via a module installed in the KDV servo amplifier ex works Therefore the type of motor position sensor must be specified when ordering the motor as well as when ordering the servo amplifier The position is determined in the position sensor e within one revolution with resolver Sincos Hiperface encoder single turn high resolution incremental encoder and EnDat encoder single turn Fo
51. e data Digital inputs signal and Digital outputs signal Alternatively inputs as well as outputs can be used freely If input Enable does not act on a drive specific function it can be used freely as 3 0 The digital inputs and outputs of connectors X3 X4 and X5 e are opto isolated and e switch towards positive PLC compatible Plus is the externally supplied voltage 24 V VO at X3 see section 4 17 1 page 48 For detailed information on the digital VO see section 4 18 page 51 The analog UO can be used for the definition of a setpoint or for the output of actual values as analog voltages The inputs and outputs can be configured via the machine data Figure 4 shows the internal circuitry of connector X3 together with an example of a connection GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 48 Operating Instructions 221072E V 7 5a 08 05 Anschlussbeispiel externe Beschaltung Servoverst rker interne Schaltung Connection example external wiring Servo amplifier interior circuitry Versorgung Schalt Ein Ausg dngef Power supply for digital 1 0 OV 24V 24V an Schait Ein Ausg nge Verbinder X4 X5 To digital 1 0 OV connectors X amp XS St rung Fault 4 Sicherheitskreis Safety circuit interne Hilfsspannung internal auxiliary voltage Analog Sollwertvorgabe setpoint Analog Monitore monitors BN
52. eet the safety requirements of the machine directive If an emergency stop or safety shutdown is required the safety requirements of the machine directive must be observed under any circumstances If input Frei Enable is set to no action no action via parameter Action enable inactive active this input can be used freely as 3 0 4 17 3 Digital Output St rung Fault The following applies to digital output St rung Fault e when the servo amplifier works properly the output is set to O e in case of a fault the output switches to 1 At the same time the fault is reported via LED St rung Fault The fault is stored status Fault and the cause of the fault can be read out in the PC as Fault code 4 17 4 Relay Contact BTB Ready The readiness of the KDV servo amplifiers is reported by a potential free relay contact via the two connections BTB Ready The following applies to this output e If the servo amplifier is not in state fault and the DC bus is within the permissible voltage range above the shutdown threshold undervoltage and below the shutdown threshold overvoltage the relay contact is closed e In all other cases if the servo amplifier is in state fault or if the DC bus is outside the permissible voltage range the relay contact is open The values for the shutdown thresholds can be found in the table in section 3 2 1 page 14 informat
53. er signals the position of the driven axes can be transmitted to other controllers or coupled axes in the form of incremental encoder signals incremental encoder simulation Output encoder signals can be realized as follows e GO not connected standard e G1 incremental encoder output 5 V push pull signals RS 422 e G2 incremental encoder output 24 V The resolution of the encoder signals and the function of the index pulse de pend on the motor position sensor used option Rx see section 3 4 2 page 22 e Resolver R1 as motor position sensor The resolution of the encoder signals can be set between 50 and 1024 pulses per revolution by means of the machine data The index pulse is given once per motor revolution the position of the index pulse can be shifted by means of the machine data The position sensed by the resolver serves as setpoint for a software control loop the regulated quantity is the frequency of the encoder sig nals At low values feedforward via speed leads to additional short pulses at output encoder signals These pulses will be corrected automatically with inverted pulses by the software control e Sincos Hiperface encoder R2 or EnDat encoder R4 as motor position sensor Depending on the resolution of the motor position sensor the resolution of the encoder signals is 512 or 2048 pulses per revolution The index pulse is not given e High resolution incremental encoder
54. erbus participants has to be carried out by means of local bus cables GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 41 according to the specifications of the Interbus installation manual IBS SYS INST UM X14 F1 Interbus In 15 pin SUB D male connector on the bottom side Pin Assignment 1 Uv 9 V Uv 9 V SLIM CKI1 7 CRI1 DI1 lee 12 SLO1 v v Connect cable shield via the SUB D housing GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 42 Operating Instructions 221072E V 7 5a 08 05 X15 F1 Interbus Out 15 pin SUB D female connector at the bottom side Pin Assignment SSS Uv 9 V Uv 9 V CKO2 CRO2 15 DO2 Connect cable shield via the SUB D housing SLO2 LEDs Two LEDs are located on the bottom side of the KDV servo amplifiers They display the state of the Interbus interface option F 1 e green with designation TR is lit when parameter data are transmitted e green with designation 5V is lit when the internal 5 are available Coding Switches do not exist for the Interbus interface GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 43 4 14 CANopen Option F2 X14 F2 X15 F2 The
55. ersion G compared with F e Extended overvoltage protection in the DC bus against overvoltage due to frequent switch on and switch off within a short period of time Changes in version F compared with E and D e Short circuit protection auxiliary voltage 15 V X3 pins 6 7 via PTCs 1250 new Table of technical specifications page 14 adapted accordingly Figure 4 to X3 page 48 internal circuit pin 6 7 changed Changes in version D compared with C B A e Additional PE terminal for mains connection X6 extended PE bolt M 6 instead of M 4 Section 4 1 page 28 PE terminal instead of bolt Section 4 2 page 29 PE bolt M 6 instead of M 4 Figure 6 page 56 connecting instructions for PE changed Section 5 4 page 57 PE bolt M 6 instead of M 4 e Tolerance for mains connection voltage 3 x 400 V AC now 10 instead of 10 min mains connection voltage 3 x 230 V AC shutdown threshold bus voltage 480 380 V instead of 60 V Table of technical specifications page 14 adapted accordingly Section 4 17 4 page 49 and section 3 3 2 table on page 20 Values shutdown threshold bus voltage adapted accordingly GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de
56. etpoint sources to pins Soll and Soll of Combicon connec tor X3 ensure proper earthing and shielding in order to avoid interferences at the amplifier input and the setpoint source GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 65 Essential measure shielding of the setpoint cable e Earth the shield at the setpoint source In particularly critical cases e connect the shield at the amplifier side with the 0 V terminal pin 1 of X3 e install a potential equalization cable with a cross section of at least 2 5 mm in parallel with the setpoint cable in order to avoid sheath currents on the shield or e establish only a high frequency connection of the shield at the amplifier side using a low induction capacitor e g 10 nF 400 V Always use the differential input to prevent zero loops that is the coupling of interferences via input O V e Apply the setpoint at the Soll input e Connect input Soll respectively with the neutral conductor as near as possi ble to the setpoint source Details on the assignment of Combicon connector X3 and the setpoint inputs can be found in sections 4 17 and 4 17 6 page 47 ff 5 16 PC Connection A PC personal computer with command and commissioning software SPP Windows is required for commissioning the KDV servo amplifiers For that a serial interface of the PC has to be connec
57. f the KDV servo amplifiers inside the amplifier it is converted into voltages of 5 V 15 V and 15 V via DC DC converters The control supply voltage is potential free towards the amplifier For connecting the control supply voltage see section 5 8 page 60 432 Brake A brake can be actuated with 24 V from the control supply voltage via relay contact Bremse Brake The following applies e 24 V control supply voltage is supplied via contact brake released actively released by 24 V e open contact control supply voltage is not supplied brake activated This output is actuated automatically by the KDV servo drive The machine data release brake selection code can be used for setting the states in which the brake is released e g whenever there is no fault or only in state operation enabled AN Actuating the brake via output Bremse Brake does not correspond to the safety requirements of the machine directive If the motor has to be braked for safety reasons or in case of an emergency stop the safety reguirements of the machine directive must be observed under all circumstances For connecting a brake see section 5 9 page 61 4 3 3 Motor Temperature Sensor As temperature sensors e a thermo switch opening in the event of overheating or e a PTC resistor increasing its value to more than 2 kQ in the event of over heating can be used O If the motor does not have a temperature
58. he inputs and outputs 4 18 1 Digital Inputs 1 0 to 12 7 These inputs can be used freely They can be queried by the part program or a higher level controller via the communication interfaces Via the machine data the inputs can be configured individually in a way that a drive specific assignment is activated e g Limit switch They then have a drive specific function and cannot be used freely any longer AN The use of digital inputs for stopping the drive e g as limit switch does not meet the safety requirements of the machine directive If an emergency stop or safety shutdown is required the safety requirements of the machine directive must be observed under all circumstances 4 18 2 Digital Outputs O 1 0 to O 1 3 and O 2 0 to O 2 3 These outputs can be used freely They can be set or reset by the part program or a higher level controller via the communication interfaces Via the machine data the outputs can be configured individually in a way that a drive specific assignment is activated e g Overload They then have a drive specific function and cannot be used freely any longer If a brake shall be actuated via this output the internal relay contact Brake has to be used GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 55 5 Installation and Connection Instructions EMC 5 1 5 2
59. heck the equipment of the device you wish to put into operation on the basis of sections 3 1 page 13 and 3 4 page 21 gain an overview of the accessories to be used on the basis of section 6 page 66 Of these accessories you require a PC with the command and commis sioning software SPP Windows as commissioning aid If you do not have this aid you cannot carry out the commissioning check the operating instructions for completeness under consideration of the included equipment and accessories on the basis of section 1 1 page 8 e Learn the basics of mounting and connecting the device For that study at least the following sections of these operating instructions Safety Instructions section 2 page 10 Technical Specifications section 3 2 page 14 Design section 3 3 page 19 Assignment of the Connectors section 4 page 28 and Installation and Connection Directions section 5 page 55 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 78 Operating Instructions 221072E V 7 5a 08 05 7 2 Learn the basics of the functions of the device For information on that see 221072 Functions and Parameters Each of the following steps is dealt with in a separate section e Connecting the Control Supply Voltage First Test e Connecting the Motor Position Sensor resolver Sincos Hiperface encoder high resolut
60. hokes supplied by Georgii Kobold are mounted in suitable housings and equipped with cable clamps Connection of Control Supply Voltage 24 V The control supply voltage 24 V DC is connected at Combicon connector X7 in the terminal compartment see figure 6 page 56 The control supply voltage connector must not be plugged or unplugged while under voltage The current rush might destroy the contacts of the connector The connectors are intended for fixed connection only For fault free operation the control supply voltage must meet the requirements specified in the Technical Specifications see section 3 2 page 14 The control supply voltage should always be checked at maximum load Please remember that the load can change during operation e g when the power circuit is enabled GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 61 Information on the assignment of Combicon connector X7 and the control supply voltage can be found in sections 4 3 and 4 3 1 page 30ff 5 9 Connection of a Brake A brake can be connected at Combicon connector X7 The internal relay con tact connects 24 V DC from the control supply voltage to this output If the leads to the brake are routed in the motor supply cable or the encoder connection cable these leads must have a shield of their own Connect the shield at the KDV servo amplif
61. ier side only For information on the assignment of Combicon connector X7 and the control supply voltage see sections 4 3 and 4 3 1 page 30ff 5 10 Connection of the Motor Temperature Sensor The motor temperature sensor is connected e usually at connector X11 R1 of the motor position sensor with option R1 resolver and R2 Sincos Hiperface encoder It can also be connected at Combicon connector X7 the corresponding pins of the two connectors are internally connected in parallel e at Combicon connector X7 with options R3 high resolution incremental encoder and R4 EnDat encoder O If the leads to the motor temperature sensor are routed within the motor supply cable or the encoder connection cable these leads must have a shield of their own Connect the shield at the KDV amplifier side only As temperature sensors can be used e a thermo switch opening in the event of overheating or e a PTC resistor increasing its value to more than 2 KO in the event of over heating If the motor does not have a temperature sensor the pins have to be jumpered at one of the connectors Otherwise the amplifier would constantly signal a motor overtemperature fault When connecting a motor temperature sensor you must ensure that it is not rendered ineffective by a jumper at the pins connected in parallel internally at the second connector options R1 and R2 gt o Information on the assignment of Combicon connector X7 and the
62. ion incremental encoder EnDat encoder e Connecting Motor and Mains e Setting the Machine Data e Connecting Other Peripheral Devices e Writing and Testing Part Programs Connecting the Control Supply Voltage First Test Connect the control supply voltage 24 V DC at connector X7 and switch it on Check the state of the LEDs after an initialization phase of some seconds e LED Usteuer Must be lit control supply voltage applied e LED St rung Fault must be lit motor position sensor not connected e LED Bereit Ready must be flashing power circuit not ready yet e The two other LEDs must be off e LED O 1 x and O 2 x may be lit or off the corresponding digital output indi cates a certain state e all other LEDs must be off For further information on the meaning of the individual LEDs please refer to section 3 3 2 page 20 For further commissioning you require a PC with the command and commis sioning software SPP Windows as commissioning aid Please refer to Operating Instructions 221102 SPP Windows Command and Commissioning Software Connect the serial interface of the PC via the cable supplied with SPP Windows with connector X1 of the KDV servo amplifier Use the SPP Windows software to establish a connection to the servo amplifier and have the type of fault reported at the KDV servo amplifier displayed by the corresponding LED The connection is established automatically during the program start or
63. ion on the load capability of this relay contact are listed in the table in section 3 2 5 page 18 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 50 Operating Instructions 221072E V 7 5a 08 05 4 17 5 Auxiliary Voltage Outputs 15 V 15 V The two auxiliary voltage outputs primarily serve for connecting an external setpoint potentiometer 10 kQ Please note that the setpoint input can handle only 10 V With an additional 10 KQ resistor in the wiper circuit drawn dash lined in fig 4 the full potentiometer control range can be used For loading the auxiliary voltages the voltage drop at the PTCs 125 Q has to be considered for maximum loading 10 mA the voltage drop is approximately 1 25 V 4 17 6 Analog Input Setpoint The setpoint input with the connections Soll and Soll1 lead to a differential amplifier The input voltage range is 10 V at 20 KQ Machine data Setpoint sources can be used for selecting the function the setpoint input acts on e target velocity e torque setpoint e current limitation Max current amount For connecting the setpoint source see section 5 15 page 64 Information on selecting the desired setpoint source is contained in Operating Instructions 221071 Functions and Parameters section Machine Data Set point Sources Options for scaling the values with a factor and for shifting zero with an offset are des
64. ly of individual devices If required the mounting can be effected in a way that the heat sink protrudes from the control cabinet e so that the heat loss does not heat up the control cabinet Suitable mounting accessories for KDV servo amplifiers KDV 2 400 to KDV 8 400 are described in section 6 2 page 66 Forthe KDV servo amplifiers KDV 12 400 and KDV 20 400 corresponding accessories are being prepared 5 3 Installation on a Mounting Plate For the installation of the amplifier on a mounting plate screw the amplifier EMC e with its bare metal housing e onto a bare metal e g zinc plated mounting plate For that the mounting plate has to be e earthed and therefore be e connected to the central zero point of the control cabinet via the potential equalization cable 5 4 Potential Equalization Cables Potential equalization cables originate in the central zero point of the control cabinet see figure 6 page 56 They e connect different zero points with one another at low resistance and e reduce equalizing currents on the cable shield Thus they prevent electrical interferences The central zero point of the control cabinet is connected to the PE protective earth conductor This connection avoids an endangering of operating and maintenance personnel in case of electrical faults Due to leakage currents of the built in RFI filter the potential equalization cable from amplifier to central zero point must like the cable
65. m the beginning all interfaces access the same parameters serial interfaces included KDV servo amplifiers equipped with a fieldbus interface have two connectors X14 and X15 as well as LEDs on their bottom side The fieldbus interface is designed as a module It can be installed by Georgii Kobold only subsequent installation on site is not possible The current consumption from the control voltage supply of the amplifier in creases by approximately 40 mA for one of options Fx GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 28 Operating Instructions 221072E V 7 5a 08 05 4 Assignment of Connectors 4 1 This section describes the assignment of the connectors The connection instructions can be found in section 5 page 55ff For information on the equip ment see section 3 4 page 21ff Connectors X6 to X9 are located in the terminal compartment Section 5 1 page 55 describes how to open the terminal compartment to get access to these connectors The connector assignments on the bottom side may vary depending on the equipment of the device For example connector X11 for the motor position sensor can be designed for a resolver option R1 a Sincos Hiperface en coder option R2 a high resolution incremental encoder option R3 or an EnDat encoder option R4 Therefore the designation of the connector e g X11 is supplemented in these operating instructi
66. mounting dimensions of amplifiers KDV 12 400 and KDV 20 400 All connections are located in the terminal compartment at the top of the front side behind a cover on the bottom side and on the front panel LEDs for indicating the operating states are located on the front panel The KDV servo amplifiers have one KDV 2 400 to KDV 8 400 or two KDV 12 400 and KDV 20 400 built in fans which are supplied internally with GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 20 Operating Instructions 221072E V 7 5a 08 05 the control voltage supplied from outside The fans do not run continuously but are switched on depending on the temperature Additionally they will be switched on for approx 1 minute after the shunt circuit has been activated The amplifier is fixed in the housing Slots for the modules described below are provided 3 3 2 LEDs On the front panel of the amplifier there are five LEDs displaying certain oper ating states as well as 24 LEDs for displaying the states of the digital VO 1 0 to 2 7 and O 1 0 to O 2 3 The LEDs have the following meanings Description Display Usteuer Lit when the control supply voltage 24 V is applied via connec tor X7 St rung red Lit or flashing when the servo amplifier indicates a fault The fault is stored state fault the cause of the fault can be read out in the PC as fault code see Operating
67. n Motor position sensor Sincos Hiperface and EnDat including the corresponding connections added descrip tion of fieldbus interfaces and section Drivers DLL Libraries and Program Examples completed external shunt resistor 021060010 added 2005 08 04 V7 5a KS MH prepared for OEM minor corrections 0 pdf Vorlagen GK 221072E 75a wpd Copyright by GEORGII KOBOLD GmbH amp Co KG 72160 Horb 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 GEORGII KOBOLD GmbH amp Co KG These operating instructions have been prepared with care However GEORGII KOBOLD GmbH amp Co KG 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 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 3 Contents 1 Preliminary Remarks D 1 1 About this Description EE 8 1 2 KDV Servo Drive Packages es Berne erde 9 2 Safety Instructions
68. nals shield connection clamps and housing 0380970107 Encoder connection cable for resolver and incremental encoder signals 8 cores 535254 twisted pair shield Encoder connection cable for Sincos Hiperface encoder 8 cores twisted pair 2 535270 cores shield Encoder connection cable for high res incremental encoder and EnDat encoder 8 535265 cores twisted pair shield 8 cores shield External shunt resistor 68 Q 600 W in housing IP20 for KDV 2 400 KDV 20 400 021058010 External shunt resistor 33 Q 1000 W in housing IP20 only for KDV 12 400 021060010 KDV 20 400 Command and commissioning software SPP Windows for PC with Windows 290 007 Z 95 98 NT 4 0 2000 XP Drivers DLL libraries and example programs for PC with Windows 95 98 NT 4 0 2000 XP also available as ready assembled cables Motor supply cable power _ I 6 2 Mounting Set 086230 With mounting set 086230 the KDV servo amplifiers KDV 2 400 to KDV 8 400 can be mounted in a way that the heat sink is located outside the control cabi net so that the heat loss of the KDV servo amplifier does not heat up the control cabinet For that holes must be provided in the rear wall of the control cabinet and in the mounting plate If mounting set 086230 is ordered together with the KDV servo amplifier it is installed at the servo amplifier by the manufacturer GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30
69. o stan dard mounting before the device can be mounted 6 2 3 General Notes for Both Mounting Types on page 16 Take appropriate action against dirt and humidity Seal the slots between the opening in the rear wall of the control cabinet and the housing of the KDV servo amplifier For mounting also see section 5 2 page 55 as well as the mounting dimension GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 69 6 3 Connector Set 099084010Z Connector set 099084010Z contains the matching counterparts for all connec tors of the standard KDV servo amplifiers except for serial interfaces X1 X2 For the scope of the standard version see section 3 1 page 13 Connector sets are also available for other connectors We also offer ready assembled cables If required please contact Georgii Kobold 6 4 Line Choke 038098010Z A line choke triple choke is required for compliance with the stricter EMC limits in a residential commercial and light industry environment see section 5 5 page 58 This is line choke 038098010Z which is supplied ready for installation and connection in a sheet metal housing IP20 with terminals Figure 9 shows the mounting dimensions the connection and the designation of the terminals Geh useh he 45 mm Housing height 45mm 130 vom Netz from mains zum Verstarker to
70. oad fuse has blown the DC bus cannot be charged again after the next switch on see preceding section The output for the shunt resistor is short circuit proof In case of a short circuit e shunt circuit and power circuit are switched off and e the amplifier signals fault overvoltage in the shunt circuit In case of an earth fault at pin R the internal overload fuse link blows see above O Operation of the device as brake regulator in which the motor mainly has to work against an external torque in braking operation requires an external shunt resistor dimensioned for the appropriate power e g shunt resistor 021058010 for KDV 2 400 to KDV 20 400 or 021060010 only for KDV 12 400 and KDV 20 400 described in the accessories see section 6 8 page 74 The internal resistor is not sufficient for that In most cases an external shunt resistor will be required for the servo amplifiers KDV 8 400 to KDV 20 400 in normal operation as well due to the high current GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 33 The resistor value for the external shunt resistor can be taken from the table in section 3 2 1 page 14 The load capability must be dimensioned according to the required braking power For connecting an external shunt resistor the jumper for the internal resistor has to be removed For further details see sec
71. obold amplifiers with CANopen interface GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de a Operating Instructions 221072E V 7 5a 08 05 4 These LEDs display the states of the CANopen interface communication LD1 green displays the state in the NMT node state diagram e flashing approx 2 Hz pre operational permanently on operational LD2 red displays the state of the send and receive monitoring of the CAN controller of the KDV servo amplifier e off OK CAN term error active e flashing 0 5 Hz warning CAN term error passive sending or receiving faults have occurred frequently device and bus run on fault CAN term bus off sending or receiving faults have occurred too many times device separated from the bus D O gt For detailed information on option F2 CANopen interface see Operating Instructions 221086 CANopen Interface 4 15 Serial Interface COM1 for PC X1 9 pin SUB D female connector X1 on the front panel Belegung TxD send data RS 232C level RxD receive data RS 232C level GND Connect cable shield via the SUB D housing A suitable cable 3 m long for connecting the serial interface to a PC is included in the scope of delivery of SPP Windows For connecting a PC see section 5 16 page 65 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 46 O
72. of the servo amplifier or the encoder may be destroyed When connecting please proceed in the following order e switch off the control supply voltage e connect the position sensor to connector X11 of the KDV servo amplifier for information on the connection see section 5 13 page 63ff When you switch on the control supply voltage again a fault should not be indicated LED St rung Fault is off LED Bereit Ready flashes Should a fault still be indicated first use the SPP Windows software to check what kind of fault it is In case of an encoder fault or a resolver fault check the connec tion O Then check the function of the encoder by e turning the motor shaft manually e checking the change of the actual position with the SPP Windows software The actual position has to increase or decrease this depends on the direction of rotation by approximately 65 000 exactly 65 535 Other values indicate that the wiring is faulty or that a conversion factor has already been stored in the KDV servo amplifier via machine data parameter Position factor To continue connecting switch off the control supply voltage GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 80 Operating Instructions 221072E V 7 5a 08 05 7 4 7 5 Connecting the Motor Power Proceed as follows for information on the connection of motor and motor
73. on is sensed for 4096 revolutions in the encoder Note The travel distance of multi turn type Sincos Hiperface and EnDat encoders must not exceed 4096 revolutions ofthe motor Thus endless axes cannot be realized with multi turn type encoders With the resolution per revolution the entire positioning range results in 4096 65536 268 435 456 228 steps The high resolution incremental encoder passes a reference signal once per revolution Before passing the reference signal for the first time the position information of the rotor is determined using a second track Z1 track Until that the position information is still inaccurate see footnote of the following table Once the reference signal has been passed the position is determined using the incremental signals and the position information reaches the high accuracy stated in the following table GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 24 Operating Instructions 221072E V 7 5a 08 05 Motor Position Sen Resolver R1 Sincos Hiper High Resolution EnDat Encoder sor System face Encoder Incremental En R4 R2 coder R3 Max operating speed 10 000 r p m 12 000 r p m 9 000 r p m Revolutions measured 4096 4096 absolute Resolution software ae 65536 volution 15 60 80 60 512 System 20 2048 accurac d Oo o a LL gen Resolution output en coder signals option 50 to 1024
74. onal injury or material damage The CE marking requires compliance with the EMC limits according to EN 55011 A and B emission and EN 50082 1 and 2 immunity The instructions marked with this symbol must be observed by all means Other wise the facility in which the amplifier is operated has to be checked for compliance with the EMC limits at the customer s own responsibility Check Prior to commissioning and in case of failures or problems check these items first Tip useful hint 2 2 Qualified Personnel AN The servo amplifiers work with dangerous voltages Contact with voltage carry ing parts can damage your health seriously Therefore only trained qualified personnel with knowledge in the fields of EMC automation systems handling of dangerous voltages standards and regulations such as EMC Directive 89 336 EEC Low Voltage Directive 73 23 EEC Machine Directive 89 392 EEC VDE regulations such as DIN VDE 0100 DIN VDE 0113 lt EN 60204 gt DIN VDE 0160 lt EN 50178 gt safety rules may install commission GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 11 e maintain and e service these devices They have to read these operating instructions carefully in advance and to observe the safety instructions permanently while working 2 3 Use for the Intended
75. one ofthe connectors Otherwise the amplifier would constantly report a motor overtemperature fault For connecting a motor temperature sensor please see section 5 10 page 61 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 34 Operating Instructions 221072E V 7 5a 08 05 4 6 Input Sincos Hiperface Encoder Option R2 X11 R2 9 pin SUB D female connector X11 on the bottom side assignment for devices equipped with option R2 Pin Assignment 2 8 V REFCOS Connect cable shield via the SUB D housing 1 With Sincos Hiperface encoders the motor temperature sensor should preferably be connected at Combicon connector X7 The Sincos Hiperface encoder input is designed for Sincos Hiperface enco ders produced by Stegmann Motors with built in Sincos Hiperface encoders are available from Georgii Kobold For the differences between the types of motor position sensors option Rx please see section 3 4 2 page 22 For connecting the Sincos Hiperface encoder see sections 5 13 and 5 13 2 page 63 0 If the motor does not have a temperature sensor the pins must be jumpered at one ofthe connectors Otherwise the amplifier would constantly report a motor overtemperature fault For connecting the motor temperature sensor via pins 3 and 7 an additional shield of the cables to the motor temperature sensor is absolutely required so that sensitive an
76. ons by the designation of the option e g X11 R1 to which the specified assignment applies Mains Connection X6 4 pin Combicon connector X6 RM 7 62 in the terminal compartment Pin Designation Assignment pe E mains mains protective earth conductor O lt en conductor To limit the inrush current the DC bus is charged via the shunt resistor internal or external see next section After exceeding the threshold value of gt VDC the current limitation will be switched off with a delay of 1 s using a power relay If the shunt resistor fails or has not been connected because e the jumper for the internal shunt resistor has not been set e the external shunt resistor is missing or e the internal overload fuse has blown the DC bus cannot be charged LED Bereit Ready flashes even if the power circuit is enabled however a fault is not reported In this case establish the connection to the internal or external shunt resistor or contact Georgii Kobold for an exchange of the internal overload fuse GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 29 When the mains is switched off the current limiting circuit is activated as soon as the DC bus voltage is below the threshold value The time required for that depends on the power circuit state Power Circuit Motor Discharge Time
77. or pin 5 41 24 V output power supply for external position encoder the voltage supplied via pin 2 Connect cable shield via the SUB D housing Input X12 L2 is equipped with an internal line receiver for single ended 24 V signals With it the KDV servo amplifier can process encoder signals An incremental encoder must be supplied with externally provided 24 V DC As this voltage is connected to pins 1 and 2 for reference the incremental encoder can be supplied via these pins For connecting the encoder signals see section 5 14 page 64 Details on input encoder signals can be found in section 3 4 4 page 26 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 3 co 4 11 Output Encoder Signals 5 V Option G1 X13 G1 15 pin SUB D male connector X13 on the bottom side assignment for devices equipped with option G1 Pin Assignment Ua1 channel A Ua2 channel B Ua0 index pulse 10 12 0 V reference voltage for encoder signals 13 Ua1 channel A 14 Ua2 channel B 15 Ua0 index pulse Housing Connect cable shield via the SUB D housing Output X13 G1 is equipped with an internal RS 422 compatible line receiver for 5 V push pull signals With it the KDV servo amplifier can output encoder signals For connecting the encoder signals see section 5 14 page 64 0 The
78. orgii Kobold The mini mal signal frequency that can be processed by the software is 250 Hz Input encoder signals can be realized as follows e LO not connected standard e L1 signal level 5 V push pull signals RS 422 e L2 signal level 24 V Both variants L1 and L2 support all above mentions functions Input encoder signals is designed as a module It can be installed by Georgii Kobold only subsequent installation on site is not possible The current consumption from the control voltage supply of the amplifier in creases by the current for the external position sensor if supplied via input encoder signals Connector X12 for input encoder signals is described in sections 4 9 and 4 10 page 37ff For connecting the encoder signals see section 5 14 page 64 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 27 3 4 5 Fieldbus Options Fx The following fieldbus interfaces are available e FO none standard e F1 Interbus local bus according to DRIVECOM profile 22 e F2 CANopen CAN according to the CANopen standards and with DRIVECOM profile 22 e F3 Interbus optical fiber local bus according to DRIVECOM profile 22 All parameters of the KDV servo drives can be accessed via the fieldbus inter face Due to the fact that the software of the KDV servo drives has been devel oped for use with a fieldbus fro
79. output data of the encoder signals number of pulses per revolution index pulse function depend on the motor position sensor used option Rx Please refer to section 3 4 3 page 24 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 40 Operating Instructions 221072E V 7 5a 08 05 4 12 Output Encoder Signals 24 V Option G2 X13 G2 4 13 15 pin SUB D connector X13 on the bottom side available for devices with option G2 Pin Assignment 24 V input power supply for output encoder signals Ua1 channel A Ua2 channel B Ua0 index pulse 12 0 V reference voltage for encoder signals and for power supply pin 5 1 14 lo oa Housing Connect cable shield via the SUB D housing Output X13 G2 is equipped with an internal line receiver for single ended 24 V signals With it the KDV servo amplifier can output encoder signals The output is short circuit proof For connecting the encoder signals see section 5 14 page 64 refer to section 3 4 3 page 24 Interbus Option F1 and F3 X14 F1 X15 F1 The Interbus interface is an optional interface It can be designed as local bus option F1 or as optical fiber local bus option F3 These operating instructions describe option F1 local bus only For further information on option F3 optical fiber local bus see Operating Instructions 221074 Communication Functions further Int
80. perating Instructions 221072E V 7 5a 08 05 4 16 Serial Interface COM2 X2 9 pin SUB D female connector X2 on the front panel Assignment RS 232C Assignment RS 485 TxD send data do not use RxD receive data ADATA GND GND IE Housing Connect cable shield via the SUB D housing T optional 5 V The standard assignment of this interface corresponds to RS 232C levels If stated in the order it can alternatively be equipped with drivers for RS 485 levels by Georgii Kobold On request pin 6 can be assigned with 5 V on request in order to supply external communication electronics GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 47 4 17 Control Signals X3 13 pin Combicon connector X3 RM 3 81 on the front panel Pin Designation Assignment _ 13 24 V I O 24 V input supply digital VO 0 VO 0 V supply digital VO 11 Freigabe Enable digital input Enable I 3 0 St rung Fault digital output Fault BTB Ready E potential free relay contact output Ready e Spe 15 V output aaa voltage 15 V sv Test Soll analog Mpu en oje ne EE k Ist1 analog output actual value 1 ep e st analog output actual vele sd output analog output actual value 2 value 2 Drive specific functions and signals can be assigned to the individual inputs and outputs by means of machin
81. put reference existing e Status of BTB contact as Betriebsbereit Ready BTB can be assigned to digital outputs Changes from V 7 0 on e EnDat motor position sensors EnDat 2 1 are supported option R4 Changes from V 6 0 on e DriveTerminal no longer supported operation and commissioning via PC only Changes from V 5 5 on Earth fault detection Changes from V 5 4d on e Support for motors with more than 7000 r p m speed Changes from V 5 4 on e E 1 7 Position spindle for function spindle positioning Changes from V 5 1 on e Drive specific functions of digital outputs 1 x and 2 x can be configured freely GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 85 Changes from V 4 7 on e Support for additional high resolution motor position sensor also see Operat ing Instructions 221071E Functions and Parameters e Support for devices with 12 A 20 A Changes from V 4 5 on e 11 5 Start reverse running O 1 3 Waste in operating mode Flying Shear Changes from V 4 4 on e O 1 3 Synchronized in operating modes electronic gearing flying shear Changes from V 4 0 on e Support for Sincos Hiperface encoders single and multi turn option R2 Changes from V 3 5 on e Analog input setpoint at X3 may also be used for current limiting also see
82. r multiple revolutions it is listed in a software counter in the KDV servo amplifier That means for positioning modes the home position has to be determined after each switch off and switch on of the control supply voltage in order to determine the absolute position of the axis e for 4096 revolutions with Sincos Hiperface and EnDat encoder multi turn The position is read out from the encoder after each switch off and switch on of the control supply voltage so that going to home position is not required Resolvers are used as standard option R1 The resolver input is dimensioned for the standard servo drive type single pole pair resolvers with a transformation ratio of 1 0 5 The excitation voltage is 7 V short circuit proof at an excitation frequency of 8 kHz Sincos Hiperface encoders high resolution incremental encoders and EnDat encoders are intended for applications in which at least one of the following criteria must be met e high accuracy e low speed ripple e absolute position sensing Sincos Hiperface or EnDat in multi turn design Two types of Sincos Hiperface encoders and EnDat encoders are avail able GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 23 e Single turn design similar to the resolver the position is sensed within one revolution of the encoder e Multi turn design the positi
83. rands using the cable clamp e Establish the shield in the same way at the shunt resistor as well Please note that the machine data have to be adapted when using an external shunt resistor Detailed information can be found in Operating Instructions 221071 Functions and Parameters 5 12 Shield Connection SUB D Connectors EMC These explanations for shield and shield connection apply to the following sections Use only shielded cables The housings of the SUB D connectors are metallized There a low resistance connection between shield and housing is made via the strain relief With that you achieve the necessary large area earth connection for the shield and avoid earthing the shield using twirled strands pigtails of the shield braid ing GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 63 5 13 Connection of a Motor Position Sensor The cable to the motor position sensor options Rx must be e laid separately from the motor supply cable and O e connected exactly according to the instructions otherwise the motor blocks the motor runs unsmoothly the motor runs with a lower torque the motor runs uncontrolled at full speed or the servo amplifier reports a fault AN This does not damage motor or amplifier but may endanger machine and commissioning personnel When connecting the shiel
84. s programming languages C Basic Pascal others on request libraries for access to the functions of the digital servo amplifiers as Win32 DLLs e interface drivers for the connection via serial interface fieldbus TCP IP e g Ethernet and DriveServer OPC GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 77 7 Commissioning 7 1 K A This section describes the commissioning step by step Knowledge of the connection directions section 5 page 55ff is assumed How to Proceed for Commissioning For the first commissioning please proceed according to the steps described here in order to prevent damage to the devices or the driven machines and yet become acquainted with the device quickly In each case the next step must not be carried out unless the previous one has been completed successfully Connections may only be established or disconnected when the devices are switched off For commissioning the servo amplifier the motor should not be mounted at the machine yet but fixed properly otherwise It is essential to ensure that possible commissioning faults such as uncontrolled running of the motor at maximum speed or excessive acceleration cannot lead to an endangering of persons or damages to property The following steps must be carried out e Check equipment accessories operating instructions c
85. servo amplifier With these part programs motion sequences can be executed independent of a higher level controller e Operating mode flying shear Special application with synchronization of two axes For a periodical posi tioning process during which the slave axis flying shear is temporarily synchronized with the master axis The slave axis receives position and speed settings of the master axis via an encoder input option Lx In practi cal operation the master axis typically ensures a continuous material flow and a tool actuated by the slave axis processes the material during the synchronous periods of time e g sawing cutting printing The desired operating mode can be selected via one of the communication interfaces variable access or by means of appropriate programming in the part program For further information on the different operating modes and the application of them please see Operating Instructions 221071 Functions and Parameters 34 Modular Equipment This section describes the various options of the KDV servo drives It is based on the type code in section 3 1 page 13 The current consumption from the control voltage supply of the servo amplifiers depends on the modular equipment Rx Gx Lx and Fx Details on the current consumption can be found in the corresponding sections The connector assignment is described in section 4 page 28ff the connection directions can be found in section 5 pag
86. so recommended are twisted pair leads for the signals C C D D and R R e g encoder connection cable 535265 specified in the accessories for further details see section 6 7 page 73 5 13 4 Connection of the EnDat Encoder For connecting the EnDat encoder option R4 to the corresponding connector X11 R4 use e a shielded cable with twisted pair leads for the signals At A B B CLOCK CLOCK DATA DATA e g encoder connection cable 535265 specified in the accessories for further details see section 6 7 page 73 5 14 Connection of Encoder Signals When connecting incremental encoder signals to the corresponding connector X12 or X13 at the bottom side of the device please observe e forthe 5 Volt version options G1 L1 choose twisted pairs for each channel e use a shielded cable e g encoder connection cable 535254 specified in the accessories for further details see section 6 7 page 73ff e connect the shield at the amplifier to the earthed amplifier housing using the metallized SUB D housing e earth the shield additionally at the controller follow the recommendations of the manufacturer of the controller regarding earthing and shield connection Information on options Gx and Lx for encoder signals can be found in sections 3 4 3 and 3 4 4 page 24ff For details on the assignment of Combicon connec tors X12 and X13 see sections 4 9 to 4 12 page 37 ff 5 15 Setpoint Connection EMC When connecting s
87. ted to the serial interface COM1 connector X1 of the KDV servo amplifier For the connection between PC and COM1 of the KDV servo amplifier a standard serial cable can be used in which the connectors with the same pin numbers are connected respectively A suitable cable 3 m long for connecting the serial interface to a PC is included in the scope of delivery of the SPP Win dows software For details on the assignment of interface COM1 X1 see section 4 15 page 45 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 66 Operating Instructions 221072E V 7 5a 08 05 6 Accessories 6 1 Available Accessories and Order Numbers Accessories Order Number Mounting set for KDV 2 400 to KDV 8 400 for mounting with heat sink outside the 086230 control cabinet Mounting set for KDV 12 400 and KDV 20 400 for mounting with heat sink outside on request the control cabinet Connector set for KDV servo amplifiers standard version Line choke triple choke with terminals and housing IP20 Motor supply cable power up to 12 A 4 cores shield Motor supply cable power up to 12 A 4 cores shield 2 cores shield up to 16 A 4 cores shield Motor supply cable power up to 16 A 4 cores shield 2 cores shield Motor supply cable power up to 20 A 4 cores shield Motor supply cable power up to 20 A 4 cores shield 2 cores shield Motor choke triple choke with termi
88. the amplifier and connect the supply cable to the inputs of the line choke Connect the connection cable to the amplifier at the outputs of the line choke Shield is not required Connection at the amplifier Combicon connector X6 e Connect the supply cable to Combicon connector X6 of the KDV servo amplifier shielding is not required GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de Operating Instructions 221072E V 7 5a 08 05 81 e Make sure that at Combicon connector X9 either the internal shunt resistor is activated by a jumper at R R or that an external shunt resistor is con nected to R R ext 7 6 Setting the Machine Data For setting the machine data follow the instructions of Operating Instructions 221071 Functions and Parameters 7 1 Connecting Other Peripheral Devices After the drive system has been put into operation in accordance with the above sections further peripheral devices can be connected to the KDV servo ampli fier 0 When connecting further peripheral devices ensure that the voltage supply of the control supply voltage is not overloaded and that 24 volts are still available for the basic device When connecting other peripheral devices it is also important to make sure that the cables are shielded and that interferences at inputs and outputs are suffi ciently suppressed so that there are no interferences in the drive
89. tion 5 11 page 62 4 4 2 DC Bus Additional KDV amplifiers without power supply unit can be supplied by the DC bus voltage of the power supply unit 4 5 Input Resolver Option R1 X11 R1 9 pin SUB D female connector X11 on the bottom side assignment for devices equipped with option R1 0 Volt connect in special cases only N 0 Volt for motor temperature sensor connected in parallel internally with the corre sponding pin at Combicon connector X7 Sine S2 4 Cosine S3 Excitation R2 Motor temperature sensor connected in parallel internally with the corresponding pin at Combicon connector X7 Sine S4 Cosine S1 Excitation R1 Connect cable shield via the SUB D housing N Hs ESCH Ee SR SS Housing Housing The resolver input is designed for the standard servo drive type single pole pair resolvers with a transformation ratio of 1 0 5 The motors with resolver supplied by Georgii Kobold are equipped with match ing resolvers Other resolvers can only be installed after consultation with Georgii Kobold The adaptation of the control to other resolver signals can only be carried out by Georgii Kobold at extra charge For the differences between the types of motor position sensors option Rx please see section 3 4 2 page 22 For connecting the resolver see sections 5 13 and 5 13 1 page 63 0 If the motor does not have a temperature sensor the pins must be jumpered at
90. tions 221072E V 7 5a 08 05 e line resistance max 80 O km at a length of 15 m to max 25 O km at a length of 1000 m e cable cross section of at least 0 25 mm at a length of 15 m to at least 0 75 mm at a length of 1000 m Coding Switches e Coding switches S1 S2 for setting the Node ID Setting of the Node ID of the CANopen participant These are 4 bit coding switches by means of which the Node ID can be set in hexadecimal format S1 for the higher valued 4 bits S1 is located near the front panel S2 for the lower valued 4 bits Permissible setting range 01 7F pex Setting range 81 x FFhex is mapped on Node ID 01 7Fhex Settings Onex and 80 are not permissible for these settings Node ID 1 has to be selected The setting of these switches is read in when the control supply voltage of the servo amplifier is switched on NMT service Reset_Communication NMT service Reset_Node The COB ID assignment depends on the set Node ID O A Node ID may be given only once in the network e Coding switch S3 for setting the transmission rate The setting of these switches is read in when the control supply voltage of the servo amplifier is switched on NMT service Reset Communication NMT service Reset Node All bus participants must be set to the same transmission rate LEDs The state LEDs LD1 red and LD2 green of the CANopen module are located on the top side of Georgii K
91. tput 24 V GK customer specific Input encoder signals for axis coupling synchronization el gearing external position encoder or pilot frequency incremental encoder signals pulse direction signals on request L1 signal level 5 V push pull signals RS 422 L2 signal level 24 V LK customer specific Fieldbus connection F1 Interbus local bus according to DRIVECOM profile 22 F2 CANopen CAN according to CANopen standards and DRIVECOM profile 22 F3 Interbus optical fibre local bus according to DRIVECOM profile 22 F5 Profibus DP in preparation Special equipment customization Number mechanical special equipment Letter electrical special equipment Sa EE BEE For further details on the eguipment please see section 3 4 page 21 GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 14 Operating Instructions 221072E V 7 5a 08 05 3 2 Technical Specifications 3 2 1 Electrical Specifications KDV 121000 Mains input 3 x 400 V AC 410 50 60 Hz approx 60 V 800 V DC 380 V DC power circuit enabled Shutdown threshold undervoltage 480 V DC power circuit disabled Maximum mains inrush peak current 17 A gt Motor output earth fault proof short circuit proof Switching frequency of power circuit Shunt circuit overload proof short circuit proof Max continuous braking power internal 100 W Max continuous braking power external
92. tware SPP Windows supports the follow ing functions e Operating selecting operating modes switching on and off displaying actual values displaying and modifying setpoints e Commissioning by means of operating functions and integrated oscilloscope e Generating modifying saving and transmitting of machine data part programs part program variables The SPP Windows software runs on IBM compatible personal computers under Windows 95 98 NT 4 0 2000 XP Further information can be found in Operating Instructions 221102 Command and Commissioning Software SPP Windows Command and commissioning software SPP Windows for personal computers is required for the commissioning of the KDV servo drives The software may also be obtained from Georgii Kobold at a later date GEORGII KOBOLD D 72160 Horb Tel 49 0 7451 5394 0 Fax 49 0 7451 5394 30 www georgii kobold de 76 Operating Instructions 221072E V 7 5a 08 05 6 10 Drivers DLL Libraries and Example Programs Drivers and DLL libraries are available for the development of own application programs under Windows 95 98 NT 4 0 2000 XP Included in the scope of delivery are example programs with documented source code which demonstrates the access to the functions of the KDV servo amplifier via serial interface COM1 of the amplifier and can be used as a basis for own developments Also included in the scope of delivery e modules for variou

Operating Instructions 221072E, V 7.5a

Contents

Download Pdf Manuals

Related Search

Related Contents