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Operating Instructions 221058E, V 1.5a 09/01

1. 05 10 24 Motor chokes and 53 aos Sa wees ae rs S eee Se end eee ae eee Chapter 4 Notes for specialists 11 Modifications to the servo amplifier 00000 0 eee eee 11 1 Modifying the controller circuitry dees eee a ds 11 1 1 Speed control range 2s 2324 shee tees Shah ee tak Re ahead 11 1 2 Number of motor pole pairs 0 020220 11 1 3 Current control instead of speed control 11 1 4 Changing the direction of rotation 00005 11 2 Modifications to the feedback 0 e eee cee eee 21 RESORT Mog che nee a 1122 Deria tes isn 11 3 Modifications to the Z1 Z2 and Z4 add on modules 11 3 1 Location of the solder bridges 00 cece eee 11 3 2 Former versions of modules Z1 and Z2 11 3 3 Power circuit ready signal instead of Motor standstill signal 11 3 4 Switching off the peak current rise 000 05 80 11 3 5 Switching off active braking at controller disable 11 3 6 Activating the ramp function 022 0 cece eee 80 11 3 7 Adjusting and limiting the component of the speed controller 11 4 Modifications to the polarity module 00 00 cee eee 11 4 1 Ready signal instead of Fault signal GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
2. GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 55 Tip e The Rough switch shifts the pulses by 22 5 per step e the Fine switch shifts them by approx 1 4 per step e The Zero LED indicates the index pulse that is the moment when the output level is High e The Rough and Fine LEDs light up when the index pulse is within the setting range of the appropriate switch Adjustment instructions 1 Turn the motor shaft to where the index pulse should be 2 Turn Fine switch until the Fine LED lights up 3 Turn Rough switch until the Rough LED lights up As with incremental encoders the index pulse here also has the width of an increment The index pulse can be adjusted in steps of approx 1 4 with the two switches This corresponds to a resolution of 256 steps on the circumference When a pulse figure of over 256 is set then the index pulse is narrower than 1 256 of the circumference For this reason the Zero LED does not light up within the entire adjust ment window of 1 4 For it to light up the motor shaft must be rotated within the window to the exact zero point 6 5 Function module Fx Various functions including customer specific functions are imple mented on the function module So far there are the hold function and the field weakening mode which wil
3. e jumper in position Seli or Sel2 special motor further details on request The number of pole pairs is factory set for the used motor see type code page 15 Kx option GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 76 Operating Instructions 221058E V 1 5a Kundenmodul Polaritatsmodul Zusatzmodul Funktionsmodul 1 P3 Customer module Polarity module Add on module Function module strom n offset Current x 14 S gene Q oO ZUSATZMOD Drehzahlbereich 50 bei 10 V Sollwert B Set SY GR ERAS Speed range aoe ea at 10 V setpoint EEEIEE HAHN g a ERBEABERBEBE T 500 3500 min oe BE Beal LHL BErFERE P 5 2 11 ATRE alB Fra IE 1000 7000 min eb JE DERBBE T 1500 10500 min JRE a nun 2000 14000 min Zia ERE TEL Tti OW OW OEA D LEISTUNGSVERST RKER 7 Ka z FUR BURSTENLOSE MOTOREN Motortyp z J w i J wei ms 077 3 Motor type p Ca TDA E EDA geay ee BEREE CREE x27 2 Polpaare 6 6 6 a 2228 2 pole pairs Jizz sm FAS BIDET ves P s 7 3 Polpaare aoao 3 pole pairs Lesy 2 4 Polpaare aofe
4. is located on the customer mod ule P4 gain holding control loop The trim potentiometer setpoint gain Sollwertverst rkung can be installed on the customer module as an option Amplification rises 5 2 Current limiting and Current rotary switch A current limiting device with I t function protects the motor and the amplifier From the unloaded state a maximum current equivalent to the preset peak current is possible If the square of this exceeds a certain given threshold value for a certain time then the current is reduced to the value of the preset continuous current and an external Overload signal is given The amplifier can be operated for any length of time in this state If the current is reduced the Overload state is canceled after some time The 16 position rotary switch Current Strom for setting the cur rent limit is located at the top of the PCA approximately 100 mm behind the customer module It is not accessible from outside so that it cannot be adjusted unintentionally The assignment of the switch positions to the values for the motor current limit continuous current GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 46 Operating Instructions 221058E V 1 5a Il aS rms value and peak current as crest value is shown in the following table Servo ae 1 5 5 com KSV 3 10 com KSV 6 20 com KSV 9 30 com
5. e Observe motor behavior at different speeds and at standstill if the feedback is set too hard the motor runs loud and rough if itis set too soft you can move the motor back and forwards a little by hand This soft behavior can cause inaccuracies later when the drive is operated with a higher level controller GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 62 Operating Instructions 221058E V 1 5a e Turn the feedback trimmer Verst rkung clockwise until the motor runs loud and rough then turn back the trimmer approx one turn 8 5 Setting the feedback critical applications How to proceed with critical applications e check limit switch connect motor to load as above e apply setpoint to amplifier input via a switch so that a setpoint jump can be generated e generate a setpoint jump e record the step reply at the Speed monitor output with a memory oscilloscope e evaluate the step reply and correct the feedback setting for most applications the speed should reach its final value as fast as possible but only with a slight overshoot Under extreme conditions the adjustment range of the feedback may be insufficient In this case the reset time must be changed For further details see section 11 2 1 page 77 8 6 Setting the feedback with Z4 add on module Tip For the purpose of commissioning a special module is availa
6. 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 41 Danger CE EMC This causes no damage either to the motor or to the amplifier but there is a risk for the machine and the installation personnel As shown in fig 6 the motor is connected using a 4 pin shielded cable e Use the motor supply cable described in the accessories for fur ther details see section 10 2 2 on page 69 e Connect the motor cable shields as described in the following section e Connect the machine earth to the central zero point of the control cabinet using an potential equilization cable with an adequate cross section 4 4 6 Shield connection motor cable A cable clamp is provided on the amplifier for the shielded motor cable Use this to e establish a large area connection between the shield and the hous ing by folding back the strands of the shield over the cable sheath and securing the whole using the cable clamp Establish a large area connection between the shield and earth at the motor in a suitable manner Atall places avoid earthing the shield using twirled strands pig tails of the shield The shield of the motor cable must not be interrupted If you have to install contactors switches or chokes in the motor cable then install these in a metallic housing and establish a large area connection between the shield and the housing using a cable clamp as described above The motor cables
7. D circuitry connection is not provided with the customer module be longing to the Z4 add on module 11 3 Modifications to the Z1 Z2 and Z4 add on modules 11 3 1 Location of the solder bridges The following figures show the position of the solder bridges on the Z1 Z2 and Z4 add on modules GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 79 Zusatzmodul Z1 Z1 add on module O Impulsstrom aus Peak current off aa Inpuls strom Aus aktiv Aktives Bremsen aus Ly Brense Aus Active braking off BN 6661 0000 00B 061 Z1 Modul ren FO er Rampenfunktion ein o weri Ramps Eines 4 Ramp function on Endcderei 198 Endstufe bereit an statt Motor steht Power circuit ready instead of Motor standstill Fig 11 Solder bridges on the Z1 module Z2 add on module Zusatzmodul Z2 O ar Impulsstrom aus I T Ip Peak current off Endstufe bereit an ti statt Motor steht Power circuit ready instead of Motor standstill BN 6661 0000 00C 062 O Fa Rampenfunktion ein Eis 4 Ramp function on BPI Aktives Bremsen aus as Active braking off e Fig 12 Solder bridges on the Z2 module GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 80 Operating Instructions 221058E V 1 5a Zusatzmodul Z4 Z4 add on module
8. Operating Instructions 221058E V 1 5a 7 12 Documentation of the settings Appendix Appendix A EC Declaration of Conformity 2222222 een Appendix B Terms of warranty 0020 Appendix C Table of faults ccooeeeeeeneeneneenennenn GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 8 Operating Instructions 221058E V 1 5a Figures Fig 1 Mounting dimensions 242 2 conkaduhesthasreasghedehachbeiweaeune oe Fig 2 Control signals switching towards zero interface details Fig 3 Control signals PLC compatible interface details nnana nananana Fig 4 Encoder signals 5 volt version interface details n nnana nananana Fig 5 Encoder signals 24 volt version interface details 2222222220 Figs COMMECHOMONCCUOMNG se nessi sen Dek sn aa an ie aos ame Fig 7 Setpoint potentiometer connection for commissioning 60 Fig Be MOLORCHOKES eshi std ik att Set etd ls eid hah ald eh teh Bech RERA E a Fig 9 Location of the jumpers on the board 0000 eee eee Fig 10 Location of the jumpers on the customer module 2222222200 Fig 11 Solder bridges on the Z1 module 0 00000 Fig 12 Solder bridges on the Z2 module euere ae oie ae ed as ga Fig 13 Solder bridges on the Z4 module 0020 e eee eee Fig 14 Solder bridges on th
9. er 12 30 com amplifier pact De pact design pact design pact design pact Eo a Peak Cont Peak a Peak Cont Peak Cont current current current current current current current current current current Ip A L A b A IA b A L A b A L A Io A I A 0 38 ea 0 75 2 5 2 25 7 5 3 0 75 3 0 9 0 0 53 1 05 3 5 3 15 10 5 2 0 4 0 12 0 12 0 0 68 2 25 1 35 4 05 13 5 13 5 075 25 10 0 15 0 15 0 0 83 2 75 1 65 11 0 495 165 66 16 5 3 0 1 8 12 0 18 0 18 0 0 98 3 25 1 95 13 0 585 195 19 5 1 05 14 0 21 0 21 0 150 6 75 225 22 5 16 0 24 0 24 0 17 0 765 255 10 2 25 5 18 0 27 0 10 8 27 0 143 475 28 19 0 855 285 11 4 28 5 1 13 3 75 2 2 15 300 _ 5 1 2 4 0 1 28 4 25 2 55 5 If the desired type of motor is given in the order the current is factory set to the permissible motor current If not the Current rotary switch is set to position 5 Current Cont Peak Cont switch 10 5 ABE _ e ceper e ef Dae fo ffel If you have changed the factory settings it is essential that you should Tip document the new switch position in the table in section 12 page 82 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 47 5 3 LEDs There are three LEDs on the left side of the front panel bel
10. sr re Be tie tn a a a eee 1 1 Aboutthis deseriplioh s sesessse sense stern 1 2 Servo Drive Packages s ss na a2 ana ken bannen nahen 2 Safety Insiflicli n8s 2 ee 2 1 Type of instruction Is Cod tattoo Cra ie os ta ed ie os or ta ox hace a 22 PeCnnical Slall serene kart eher soe he ehh ee dome 2 3 Use for the intended purpose 2 ieee ei ede ee wees ee eee ee ee 2 4 Protective earthing agecie Br ec eb eit teri ete a ect eas 2 5 Hazard warnings a2 erregen 2 0 WVU ese seele en ee 27 GE marking 2 tre 3s Bret hbo fh Sa iy SB aaa a aaa aai 2 8 Preconditions for commissioning sata rer 2 9 Working with the amplifier anann a 454 Eile Chapter 2 Servo amplifier 3 Technical specifications 0 0 00 es 3 1 3 2 3 3 4 Connection Assignment of connectors and details 4 1 UVC OOS RE ER EEE EURER Technical specifications usa us et Betas ee er 3 3 1 DESIGN rn ee dyer aaraa ee ee ee 3 3 2 Installation in the control cabinet 0 0c eee eee Cohheelor assianmentis senden Peas an er ake ee a 4 1 1 Motor and operating voltage Combicon connector X1 4 1 2 Mains and operating voltage Combicon connector X5 4 1 3 Control signals Steuersignale SUB D fem connector X2 15 pin 4 1 3 1 Version without add on module 4 1 3 2 Version with Z1 add on module 4 1 3 3 Version with Z2 add on module 4 1
11. tion of settings revised 13 01 00 V 1 5 MH add on modules Z1 and Z2 revised figures new add on module Z4 new type code updated table Documenta tion of the settings revised fig 9 new corrections doc ument styles similar to German version V 1 5 24 09 01 V 1 5a MH OEM preparation corrections similar to German version V 1 5a 0 pdf Vorlagen GK 221058E_15a wpd Copyright by GEORGII KOBOLD AUGUST HEINE GmbH amp Co D 70771 Leinfelden Echterdingen Germany All rights reserved including those of translation No part of these operating instructions may be copied reproduced stored or processed in an information system or transmitted in any other form without prior written permission by GEORGII KOBOLD AUGUST HEINE GmbH amp Co These operating instructions have been prepared with care However GEORGII KOBOLD AUGUST HEINE GmbH amp Co can accept no liability for any errors in these operating instructions or possible consequences Neither can any liability be accepted for direct or indirect damage resulting from abuse of the device The relevant regulations concerning safety technology and electromagnetic compatibility must be complied with when using the device Subject to alteration GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 3 Contents Chapter 1 General information 1 Preliminary remarks
12. 0 711 75903 53 82 Operating Instructions 221058E V 1 5a Figure 13 shows the location of the solder bridges The following applies Solder bridge time constant no component 25 ms 2 5 ms 2 1 25 ms t1 12 0 8 ms Potentiometer 1 25 25 ms only on special module for commissioning aid none Using the lim1 to lim3 solder bridges the component can be limited on the Z4 add on module The limitation threshold is given in percent of the maximum permissible pulse current The following applies Solder bridge Limitation threshold none 100 lim1 10 lim3 30 Potentiometer 0 55 only on special module for commissioning aid 11 4 Modifications to the polarity module 11 4 1 Ready signal instead of Fault signal The P1 polarity module supplies among other things the Fault signal while the P2 polarity module supplies the Ready signal To convert from P1 to P2 connect the two soldering areas labeled Be on the polarity mod ule see fig 14 453 GHG H X ACCELERERA meere TEE EEBB BSS I tree BN 6661 0000 00B 063 INGOW d Fig 14 Solder bridges on the P1 and P2 modules GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 83 12 Documentation of the settings Copy this page and enter into the following tables the nameplate Tip infor
13. 3 4 Version with Z4 add on module GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 4 Operating Instructions 221058E V 1 5a 4 1 5 Encoder signals Gebersignale SUB D male connector X4 al oh yest Ee eee REN Reale ae eek A 23 4 2 Details about the signals 0 ccc cece eee eee 4 2 1 Auxiliary voltage Ouipuis 1 2cececes nn las 4 2 2 Setpoint through differential amplifier 2222222200 4 2 3 Switching inputs and switching outputs 4 2 3 1 Properties of the switching inputs and outputs 4 2 3 2 Switching input Controller enable 4 2 3 3 Switching input Reset fault 4 2 3 4 Switching output Fault or Ready 4 2 3 5 Switching output Overload i 4 2 3 6 Switching output Motor standstill or Power circuit hor ee ee oe ee Ree Pe OUe An me CO Rms oe RR 27 4 2 4 AAO outputs 4105 tienda sera 4 2 5 Encoder signals holding function 222222222220 4 2 6 Position Sensor user nee 4 2 7 Motor temperature sensor 00 cece eee eee 4 2 8 Sensor fault detection 00 ccc cece eee ee eee 4 2 9 Block protection 23238 a8 fv Sit a do ht Bist Sk Be 4 2 10 Fault Memory ta ee ee ee dees deeded Keine Klas Kelle AS Wilertace details rt ciel a oh ok ord oh de Se 4 3 1 Connector X2 control
14. 400 mA at 24 V Climatic category DIN EN 50178 opera tion storage transport Seen Setpoint value 10 V at 20 KQ 1 7 3500 r p m 2 V 1000 r p m Output speed monitor 1 V 1000 r p m Ra 10 KQ at speed range 10 500 r p m 0 67 V 1000 r p m 0 5 V 1000 r p m Output current monitor RA 10 kQ 10 V for maximum pulse current a a Frequency of current ripple 32 kHz a ee Load capacity of auxiliary voltages 10 mA each via 125 O PTC Permissible ambient temperature in con 50 C tinuous operation Recommended Wiring to Combicon Cross section en Minimum cross 1 0 mm 1 5mm 1 5 mm section 1 The load factor given is for calculating the number of amplifiers that can be operated by one common power supply For further details see Section 9 1 page 64 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 17 KSV 1 5 5 Ksvar o Ksvrao Ksvorso KSV 12 3 Servo amplifier compact compact compact compact actda design design design design pac sign Height without with mounting straps 240 275 mm 270 305 mm Depth without connectors Weight 35k 40k 3 3 Details 3 3 1 Design KSV 6HE servo amplifiers are manufactured in a compact design for screwing onto a mounting plate The amplifier is permanently installed in the housing Slots for the modules described below are provided Figure 1 shows the
15. 60 Operating Instructions 221058E V 1 5a 8 Commissioning For the initial commissioning proceed as described below Deviate Tip from this procedure only when you have gained enough experience with the devices 8 1 Precautions For commissioning you must always Danger e disengage the motor from the machine part to be driven so that its operation can be observed without endangering the machine e switch off the mains voltage when carrying out connections and Power off disconnections or replacing components in the amplifier or when wait gt 1 min working on the motor If you wish to proceed particularly cautiously because a high risk can be expected with a particular machine in the event of operating error e you should allow a small current only and thus a low torque Make a note of the actual setting of the rotary switch for current limiting see section 5 2 page 44 Set the rotary switch to a low value near the 0 position After commissioning restore the original setting of the rotary switch 8 2 Switching on for the first time Before switching on carefully check Check e to see whether all connections have been correctly established e to ensure that the controller enable input does not block the con troller to ensure that the limit switches are closed if the Z1 or Z4 add on module is being used Supply the setpoint using a potentiometer You can do this as shown in fig 7 using
16. D connector 4 1 4 Position sensor Lagegeber SUB D female connector X3 9 pin Pin Assignment 0 volt connect only in special cases 0 volt for motor temperature sensor Sine S 2 Cosine S 3 Excitation R 2 Motor temperature sensor if there is no sensor connect to 2 Sine S 4 Cosine S 1 Excitation R 1 Connect cable shield to the housing of the SUB D connector Ta Housin If the motors has no temperature sensor then connect pins 2 and 6 in the 9 pin connector GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 24 Operating Instructions 221058E V 1 5a 4 1 5 Encoder signals Gebersignale SUB D male connector X4 9 pin The 9 pin SUB D connector Encoder signals is only fitted when one of the encoder modules options G1 to G4 is installed Pin Assignment Switching input Hold only with option F1 Holding control loop 0 Volt Pulse output phase 1 U Pulse output phase 2 U Pulse output index pulse Ua Voltage supply encoder module 24 V only with 24 V version Pulse output phase 1 inverse U for 24 V vers not assigned Pulse output phase 2 inverse U for 24 V vers not assigned Pulse output index pulse inverse U for 24 V vers not assigned Housing Connect cable shield to the housing of the SUB D connector cE 4 2 Details about the signals This section describ
17. Instructions 221058E V 1 5a 15 Chapter 2 Servo amplifier 3 Technical specifications 3 1 Type code The type code clearly identifies a servo amplifier equipped in a certain way The type code also applies for devices of the 19 series Example gt KSV 3 10 N2 K4 Z1 P1 G1 FO E1 S0O WO U 3 10 N2 K4 Z1 P1 G1 FO E1 So wo Design Power no text 19 plug in module 1 5 5 compact design compact device 3 10 6 20 9 30 12 30 Power supply 320 V DC bus output 1 5 Ams rated current 5 A peak current 320 V DC bus output 3 Ams rated current 10 A peak current 320 V DC bus output 6 Ams rated current 20 A peak current 320 V DC bus output 9 Ams rated current 30 A peak current 320 V DC bus output 12 A rated current 30 A peak current NO no power supply external power supply KSN 8 M1 280014000 needed N2 power supply 3 phase 3 x 230 V standard Controller switching customer module and jumpers KO none device not ready for operation K1 2 pole pair motor speed control 3 500 min K2 2 pole pair motor speed control 7 000 min K3 2 pole pair motor current control K4 3 pole pair motor speed control 3 500 min Additional equipment through add on modules ZO none standard Zi limit switch ramp controller inhibit braking Z2 external current limiting rotation reversal Input output polarity polarity module PO switching towards zero standard P1 PLC compat
18. The pluggable customer module contains e all assemblies to be set during installation e assemblies for special features such as current control or speed control When an amplifier is replaced the customer module can be trans ferred to the new amplifier Readjustment is therefore not necessary The customer module is fitted in all versions To replace the customer module e remove fixing bolt and take out the module The customer module is located on the left Amplifiers equipped with different customer modules differ also in the arrangement of the jumpers on the amplifier board 6 2 Add on modules Zx Many additional characteristics can be implemented by means of add on modules The mode of operation of the Z1 Z2 and Z4 add on modules is described in the following further add on modules are available on request GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 49 6 2 1 Add on module Z1 Additional characteristics when fitted with the Z1 add on module e 2 limit switch inputs directional braked e controller enable braking in case of shutdown can be switched to non braking using a solder bridge e switching output internally selectable Motor standstill or Power circuit ready e peak current can be switched off by means of a solder bridge e ramp function can be switched on by means of a solder bridge Using
19. e have to leave the control cabinet at shortest possible distance must not be laid parallel to sensible control leads or unshielded mains cables lf parallel arrangement cannot be avoided ensure a distance of min 25 cm to the other cables GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 42 Operating Instructions 221058E V 1 5a 4 4 7 Motor choke Longer motor cables can overload the device and lead to intolerable high emission e If the motor cable is longer than 7 m install the appropriate motor choke supplied by us in the motor cable at the amplifier side For cable lengths order numbers and technical specifications of the chokes please refer to section 10 2 4 page 71 4 4 8 Shield connection of the external shunt resistor cable If an external shunt resistor is connected see section 9 2 5 page 66 for further details e use a shielded cable e connect the shield to the amplifier housing using the cable clamp provided as shown in fig 6 Earth the shield at the other end of the cable as well that is at the housing of the shunt resistor 4 4 9 Connection shielding and laying of the control leads These notes on connection shielding and laying of the control leads apply for the following three sections e Use only shielded leads e The SUB D connectors must have metal plated housings like the connectors supplied by us Th
20. not implemented these inputs and outputs switch towards zero 6 4 Encoder modules G1 to G4 Application of the encoder signals e Connection of positioning controls e Connection of a digital speed counter for monitoring the motor speed For all encoder modules 16 different pulse numbers can be set Encoder signals are available only if the encoder module is fitted For the various encoder modules see type code section 3 1 on page 15 e Standard G1 encoder module outputs like standard incremental encoder 5 volt push pull RS 422 interface with SN 75114 line driver phase 1 phase 2 index pulse and corresponding complement that is 6 lines outputs electrically connected to the amplifier circuit e G3 encoder module characteristics like G1 but in addition with adjustable index pulse The index pulse can be shifted in 256 steps within one motor revolution For further details see section 6 4 2 page 53 e G2 encoder module pulse output for 24 volts interface push pull outputs actively switching towards zero and towards 24 volts phase 1 phase 2 and index pulse without complement over 3 lines outputs electrically connected to the amplifier circuit outputs short circuit proof GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 54 Operating Instructions 221058E V 1 5a external supply as with incremental encoders wit
21. of ZVEI German electrical and electronic manufacturers association In the event of a defect or in case of absence of a guaranteed property the device is to be returned It is repaired in the works of the manufacturer free of charge or replaced at our discretion No other claims for damage which has not occurred in our device can be accepted No claims for indirect damage resulting from a malfunction of or defect in our device may be put forward Appendix C Table of faults If the drive does not work as desired the following table of faults can help you to detect and eliminate the cause of the fault No LED lights up No operating voltage for amplifier Check input voltage Green Ready LED flashes Controller enable or limit switch open Check cables connections limit swit ches No supply voltage this display only in case of Switch on operating voltage check option E1 emergency stop circuit Operating voltage too low Measure operating voltage must be gt 160 V With option E1 only External control circuit Measure voltage must be gt 19 V supply voltage too low or has dips from poor check for dips below 19 V ly filtered rectification Faulty auxiliary voltage Measure auxiliary voltage at connector for control signals 15 V and 15 V 10 Red Fault LED lights up and green Ready LED flashes Short circuit or earth fault in motor cables or Check wiring and motor for sh
22. of the shield and the marking of the terminals During operation under full load the chokes can reach a temperature Caution of over 100 C To ensure adequate heat dissipation they must be screwed to a sufficiently large metal plate Technical specifications Motor choke 038096010Z 038097010Z Permissible current 10A 12A For cable lengths when using 7 to 25m more than 25 m KSV 6HE amplifiers Internal design partially compensated 3 single chokes triple choke GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 73 zum Motor to the motor Q RR erate vom Verst rker a from el x BN3845 0000 00 A050 Housing height Internal choke Input Output on om y 0380970102 v 3 W Z Fig 8 Motor chokes GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 74 Operating Instructions 221058E V 1 5a Chapter 4 Notes for specialists 11 Modifications to the servo amplifier This section describes how the factory settings can be changed If you have changed the factory settings it is essential that you should Tip document the new settings in the table in section 12 page 82 11 1 Modifying the controller circuitry The controller circuit is defined by the name of the customer module see type code section 3 1 page 15 In some c
23. purpose of commissioning a special module is available on which e potentiometers for time constant and limitation threshold are mounted The special module is not suitable for normal operation because the potentiometers e can only be adjusted when the device is open Using the limit switch inputs the motor is e shut down depending on the direction of rotation and is actively braked by reversal PLC compatible The Controller enable input also e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 77 An additional switching output supplies e the Power circuit ready signal PLC compatible If the peak current rise is to be switched off a solder bridge must be installed e for further details see section 11 3 page 77 It is essential that you should document all changes in the table in section 12 page 82 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 53 6 2 4 Further add on modules Further add on modules are available as e customer specific solutions specially adapted to the application 6 3 Polarity module Px The function of the polarity module has already been described in section 4 2 3 1 on page 24 it ensures that the switching inputs and outputs are PLC compatible that is that they switch towards 24 V If it is
24. ready signal GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 81 11 3 4 Switching off the peak current rise To switch off the peak current rise e seta solder bridge on the add on module The position of the solder bridge is labeled see fig 11 12 or 13 e Impulsstrom Aus on the Z1 and Z4 modules e I on the Z2 module 11 3 5 Switching off active braking at controller disable If the motor should not be braked actively by reverse current when controller enable is suspended that is at controller disable e seta solder bridge on the add on module The position of the solder bridge is labeled see fig 11 12 or 13 e aktive Bremse Aus on the Z1 and Z4 modules e BR1 on the Z2 module 11 3 6 Activating the ramp function The ramp function is disabled as delivered It is activated e by setting a solder bridge on the add on module The position of the solder bridge is labeled see fig 11 or 12 e Sollwert Rampe Ein on the Z1 module e Ein on the Z2 module The Z4 add on module has no ramp function 11 3 7 Adjusting and limiting the component of the speed controller Using the t0 t1 and t2 solder bridges the time constant of the speed controller component can be adjusted on the Z4 add on module GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49
25. shunt circuit for accepting Ballast the energy returned when the motor is brak ed is switched on 9 2 4 Technical specifications of the power supply The technical specifications for the built in power supply are matched to the appropriate amplifier The following data for the built in power supply are only of interest in special cases GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 67 Powersupply SSS Mains connection via isolating transformer 3 x 230 V AC 10 Minimum mains voltage 3x 120 V 3x120VAC e Nominal bus voltage 320 V DC Min bus voltage a Response threshold of shunt regulator 380 V DC Maximum continuous braking power a Peak braking power 2 switching cycle 2 sec 1200 W Temperature switch off threshold for shunt resistor neun me Fuse ink shunt circuit 6x 32mm shunt circuit 6 x 32 Fuse ink shunt circuit 6x 32mm C awat 15 C awat E T 9 2 5 External shunt resistor CE EMC CE EMC Operating the unit as a braking controller where the motors mainly have to work against an external torque in braking mode requires an external shunt resistor dimensioned for the required power The internal resistor is insufficient for this The resistance of the external shunt resistor should lie between 27 Q and 33 Q The load capability has to be dimensioned according to the required braking power If
26. the auxiliary voltage outputs section 4 2 1 page 23 Recommended value 5 to 10 kQ If the supply voltage is now applied while the motor is connected e the green LED must light up e andthe motor must rotate at a speed corresponding to the setpoint applied GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 61 If this is not the case please check the connection once more Con sult the fault chart in the appendix as well Pins of the connector X2 encoder signals Steuersignale BN 6646 0000 00A 057 Fig 7 Setpoint potentiometer connection for commissioning 8 3 Setting the speed During commissioning the speed is set with the trimmer Speed Drehzahl for the given setpoint The speed control range is factory set for the used motor if Known see type code page 15 Kx option To obtain good speed resolution the lowest possible range for the application should be selected For conversion on site see section 11 1 1 page 73 8 4 Setting the feedback normal case How to proceed with a speed controller e for drives with limited paths e g carriage drives check the correct Caution functioning of the limit switches e engage the motor with the load to be driven e disconnect the higher level controller apply the setpoint using the setpoint potentiometer Be careful with drives with limited paths
27. the current limit atthe open device through the Current rotary switch see section 5 2 page 44 It is essential that you should document the new switch position in the table in section 12 page 82 if you have changed the factory settings Never set the continuous current higher than permissible for the motor Otherwise may damage the motor Should the motor require a higher current in order to work properly then it has not been dimen sioned adequately and a more powerful motor must be selected 8 8 Setting the offset Set the offset only when the device has reached operating tempera ture How to proceed e make setpoint zero the best way is to disconnect the setpoint cable from the source directly at the setpoint source and short circuit it e observe motor shaft e or observe pulse output if an encoder module is fitted e set offset trimmer so that the motor comes to a standstill as well as possible GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 64 Operating Instructions 221058E V 1 5a 8 9 Setting the holding control loop amplification Applicable only if the F1 function module Hold function for the hold ing control loop is fitted How to proceed e set the Hold trim potentiometer in accordance with the applica tion Excessive amplification leads to unevenness or vibrations in the drive To adjust the Hold trim potentiometer e remove
28. the limit switch inputs the motor is e shut down depending on the direction of rotation and is actively braked by reversal The Controller enable input also e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 77 An additional switching output supplies e the Motor standstill signal or e the Power circuit ready signal as a special version For conversion to the version with the Power circuit ready signal see section 11 3 page 77 If the peak current rise is to be switched off a solder bridge must be installed for further details see section 11 3 page 77 The ramp function is not active as delivered To activate it a solder bridge must be installed e for further details see section 11 3 page 77 The ramp rise can be set with a potentiometer on the add on module The potentiometer is marked with two ramp symbols e Left hand limit slope of 7 ms per 1 V of setpoint voltage e right hand limit slope of 70 ms per 1 V of setpoint voltage that means a setpoint jump of 10 volts leads to a linear rise of the internally effective setpoint within 0 7 seconds GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 50 Operating Instructions 221058E V 1 5a 6 2 2 Tip The ramp function is effective in all 4 quadrants It is also effective e when actuati
29. the mains voltage The servo amplifier must not be operated when it is open e pull the servo amplifier out of the chassis for about 40 mm The trim potentiometer on the customer module is now accessible GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 65 Chapter 3 Power supply and accessories 9 Power supply of the servo amplifiers 9 1 Load factor The load factor gives the number of amplifiers that can be connected You will find it in the technical specifications for the amplifiers and the mains transformers The following applies e When all amplifiers are being operated simultaneously at full load the sum of their load factors must not exceed the load factor of the mains transformer e When not all amplifiers are being operated simultaneously at full load which is frequently the case with servo drives the total load factor is the sum of the load factors of the amplifiers being oper ated simultaneously e When amplifiers are operated under part load only their load fac tors are reduced for purposes of the calculation in proportion to the part load Example e The KSV 3 10 compact design KSV 6HE amplifier has a load factor of 8 the 038100090Z mains transformer has a load factor of 40 this means that this mains transformer can run 4 of these amplifiers simultaneously at full load and a further amplifier at 37 of its l
30. therefore e either carry the central zero point on its own or e be connected to the central zero point via a shortest possible potential equilization cable of cross section 10 mm or more or better using a wide copper braiding earth strip GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 38 Operating Instructions 221058E V 1 5a Positioniersteuerung Position controller Sollwert quelle Steuersignale Control signals Gebersignale Encoder signais Resolver Lagegeber Position sensor Option ext Ballastwiderstand ext shunt resistor PE Bo zen am Verst f PE bolt of the amplifie Zentraler Nutipunkt im Schaltschrank Central zero point in the control cabinet PE BN 6661 0000 004 056 Fig 6 Connection directions GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 39 4 4 2 Potential equilization cables Figure 6 shows potential equilization cables They come from the central zero point of the control cabinet Their tasks are e they form alow resistance connection between various zero points e they reduce compensating current on the cable shield and thus prevent electrical faults The central zero point of the control cabinet is connected to the PE protective earth conductor This connection e ensur
31. with the data given the transformers can also be ordered by the user from a local manufacturer in order to save the comparatively high costs of post and packaging The transformers have separate primary and secondary windings CE EMC Autotransformers are not permissible 9 3 2 Connections The connections are clearly labeled on the terminals of the trans formers GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 6 co 9 3 3 Technical specifications of the mains transformers 038100050Z 038100070Z 038100090Z 038100130Z Mains connection primary 3 x 400 V Output voltage 3 x 230 V Load factor power supply dimensioning Rated output 1 2 kVA 2 5 kVA 3 5 kVA 7 5 Primary side back up fuses 3x4AT 3x6AT 3x 10AT 3x 16AT Wiring Recomm cross section 1 5 mm 1 5 mm 2 5 mm 4 0 mm Minimum cross section 1 0 mm 1 5 mm Dimensions 240 x 155 x 260 x 150 x 340 x 194 x 200 x 123 x En 175 The following applies for combinations of several amplifiers with one transformer e The load factors of the amplifiers working simultaneously at full load are added and the proportionally reduced load factors of the amplifiers working under part load are added The total load factor thus calculated determines the transformer required GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 71
32. 000 eee 8 6 Setting the feedback with Z4 add on module nnna anaana anaana 8 7 Setting the current limit nnana nannaa 8 8 Setting the OSCR u irrt 8 9 Setting the holding control loop amplification Chapter 3 Power supply and accessories 9 Power supply of the servo amplifiers 0 222 2 cece eee 9 Fama Bese factor ra Re te oe ear eae GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 6 Operating Instructions 221058E V 1 5a 927 PGOWEF SUDO cto t uke ne et eho ae det eae eS talee ede a eee Rak 9 2 1 DESIGN macae sr Sed ee See oe Hee ees Seas te 9 2 2 Sh ntregalator ete neat ae ee Sond ete eet 9 2 3 Er as er al ete pear tian atid an festa ae eee aera geet 9 2 4 Technical specifications of the power supply 9 2 5 External shunt resistor 3c wa a etek neh Be Mi Sard Be ce de 9 3 IMBINS TAM STORINEIS i cauaa ee 9 3 1 General information aa 9 3 2 CZONMECTONS ee Ae Re a Br de gol ace 9 3 3 Technical specifications of the mains transformers 10 AGGCESSOMES van as Ne a a ts tae aa ae A eae Vad a Sad Aue Sad tag 2 10 1 Available accessories and order numbers 2 00000 c ee eee 10 2 Description Gt accessories una se a Peg waa a sl 10 2 1 Connector sets and ss 3444444 ia air 10 2 2 Motor connection cables and 00 cece eee 10 2 3 Resolver Encoder connection cable
33. 1 75903 53 70 Operating Instructions 221058E V 1 5a 10 Accessories 10 1 Available accessories and order numbers Accessories Order number Connector set for KSV 6HE servo amplifier without encoder module option 0990660102 Connector set for KSV 6HE servo amplifier with encoder module option 0990660202 Motor connection cable 4 cores cross section 1 5 mm shield 535246 Z Motor connection cable 4 cores cross section 2 5 mm shield 535264 Z Resolver Encoder connection cable 8 cores twisted pair shield Motor choke with terminals and enclosure for medium length cables up to 25 m 038096010Z Motor choke with terminals and enclosure for longer cables more than 25 m 10 2 Description of accessories 10 2 1 Connector sets 099066010Z and 099066020Z The amplifiers are supplied without mating connectors The connector set comprises all necessary connectors e The connector set 0990660 10Z includes connectors for the version without encoder module GO two SUB D connectors with screwable housings and one 7 pole and one 10 pole Combicon female connector e The connector set 099066020Z for the version with one of the encoder module options G1 to G4 includes one additional SUB D connector with screwable housing The housings of the connectors are metallized and therefore shielded 10 2 2 Motor connection cables 535246 Z and 535264 Z The motor must be connected with a shielded cable Charac
34. 15 V Input setpoint E Input setpoint E Switching input Controller enable not assigned not assigned TE Switching input Reset fault 1 Input 24 V for modules P1 P2 and or E1 only if fitted 11 not assigned 9 0 Switching output Fault or Ready Analog output Speed monitor 14 15 Analog output Current monitor Housin Connect cable shield to the housing of the SUB D connector Switching output Overload Elche J GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 22 Operating Instructions 221058E V 1 5a 4 1 3 2 Version with Z1 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable Switching input Limit switch 1 Switching input Limit switch 2 Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted Switching output Motor standstill or Power circuit ready 12 Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A EE Analog output Current monitor Connect cable shield to the housing of the SUB D connector 4 1 3 3 Version with Z2 add on module Pin Assignment 1 0 Volt Output auxiliary volt
35. 4 3 3 Connector X4 encoder signals 5 volt version The following figure shows the interface details internal circuit at the 9 pin SUB D connector for the encoder signals section 4 1 5 on page 23 for the 5 volt version e viewing the connector from the front that is looking at the front panel If the option F1 Holding control loop is missing connection point 1 is not connected Pulse output index pulse Pulse output index pulse inverse Pulse output phase 2 Pulse output phase 2 inverse Pulse output phase 1 Pulse output phase 1 inverse OV schaitend 4 SPS kompatibel switching towards PLC compatible frei 6 Voltage supply 5 V Switching input Hold only with option F1 Holding control loop BN 6661 0000 00A 054 Fig 4 Encoder signals 5 volt version interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 36 Operating Instructions 221058E V 1 5a 4 3 4 Connector X4 encoder signals 24 volt version The following figure shows the interface details internal circuit at the 9 pin SUB D connector for the encoder signals section 4 1 5 on page 23 e for the 24 volt version e viewing the connector from the front that is looking at the front panel If the option F1 Holding control loop is missing connection point 1 is not connected Please note e the separate voltage supply
36. 4 pole pairs Gebermodul Synchronisation Encoder module Synchronization BN 6661 0000 00B 059 Fig 9 Location of the jumpers on the board 11 1 3 Current control instead of speed control Whether the servo amplifier is set for speed control or for current control is implemented on the customer module module K3 for 2 pole pair or K6 for 3 pole pair motors GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 77 To switch the servo amplifier from speed control as supplied to current control e insert a jumper in the Moment torque position Figure 10 shows the location of the jumper The following then applies e 10 V setpoint corresponds to the peak current set at the Current rotary switch S1 Bp a tal Eye Drehrichtungsumschaltung Haltekreis Verst rkung Carat g ks 3 Change direction of rotation nur bei Option F1 gt Hold circuit amplification a only with option F1 EA z 7 ur i B i D Anteil nicht best ckt B Sa D Adjustment not assembled R ckf hr Zeitkonstante z Steckbr cken t1 und t2 2 v Feedback time constant noge T Jumpers t1 and t2 Steckbr cke Stromregelung Moment BN 6661 0000 00C 060 Jumper current control torque Fig 10 Location of the jumpers on the customer module Current control is not provided with the customer module belonging to the Z4 add on
37. KSV 6HE Servo Amplifier for Brushless Motors KSV 1 5 5 compact design to KSV 12 30 compact design Compact design three phase power connection Built in RFI filter Operating Instructions 221058E V 1 5a 09 01 These operating instructions apply to e KSV 6HE KSV 1 5 5 compact design to KSV 12 30 compact design servo amplifiers compact design odd numbers with integrated power supply for three phase power connection and built in RFI filter e 038100050Z 038100070Z 038100090Z and 038100130Z mains transformers e accessories GEORGII KOBOLD AUGUST HEINE GmbH amp Co Fasanenweg 6 8 D 70771 Leinfelden Echterdingen Federal Republic of Germany Tel 49 0 711 7 59 03 0 E mail service georgii kobold de Fax 49 0 711 7 59 03 53 www georgii kobold de 2 Operating Instructions 221058E V 1 5a Versions of the document 20 11 96 V 1 1 Pol German V 1 4 translated into English 11 03 97 V 1 4 Pol revised adapted to Printer 5 Si MX 28 05 98 V 1 4e StP English terms corrected Georgii Kobold dictionary revised and enhanced following German V 1 4d addi tional data speed monitor cable length motor choke corrected text figure 11 in section 11 3 changed new version of type code integration of figure files adapted to WP 8 PS Printer prepared for pdf conversion revised and enhanced following German V 1 4e new versions of add on modules Z1 Z2 revision of sections 11 12 Section 6 2 Fig 10 11 and Table Documenta
38. O Oo Z4 Modul EEE EN N l Zeitkonstante ol time constant Peak current off gt jea laele 1 rile g ktiv gt I Aktives Bremsen aus P s Bremse Aus H Sp Active braking off SF m Begrenzungsschwelle VIENNA Limitation threshold A i i un ine ojo ll n Kiil 1 7 ral e e a n X Potentiometer nur auf Sondermodul BN 6661 0000 00A 064 Potentiometer on special module only Fig 13 Solder bridges on the Z4 module 11 3 2 Former versions of modules Z1 and Z2 The following description of the Z1 and Z2 add on modules applies to the devices delivered now Former versions of the add on modules have other jumpers or fewer functions They have other layouts as the modules shown in fig 11 and 12 If your amplifier is fitted with other modules please contact us so that we can send you matching docu mentation 11 3 3 Power circuit ready signal instead of Motor standstill signal If one of the Z1 or Z2 add on modules is fitted the switching output provides the signal Motor standstill factory setting Modify by setting a solder bridge on the add on module e without solder bridge Motor standstill signal e with solder bridge Power circuit ready signal The position of the solder bridge is labeled see fig 11 or 12 e Signal End Bereit on the Z1 module Be on the Z2 module The Z4 add on module provides the Power circuit
39. Operating Instructions 221058E V 1 5a 4 3 2 Connector X2 control signals PLC compatible The following figure shows the interface details internal circuit at the 15 pin SUB D male connector for the control signals section 4 1 3 2 page 21 e for the version with polarity module PLC compatible version e forthe version with Z1 add on module e viewing the connector from the front that is looking at the front panel In the version without the Z1 module section 4 2 1 1 the unassigned inputs and outputs are not connected Switching input 100ka ka u O Limit switch 2 nF Zw 47ka Analog output Current monitor One I nF 100kn 7ka 7 12V 47ka 100ka Id ate Switching input Limit switch 1 Switching output Overload Switching input Con troller enable Analog output Speed monitor Input setpoint E Switching output Fault or Ready Input setpoint E Switching output Motor standstill or Power circuit ready Output auxiliary voltage 15 V Input 24 V for polarity module and if option E1 Output auxiliary voltage 15 V Switching input Reset fault 100ka paa fod 10nF 0 Volt BN 6661 0000 00A 053 Fig 3 Control signals PLC compatible interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 35
40. age 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable Switching input Setpoint reversing Analog input Current reduction Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted Switching output Motor standstill or Power circuit ready 12 Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A Analog output Current monitor Connect cable shield to the housing of the SUB D connector GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 oo Operating Instructions 221058E V 1 5a 2 4 1 3 4 Version with Z4 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable Switching input Limit switch 1 Switching input Limit switch 2 Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted Switching output Power circuit ready Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor A Analog output Current monitor Connect cable shield to the housing of the SUB
41. amended by 93 68 EWG of exclusive responsibility of company GEORGII KOBOLD Postfach 10 01 54 D 70745 Leinfelden Echterdingen Fasanenweg 6 8 D 70771 Leinfelden Echterdingen AUGUST HEINE GmbH amp Co Telefon 0711 75903 0 Fax 0711 7590353 The signers are Schilhab head of quality department Schramm technical director The following harmonised Standards are used EN 55011 1991 class A and B DIN VDE 0875 part 11 DIN EN 50082 1 1994 DIN EN 50082 2 1995 DIN pr EN 50178 1994 Cede A technical documentation is completely available An operation instruction is available in the original version O in the native language of the USEF ccc cesesscssessesssecsecseccesscsecseesscssenscauceasseecsecsesessensasesasanss Dok Nr Ausgabestand ersteilt ge ndert Seite Schilhab Datum Signum 9977 10 4 31 4 18 Januar 2000 1 Mrika Datum Signum 18 Januar 2000 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 85 Appendix B Terms of warranty warrants that the device is free of material and production defects In quality assurance measured values are recorded in the final inspection and testing The warranty period begins with delivery It lasts for 12 months Delivery is based on the General Terms of Delivery for Products and Services of the Electrical Industry green terms
42. an about 4 seconds at maximum current the drive is shut down and the fault is reported through the Fault output and through the Fault LED flashing GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 31 4 2 10 Fault memory The following faults do not lead to damage but to a machine shut down and to a fault signal e overheating of the power circuit e overheating of the motor if it is fitted with a temperature sensor e short circuit between one or more motor leads and earth or protec tive earth conductor e short circuit between the motor leads e faulty internal auxiliary voltage e operating voltage too high or too low e customer module absent e fault in resolver or its supply leads e motor blocked for longer than about 4 seconds External fault signal except in the case of overheating see below e Fault switching output switches to 1 and e Fault LED lights up The fault is stored exception Operating voltage too low A fault signal can only be reset when the cause of the fault has been elimi nated To reset e the switching input Reset fault is switched briefly from 0 to 1 This does not reset resolver faults Or e the operating voltage is switched off and then on again or the supply voltage in the case of the external supply of the contro
43. ases it is implemented on the customer module itself in some cases through jumpers on the board Electronics specialists can change the controller circuitry on site if required 11 1 1 Speed control range The speed control range is determined using the option K K1 K2 K4 K5 KA and KB However it is not implemented on the customer module but by means of jumpers on the board Modify by relocating the jumpers on the X 14 field labeled DREHZAHL speed 2 jumpers must always be placed at the same time The positions are marked 1 and 2 Figure 9 shows the location of the jumpers and the locating options The speed control range is factory set for the used motor if Known see type code page 15 Kx option To obtain good speed resolution the lowest possible range for the application should be selected Relocating the jumpers changes the offset of the amplifier e If no add on module is fitted the offset can be reset using the offset trimmer on the front panel If the amplifier is fitted with an add on module the offset must be readjusted in the manner described below To do this the offset trimmer on the front panel is required as well as the potentiometer inside the device which is marked n OFFSET It is located at the very top behind the front panel see fig 9 There are two options for offset adjustment e With measuring device Switch off the controller enable GEORGII KOBOLD D 70771 Leinfe
44. ble on which e potentiometers for the time constant and limitation threshold are mounted The special module is not suitable for normal operation because the potentiometers e jut out of the amplifier and e can only be adjusted when the device is open The locations of the solder bridges on the Z4 add on module are indicated in section 11 3 page 77ff How to proceed with a speed controller with component limitation e check limit switch connect motor to load as above e switch off component close t0 solder bridge e adjust P controller turn the feedback trimmer Verst rkung clockwise until the motor runs loud and rough then turn back the trimmer approx one turn GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 63 set limitation threshold to 20 close lim2 solder bridge e switch on component open tO solder bridge e apply reversing motion by position control optimize step response by reducing the time constant t1 and t2 solder bridges e select limitation threshold disturbing overshoot decrease limitation lim1 following error increase limitation lim3 optimize time constant again if necessary 8 7 Setting the current limit Tip Factory setting for delivery of drive packages amplifier and motor Current limit is set to the rated current of the motor For changing
45. d LED lights up continuously green LED flashes Amplifier motor has cooled down temperature sensor has switched back fault can now be reset Yellow Overload LED lights up Motor is overloaded or blocked Check mechanical system Current limit set too low Compare nominal motor data with set ting Motor is not connected or a motor lead is Check motor wiring interrupted Motor is at a standstill with power Setpoint missing setpoint lead interrupted or Check setpoint lead connection mt drifts slowly but cannot be controlled short circuited Offset adjustment incorrect Adjust offset potentiometer One setpoint lead is open shield is not cor Check setpoint lead It must be con rect motor is not earthed transformer neutral nected on one side to setpoint source point is not earthed zero volts Check shield check zero Motor runs slowly at setpoint zero Disturbing noise when motor is run ning humming whistling chirping Motor runs in the wrong direction Setpoint inputs transposed Transpose E and E or set jumper on customer module Motor runs too slowly or too fast at Speed standardization incorrect Set to desired speed using Speed given setpoint potentiometer adjust speed control range if necessary section 11 1 1 Speed adjustment also influences feedback Adjust feedback setting Feedback too hard Motor runs rough or soft aft
46. dingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 20 Operating Instructions 221058E V 1 5a 4 Connection Assignment of connectors and details 4 1 Connector assignments For details concerning connections and the optional modules please refer to the later sections 4 1 1 Motor and operating voltage Combicon connector X1 Marking Assignment Motor connection U o Q am Motor V Motor connection V Motor connection W PE PE for motor cable PE from power supply Us Negative pole of bus voltage from power supply Positive pole of bus voltage from power suppl 4 1 2 Mains and operating voltage Combicon connector X5 Marking Roxi R Either connect external shunt resistor between Rex and R or mt install jumper from Rim to Rg Jumper is factory set R Phase 1 secondary side transformer Phase 2 secondary side transformer Phase 3 secondary side transformer i L1 L2 L3 PE Power safety ground PE PE to amplifier Us Negative pole of bus voltage to amplifier U Positive pole of bus voltage to amplifier GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 2 4 1 3 Control signals Steuersignale SUB D fem connector X2 15 pin 4 1 3 1 Version without add on module Pin Assignment 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage
47. e P1 and P2 modules 00002 eee GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 9 Chapter 1 General information 1 Preliminary remarks 1 1 About this description These operating instructions explain the characteristics connection installation and setting up of e the KSV 6HE servo amplifiers in the version with built in power supply and built in RFI filter e the mains transformers for the connection to 3 x 230 V three phase current e accessories e and provides notes for specialists The operation instructions are divided up into 4 chapters and 12 sections After the safety instructions and the technical specifications the connection of the servo amplifier is described In some cases you will require details which are not explained more fully until later It is therefore important that you should read the sections important for your application in a sequence commensurate with your previous knowledge The chapter Notes for the specialist describes changes which can be carried out on site by specially qualified electronics experts at their own risk providing that all precautions have been taken 1 2 KSV 6HE Servo Drive Packages KSV 6HE servo drive packages in 19 design consist of e the brushless motor with coupled resolver as a speed and position sensor e the analog servo amplifier with built in po
48. e of the connected machine part depends on the moment of inertia of the drive and on the mass of the part to be moved e g of the machine carriage Example assumed values Braking time for active braking limit switch or zeroing of setpoint 0 1 seconds e linear braking from a velocity of 10 meters per minute e results in a braking distance of approx 8 millimeters This means that with the values of this example the setpoint must be set to zero at least 8 millimeters before the mechanical limit stop if the stop is not to be struck hard 7 3 Emergency stop and safety regulations The safety regulations to be derived from the machinery directive do not allow safety functions to be carried out by electronic circuits since the risk of failure cannot be fully ruled out e An emergency stop or any other safety circuit must not only be effected by zeroing the setpoint or by using the controller enable With emergency stop switches or other functions important for the safety of persons or property it must therefore be ensured that the shutdown e is effected directly by positively driven contacts which shut down either the motor supply line or the power supply to the amplifier For further details see the relevant regulations including DIN VDE 0113 EN 60204 Safety of machines electrical equipment in ma chines GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
49. ed of the motor in good time before the position so that later no more than a single revolution will be needed to brake the motor e a sensor gives the hold command at the position e the motor brakes and the internal holding control loop recalls it to the switching point of the position sensor In many cases the holding control loop makes a magnetic brake on the motor superfluous If the safety aspects derived from the machine directive require the brake however it cannot be replaced by the holding control loop 6 5 2 Field weakening mode F2 In AC servo drives the maximum speed that can be reached can be increased at reduced torque by shifting the phase of the motor current at higher speeds Since the phase shift results in a weakening of the torque forming part of the magnetic rotary field this operating mode is also called Field weakening mode by analogy with the terms used for DC drives The F2 function module Field weakening mode shifts the phase of the motor current in the desired direction from a predefined speed depending on the direction of rotation This predefined speed is fac tory set on a trim potentiometer on the module This setting must not be changed GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 57 6 6 Option E1 external supply of control circuit In the standard version the E1 module External sup
50. er 4 2 3 1 Properties of the switching inputs and outputs Two possible polarities by means of polarity module P module see also type code e Switching towards zero when no polarity module is used PO in type code e Switching towards positive PLC compatible when polarity module is used P1 in type code Positive is either the externally supplied PLC operating voltage 15 35 V preferably 24 V or the internal auxiliary voltage of 15 V The outputs are applied via PTC resistors and are thus short circuit proof Each output can operate a miniature relay max 30 mA at max 35 V e The coil must be cleared by a diode The specifications are shown in the following table GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 26 Operating Instructions 221058E V 1 5a Technical data of the Switching PLC compatible version switching inputs and towards switching outputs zero version With internal With externally auxiliary voltage supplied PLC voltage Input resistor switching 22 KQ to 2 2 kQ 2 2 KQ towards input wards 15 V towards 0 V oV Output resistor switching 125 Q to 1250 125 Q towards output wards 0 V towards 14 V PLC voltage Maximum permissible load current Logic level for logical 0 open or open or lt 2 V gt 13 V Logic level for logical 1 lt 2 V Permissible PLC signal 15 35 V voltage 4 2 3 2 Switching inpu
51. er connection cable 535245 Z e 8 core shielded e twisted pair e suitable as trailing cable GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 72 Operating Instructions 221058E V 1 5a Technical specifications Res Enc connection cable 535245 Z Cable code KWLiFPETP C 11YP OB 2 x 4 x 0 25 mm Single core 0 25 mm C Litz bare 19 x 0 127 mm Structure 4 pairs stranded with short length of twist Color coding white brown green yellow grey pink blue red Total shield Cu mixed braiding tin coated coverage 85 Total sheath Polyurethane orange RAL 2003 Diameter 6 4 0 3 mm Bending radius for single min 80 mm bend fixed installation Rolling radius for continuous min 150 mm altern bending trailing use Operating temperature 40 bis 80 C fixed installation 30 bis 70 C trailing use 10 2 4 Motor chokes 038096010Z and 038097010Z Longer motor cables can overload the device and cause unacceptably CE EMC high interference emission e For this reason a motor choke must be fitted in the motor cable if Check the cable is longer than 7 m For the correct choke please refer to the following table Both motor chokes are supplied in a steel plate housing ready for installation and connection They are supplied with terminals and with cable clamps Figure 8 shows the mounting dimensions the connection please note the connection
52. er speed adjustment at speed potentiometer Motor runs roughly or vibrates Turn Feedback potentiometer to the left until motor runs smoothly Motor shaft can be moved out of posi Feedback too soft Turn Feedback potentiometer to the tion by hand at standstill right until motor runs roughly vibrates then to the left until motor runs smoothly Motor Bee to turn slowly at setpoint Zero loop e g between amplifier zero and Use differential input see section zero Bee increasing load control zero 4 4 10 page 42 Supplement for KSV 6HE with F1 option Holding control loop Motor is at a standstill with power with Holding control loop accidentally activated Check Hold signal connection out drift cannot be regulated Motor shaft can be moved by hand at If holding control loop is activated Holding Adjust Hold potentiometer standstill control loop too soft End of Operating Instructions 221058E GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
53. ere the shield is connected with a low resistance to the hous ing via the strain relief e This allows you to achieve the necessary large area earth connec tion for the shield and to avoid earthing the shield using twirled strands pigtails of the shield Do not lay control leads parallel to motor cables GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 43 4 4 10 Setpoint connection When connecting the setpoint source top right in fig 6 e ensure that earthing and shielding have been correctly carried out to avoid faults at the amplifier input to prevent faults at the setpoint source e First precaution shield the setpoint lead Connect the shield on the setpoint source to the appropriate zero In particularly critical cases e to avoid sheath current install an potential equilization cable on the shield parallel to the setpoint lead with a cross section of at least 2 5 mm Or e apply only a high frequency shield on the side of the setpoint sour ce using a low induction capacitor e g 10 nF 400 V Always use the differential input Tip ae e this prevents zero loops that is the coupling of interference via the input zero Apply the setpoint at input E Connect input E with zero at the setpoint source 4 4 11 Connection of the encoder signals Figure 6 top right shows the connecti
54. es details about the signals named in the connec tion assignments The sequence corresponds to the sequence of connectors given above 4 2 1 Auxiliary voltage outputs The two auxiliary voltage outputs are primarily for connecting an external setpoint potentiometer for initial tests see fig 7 page 60 The auxiliary voltage outputs are led via PTC resistors and therefore short circuit proof For further details see the table Technical specifi cations page 15 The auxiliary voltages are only roughly stabilized their voltage values vary within the given tolerances when the ampli fier output is placed under load 4 2 2 Setpoint through differential amplifier The setpoint input is applied to a internal differential amplifier with the two inputs E and E e When correctly connected see section 4 4 10 page 42 you avoid faults caused by neutral loops with the differential input GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 25 i A positive setpoint E positive against E results in a clockwise Tip rotation of the motor shaft when looking towards the bearing plate This applies if e the costumer module has not been modified 4 2 3 Switching inputs and switching outputs Through the switching inputs and switching outputs the servo ampli fier works together with e with external switches e with the primary controll
55. es protection of the operating and maintenance personnel in Danger case of electrical faults Due to leakage current from the built in RFI filter the potential equilization cable from the central zero point to the PE bolt of the amplifier must in accordance with DIN VDE 0160 like the protective earth conductor have a cable cross section of at least 10 mm Cu The other potential equilization cables must have a cross section of at least 2 5 mm or preferably 4 mm It is true that drives can run without potential equilization cables without shielded cables and without compliance with safety regula tions However this e is contrary to elementary safety requirements Do not e violates statutory regulations and endangers the safety of persons endangers the operational safety of the system and may lead to faults from and in other parts of the system 4 4 3 Mains connection The mains transformer e is chosen corresponding to the technical specifications of the trans formers in section 9 3 3 page 68 The connections are clearly labeled at the terminals of the transform ers The cable between mains and the transformer e is led through line side fuses see the table on page 68 for values GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 40 Operating Instructions 221058E V 1 5a e must have an adequate cross section for the chosen mains tran
56. g voltage has been reached again GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 33 4 3 Interface details 4 3 1 Connector X2 control signals switching towards zero The following figure shows the interface details internal circuit at the 15 pin SUB D male connector for the control signals section 4 1 3 2 page 21 e for the version without polarity module switching towards zero e for the version with Z1 add on module e viewing the connector from the front that is looking at the front panel In the version without the Z1 module section 4 2 1 1 the unassigned inputs and outputs are not connected Switching input Limit switch 2 Analog output Current monitor Switching input Limit switch 1 Switching output Overload 5 Switching input Con troller enable Analog output Speed monitor Input setpoint E Switching output Fault or Ready Input setpoint E Switching output Motor standstill or Power circuit ready Output auxiliary voltage 15 V Input 24 V if option E1 Output auxiliary voltage 15 V Switching input Reset fault 0 Volt BN 6661 0000 00A 052 Fig 2 Control signals switching towards zero interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 34
57. h 24 V 20 e G4 encoder module characteristics like G2 but in addition with adjustable index pulse The index pulse can be shifted in 256 steps within one motor revolution For further details see section 6 4 2 page 53 Ti The following applies for all encoder modules p e When the motor shaft rotates clockwise looking towards the bear ing plate phase 2 lags behind phase 1 This corresponds to the definition with the output impulses of an incremental encoder e With all pulse figures the index pulse like standard incremental encoders has half the width of the pulses from phase 1 and phase 2 6 4 1 Pulse setting A rotary switch with 16 positions on the encoder module is for setting the pulse number The following applies Switch setting Pulses per per Switch setting setting Pulses ee m B a a a as a ee ee el BEA factory setting HH errr specially intended for speed display with frequency meter Gives direct revolutions per minute if the display is set to Hz It is essential that you should document the switch position in the Tip table in section 12 page 82 if you have changed the factory settings 6 4 2 Index pulse adjustment With the G3 and G4 encoder modules adjustable index pulse the position of the index pulse can be shifted within a motor revolution For this purpose the encoder module has two rotary switches Rough and Fine and three LEDs
58. her details see section 10 2 3 page 70 e connect the shield using the strain relief of the metal plated SUB D housing this allows you to achieve the necessary large area earth con nection for the shield and to avoid earthing the shield using twirled strands pigtails of the shield e Do not connect the shield at the motor side 4 4 13 Connection of the motor temperature sensor The motor temperature sensor is connected via the cable for the position sensor and its connector e If the motor has no temperature sensor the two connecting points provided for this purpose in the 9 pin male connector of the position sensor are connected to each other GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 45 5 Adjustment and display elements The adjustment and display elements contained in all KSV 6HE ver sions are described here Special information for the versions with expansion modules is given with the appropriate options 5 1 Trim potentiometers 3 trim potentiometers are accessible on the front panel of the ampli fier Their significance is in the sequence from top to bottom Schematic en Effect with clockwise Feedback P Amplification speed Verst rkung control circuit Speed Offset If the module F1 for activating the holding control loop is fitted the trim potentiometer Hold Halten
59. ible fault output Additional equipment through encoder modules incremental encoder emulation GO no pulse outputs standard G1 pulse outputs 5 V push pull signals RS 422 G2 pulse outputs 24 V push pull signals Additional equipment through function modules FO none standard F1 holding control loop Supply of control circuit cannot be refitted EO internal supply from DC bus standard Special equipment customization so none standard S2 reinforced terminals 20 A Front panel WO standard For further details on the modular expansion options please refer to section 6 page 47 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 16 Operating Instructions 221058E V 1 5a 3 2 Technical specifications KSV 1 5 5 Ksvar o KSv6 20 Ksvorso KSV 12 3 Servo amplifier compact compact compact compact Ser design design design design pac sign Mains connection via isolat transformer 3 x 120 230 V AC 10 Bus voltage 320 V DC Minimum bus voltage 160 V DC Maximum permissible bus voltage 420 V DC Maximum continuous current rms value 1 5A 3A Maximum peak current crest value 10A 20A 30A 30A Current limiting adjustable from to 0 4 1 5 A 0 8 3 A 1 5 6 A 2 3 9 A 3 12 A Load factor in conjunction with mains 4 8 transformer T i E1 external control circuit 24 V DC 15 20 approx
60. ition sensor The input for the position sensor is dimensioned for the common servo drive type e 2 pin resolver 1 pole pair with a gear ratio of 1 0 5 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 30 Operating Instructions 221058E V 1 5a 4 2 7 Motor temperature sensor At the Position sensor connector the e motor temperature sensor is also connected e Ifthe motor has no temperature sensor the two connections 2 and 6 in the male connector must be jumpered The following are suitable as temperature sensors e Thermo switch which opens in case of overheating or e PTC resistor which raises its value to over 2 KQ in case of over heating 4 2 8 Sensor fault detection The position sensor resolver and its supply leads are monitored e If the resolver breaks down or e if one or more resolver leads are interrupted the drive is shut down immediately the fault memory is enabled the fault is reported through the Fault output and displayed by the Fault LED flashing With this fault the fault memory cannot be reset through the Reset fault input but only by switching the operating voltage off and on again or the supply voltage in the case of the external supply of the control circuit module E1 4 2 9 Block protection If the motor is blocked this is not a case of normal operation e If the motor is at a standstill for longer th
61. l circuit module E1 This also resets resolver faults Before switching back on wait until the Fault LED has gone out In the case of the external supply of the control circuit mod ule E1 if the supply voltage is switched off and then on again to reset the fault the position information stored in the control circuit is deleted External fault signal in the case of overheating power circuit or mo tor e Fault switching output switches to 1 and e Fault LED flashes as long as the temperature limited is exceeded GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 32 Operating Instructions 221058E V 1 5a lights up constantly when it has cooled down below the tempera ture limit Only then can the fault memory be reset The operating voltage may reach an excessively high value e ifthe motor is braked and the shunt regulator is missing For further details see section 9 2 2 page 65 f the operating voltage is too high the fault is stored If the voltage falls below the minimum permitted operating voltage or in the case of the external supply of the control circuit module E1 if it falls below the minimum permitted supply voltage e this is reported as a fault through the Fault switching output and the Fault LED This fault is not stored e it disappears when the correct operatin
62. l be described in the follow ing 6 5 1 Hold function F1 Disadvantages of conventional servo drives when the motor is at a standstill e If the controller enable is canceled the motor is at a standstill without torque e Ifthe torque setpoint is made zero the motor comes to a standstill with holding torque but due to the offset drift of the speed control ler it rotates slowly in the one or the other direction These disadvantages can be avoided if the F1 Hold function module is used In many cases the magnetic brake which is otherwise neces sary is no longer required GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 56 Operating Instructions 221058E V 1 5a Mode of operation of the hold function when the hold command is entered at the Hold input through logical 1 then e the external setpoint is switched off internally e The internal holding control loop digitally saves the position of the motor at the moment the command was given e The holding control loop returns the motor to this position and holds the motor in this position with its full torque The holding control loop monitors the position within one revolution If the motor has required more than one revolution to come to a standstill from a higher speed due to inertia these revolutions are not recalled Example of a simple positioning solution e A pre sensor reduces the spe
63. lden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 75 measure the voltage at the analog output Speed monitor and then make this voltage zero using the potentiometer n OFF SET e Without measuring device Make the setpoint zero before changing the jumpers adjust the offset with the trim po tentiometer on the front panel so that the motor comes to a standstill as good as possible Switch off the mains only then change the jumpers switch on again Then adjust the offset again but this time using the potentiome ter n OFFSET inside the device Note If this adjustment is not carried out in this way when the Z mod ule is in position the tacho window could not be switched on when the motor is at a standstill and therefore the amplifier would not be en abled at a standstill 11 1 2 Number of motor pole pairs The adaptation of the number of motor pole pairs is determined by the option K K1 K2 K3 K4 K5 K6 KA and KB It is realized by jump ers on the board Modify by relocating the jumpers on the field X 13 There are 4 positions for each jumper The positions are labeled 2PP 4PP Seli and Sel2 Figure 9 shows the location of the jumpers and the locating options Jumper in position 2PP motor with 2 pole pairs no jumper plugged in motor with 3 pole pairs e jumper in position 4PP motor with 4 pole pairs
64. lty or e disabled then the Power circuit ready output switches to O For further details on fault monitoring please refer to section 4 2 10 Fault memory page 30 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 29 4 2 4 Analog outputs The analog output Speed monitor supplies a e voltage proportional to the motor speed the polarity corresponds to the direction of rotation for example to connect a measuring instrument to display the speed The analog output Current monitor supplies a e voltage proportional to the current flowing in the motor the polarity corresponds to the direction of the torque Preconditions e Motor correctly connected Motor operating within the voltage limits of the amplifier For values of both outputs see table Technical specifications on page 15 4 2 5 Encoder signals holding function Encoder signals are available e only when a encoder module is in position Encoder modules are available e with 5 volt outputs and e with 24 volt outputs For further details see section 6 4 page 52 The Hold switching input is only available e when the Holding function module is in position The motor can then be shut down with holding torque without the motor shaft continuing to turn slowly For further details see section 6 5 1 page 54 4 2 6 Pos
65. mation and all of the settings and modifications you have carried out Keep these sheets with your documentation If you should later require a similarly configured or modified device send us a copy of these tables Nameplate information In case of multiple devices Device No Current setting the switch setting is marked with a cross Lol 2 3 al 5 e 7 e 9 af el cl oJ ef F Encoder pulse setting the switch setting is marked with a cross 1 F231 al sl sl 7 81 of a B cf oJ E Speed control range the range set is marked with a cross 3 500 min open 7 000 min 1 10 500 min 2 14 000 min 1 2 No of pole pairs set number of pole pairs is marked with a cross 2 pole pairs 2PP 3 pole pairs open 4 pole pairs 4PP Current control instead of speed control marked with a cross if jumper is set Jumper in position torque Moment Standard direction of rotation set direction of rotation is marked with a cross SHE Reset time the set time constant is marked with a cross 3 3 ms open 6 6 ms t1 10 ms t2 14 ms t1 12 Modifications to Z1 Z2 add on module closed solder bridges marked with a cross Power circuit ready Signal End Bereit Be Peak current off Impulsstrom Aus I Active braking off aktive Bremse Aus BR1 Ramp function on Sollwer Rrampe Ein Ein Modifications to Z4 add on module Feedback time co
66. may therefore e install e commission e maintain and e service these units They must read these operating instructions carefully beforehand and always follow the safety instructions while working 2 3 Use for the intended purpose The servo amplifiers have been developed manufactured tested and documented 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 manner described here and that the safety regula tions mentioned are adhered to i When using the devices use for the intended purpose includes com Caution pliance with the relevant regulations with respect to safety machinery directive and electromagnetic compatibility EMC directive Dispose of the apparatus at the end of its useful service life in accor dance with the current regulations can accept no liability for direct or indirect damage resulting from abuse of the devices 2 4 Protective earthing On account of leakage current from the built in RFI filter the protec tive earth conductor in accordance with DIN VDE 0160 must e either be run double to the amplifier or e have a cable cross section of at least 10 mm Cu Operation using an earth leakage circuit breaker is not possible e due to the leakage current of the RFI filter and e since in case of earth leakage a part of the direct curren
67. module 11 1 4 Changing the direction of rotation The assignment of the direction of rotation to the polarity of the set points is described in section 4 2 2 page 23 If it is to be changed so that it corresponds to the direction of rotation assignment of the Georgii Kobold 3 units high servo amplifiers e then relocate the jumpers on the customer module from position 6 HE to position 3 HE GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 78 Operating Instructions 221058E V 1 5a 11 2 Modifications to the feedback As standard the speed control is realized as Pl controller 11 2 1 Reset time The customer module has two additional capacitors with which the reset time of the speed controller can be increased These capacitors can be connected to the existing capacitor by means of the jumpers ti and 22 Figure 10 shows the location of the jumpers The following applies Solder bridge Reset time 6 6 ms 10 ms t1 12 standard factory setting With the Z4 add on module the time constant can be adjusted on the add on module itself 11 2 2 D circuit If a D circuitry is to be connected to the speed feedback PID con troller the components C 2 and R 10 must be installed on the custo mer module Their locations are printed on the board see fig 10 The values must be determined by experiment 100 nF and 100 kQ can be regarded as guide values
68. mounting dimensions All connections trim potentiometers and LEDs are located at the front panel e motor and operating voltage input 7 pin Combicon connector e mains connection operating voltage output shunt resistor 10 pin Combicon connector e control signals 15 pin SUB D female connector e output for encoder signals 15 pin SUB D male connector present only if encoder module is mounted e position sensor resolver 9 pin SUB D female connector The devices for continuous currents up to 6 A e work with natural convection The devices for continuous currents of 9 A and higher e have built in fans with internal voltage supply e have somewhat larger dimensions than the devices up to 6 A see table Technical specifications and fig 1 The power supply is located in the right hand side panel It can be removed together with the side panel This is necessary if you wish to work on the amplifier GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a H H3 f cm af NHooonooooo memwa ac gt iT BN 6661 0000 00A 051 dimension mm order number servo amplifier B H H H KSV 1 5 5 compact design 85 275 260 255 Fig 1 Mounting dimensions GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Inst
69. n re el eae Oa Re U a a A RA ES a ae 6 Modular fittings and expansions 0 000 eee G61 BUstiemermodule Kx ineine ee Busse re 5 2 Add on MOdUIESIZX zur 8 2 bere Bee Meee eee ed 6 2 1 Add on module ZT er aaa 6 2 2 Add mmod le Z2 a Tan E EEEE EE ENEE E NE E 6 2 3 Add on module ZA 000 cece 6 2 4 Further add on modules 00 nennen 8 3 Polarity module PX 2 22222 eee serge ee eee eee ee eee ee eee as 6 4 Encoder modules G1 to G4 0 0 es 6 4 1 PUIG Se UIs 6 sey te ese eae eo heen ee meer ce eee eee 6 4 2 Index pulse adjustment lt ses veseseteveu duet ev et dese ae 8 3 Function module FX session rare 6 5 1 Hold function Ei sans ea as h Aaa Sis es ig res Gas Sa 6 5 2 Field weakening mode F2 200 cece ee eee 6 6 Option E1 external supply of control circuit 000005 7 Shutting down the motor and safety shutdown 7 1 SMUINGIOOWRMODIOMSH ur ee ie Meare tated Seana 7 2 Estimating the braking distance 0002 eee eee 7 3 Emergency stop and safety regulations 02000005 8 GOMMISSIONIAG neran ea oa e res Bed R a E15 AOT E at E AAT E EA ee 8 2 Switching on for the first time ass Se 5 crac Pete Sore Pete ie See as 8 3 Setting the speed uses ee ee ee 8 4 Setting the feedback normal case anana a anaa anaana 8 5 Setting the feedback critical applications 2220
70. ng a limit switch and e when actuating the controller enable Please note the Z1 add on module is practical only for speed con trolled drives In a KSV 6HE amplifier configured for current control the functions Limit switch and Controller enable do not have a braking effect It is essential that you should document all changes in the table in section 12 page 82 Add on module Z2 Additional characteristics when Z2 add on module is fitted e externally adjustable current reduction e externally switchable setpoint reversing for PLC with single pole analog output e controller enable braking in case of shutdown can be switched to non braking using a solder bridge e switching output Motor standstill or Power circuit ready internally selectable e peak current can be switched off using a solder bridge e ramp function can be switched off using a solder bridge The external analog input Current reduction proportionally reduces the current limit set with the Current selector switch e If the input is open or if it is set to 10 V the current limit has the effect which has been set at the Cur rent selector switch e If there is a voltage of less than 10 V at the input the current limit is reduced proportionally First only the peak current is reduced Only when the current limit is lowered by the external setpoint below the peak current value the continuous current i
71. nstant the set time constant is marked with a cross Limitation of the speed controller component the set limitation is marked with a cross 100 open 10 lim 20 lim2 30 lim3 Modification to polarity module marked with a cross when solder bridge closed pe ee GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 84 Operating Instructions 221058E V 1 5a Appendix Appendix A EC Declaration of Conformity GEORGII KOBOLD Form AUGUST HEINE GmbH amp Co Certificate of Conformity Total Quality Certificate of Conformity in the sense of EC Directive Here with we confirm that the products Product GEORGII KOBOLD Type KSV 6HE compact design Series KSV Servo Amplifier correspond to the EC directives standards and regulations below and are designed for installation in a ma chine According to EC directive Machines commissioning is prohibited until it has been ascertained that the machine in which the above product is installed meets the provisions of the EC directive The requirements of the EC directives standards and regulations will only be met if the directions for instal lation and cabling given in the operating instructions are observed Operating instructions 22 10 58E The products are developed constructed and produced in accordance to EC Directive EMC directive 89 336 EWG amended by 91 263 EWG 92 31 EWG 93 68 EWG Low voltage directive 73 23 EWG
72. oad 9 2 Power supply The power supply is located in the right hand side panel of the servo amplifier 9 2 1 Design The power supply contains e the input RFI filter e the mains rectifier e the charging capacitors e the monitoring circuit and e the shunt regulator with a shunt resistor sufficient for common servo applications GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 66 Operating Instructions 221058E V 1 5a On the front panel to the right of the LEDs of the amplifier are e the three LEDs of the power supply 9 2 2 Shunt regulator During braking the kinetic energy of a rotating servo motor is fed back into the power supply as electrical energy e this causes the bus voltage to rise A shunt regulator also called shunt circuit built into the power supply e prevents that the power transistors are destroyed by that For higher shunt performance an external shunt resistor can be used For further details see section 9 2 5 page 66 9 2 3 LEDs The three LEDs have the following meanings Check Marking Color Display Fault St rung e lights up when input voltage is too low e lights up when shunt resistor is overheated e lights up when fuse is defective e lights up when shunt circuit is short circuited Ready green lights up when output voltage gt 160 V and Bereit there is no fault Shunt yellow lights up when the
73. of 7 ms per 1 V of setpoint voltage e right hand limit slope of 70 ms per 1 V of setpoint voltage that means a setpoint jump of 10 volts leads to a linear rise of the internally effective setpoint within 0 7 seconds 6 2 3 Add on module Z4 The customer module labeled P I l lim has to be installed when using the Z4 add on module Additional characteristics when fitted with the Z1 add on module e speed control with limitation of the component e 2 limit switch inputs directional braked e controller enable braking in case of shutdown can be switched to non braking using a solder bridge e switching output Power circuit ready e peak current can be switched off by means of a solder bridge GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 52 Operating Instructions 221058E V 1 5a Tip Tip The speed control loop is divided e inthe P component P controller adjustable with the Feedback Verstarkung potentiometer on the front panel e and the component I controller The time constant can be selected by solder bridges on the Z4 add on module for further details see section 11 3 7 page 80 For overshoot suppression in the speed control loop e the component can be limited The limitation threshold can be selected by solder bridges on the Z4 add on module for further details see section 11 3 7 pa ge 80 For the
74. of the output Pulse output index pulse Pulse output phase 2 Pulse output phase 1 Supply 0 V schaltend SPS kompatibel switching towards PLC compatible Voltage supply 24 V Switching input Hold only with option F1 Holding control loop BN 6661 0000 00A 055 Fig 5 Encoder signals 24 volt version interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 37 4 4 Connection directions The EMC limits in accordance with EN 55011 A and B emission as CE EMC well as EN 50082 1 and 2 immunity are complied with e if the KSV 6HE drive package is connected in accordance with the directions given here e Only then is the CE marking valid If the connection directions are not complied with e the installation in which the amplifiers are being operated must be checked for compliance with the EMC limits at the discretion of the customer Figure 6 shows for one axis of the KSV 6HE drive package e the prescribed connection e the laying of the cables and of the potential equilization cables e the prescribed earthing of the cable shields 4 4 1 Installation on the mounting plate When installing the amplifier on a mounting plate screw the device onto the bare metal e g zinc plated mounting plate e with the bare metal housing CE EMC The mounting plate has to be earthed and
75. on of the encoder signals to a positioning controller Please note e Choose twisted pair cables for the 5 volt version e Use a shielded cable for example the resolver encoder connecting cable mentioned in the accessories for further details see section 10 page 69ff Connect the shield at the amplifier to the earthed amplifier hous ing using the metal plated SUB D housing Additionally earth the shield at the controller follow the recommendations of the controller manufacturer concerning earthing and shield connection GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 44 Operating Instructions 221058E V 1 5a 4 4 12 Connecting the position sensor resolver The connection cable to the position sensor resolver must e be laid separate from the motor cable be connected exactly according to the instructions otherwise Check the motor blocks the motor runs roughly the motor runs uncontrolled at full speed or the servo amplifier reports a fault This causes no damage either to the motor or to the amplifier but there is a risk for the machine and the installation person nel the motor runs with a low torque Danger To connect up the resolver as shown in fig 6 e use twisted pairs of leads for channel 1 channel 2 and excitation forexample the resolver encoder connection cable mentioned in the accessories for furt
76. ort circuit in motor and earth fault Customer module missing or incorrectly in Customer module forgotten or incor serted rectly inserted after amplifier replace ment Blocking protection device triggered Electrical fault motor or resolver ca bles transposed Mechanical fault mechanism jammed or faulty Operating voltage increases excessively due Check shunt circuit shunt resistor to fault in shunt circuit missing or defective many axes brak ing at the same time GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 86 Operating Instructions 221058E V 1 5a Red and green LEDs am alternately Sensor not connected one or more leads not connected one or more leads Check sensor wiring when device is cold or at operating interrupted one or more leads short circuited temperature This fault can be reset only by switch ing the operating voltage off and on again with E1 of the external 24 V supply Red and green LEDs flash alternately after some period of operation Amplifier has switched off due to overtemperature of its heat sink or due to motor overheating Amplifier or motor cooling inade quate temperature sensor has not yet switched back fault reset not possible now After some time the display changes to the following condition see next row Current limit set too high Set to the current given for the motor Re
77. output Motor standstill or Power circuit ready The Motor standstill output is available only e if the standard version of the Z1 or Z2 add on module is used If the servo motor is operated at a speed greater than 1 of the maximum possible speed e the Motor standstill output is set to 0 If the servo motor runs more slowly or is at a standstill then e the Motor standstill output is set to 1 On request the Power circuit ready output can be switched instead of the Motor standstill output Since the same connector pin on the control signal male connector is used for both options the two outputs cannot be present at the same time The Power circuit ready output reports that the power circuit is ready that is functional It is only available e if the standard version of the Z4 add on module or if the appropriate special version of the Z1 or Z2 add on module is used The Z1 or Z2 add on module can be converted from the standard version Motor standstill into the special version Power circuit ready by means of a solder bridge For further information please refer to section 11 Notes for specialists on page 73ff When the servo amplifier e is working correctly and e is not disabled either by the controller enable or by means of a limit switch then the Power circuit ready output is set to 1 When the servo amplifier e is fau
78. ow the trimming potentiometers Marking Color A Fault red e lights up when fault is stored St rung e flashes as long as power circuit or motor is over heated flashes in the event of a resolver fault Ready green lights up when amplifier is ready Bereit flashes when amplifier is disabled flashes when fault is stored Overload yellow lights up when switched from peak current to con Uberlast tinuous current in the event of an overload When the mains voltage is switched on the amplifier remains dis abled until all voltages are stable During this time which lasts for some tenths of a second the red LED lights up GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 48 Operating Instructions 221058E V 1 5a 6 Modular fittings and expansions This section describes the functions of the modules The modules of a special KSV 6HE servo amplifier are given in a special type code as initials For further details on the type code see section 3 1 page 15 The modules are called e Customer module Kundenmodul e Add on module Zusatzmodul e Polarity module Polaritatsmodul e Encoder module Gebermodul e Function module Funktionsmodul e External supply for control circuit Not all modules are real boards variants that have been implemen ted differently are also possible 6 1 Customer module Kx Tip
79. ply of control circuit module is not fitted When the supply voltage is switched off e the position information disappears The version with the E1 module External supply of control circuit has an input for the separate feeding of a supply voltage of 24 V see table Technical specifications page 15 for connection see section 4 1 3 page 20 When the supply voltage is switched off e the position information is saved as long as the external supply voltage is connected This module is used e when for example in case of an emergency stop the supply volt age of the amplifier is switched off and e the position information must be saved The External supply of control circuit module is not a pluggable module but a modular variation which cannot be retrofitted on site GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 58 Operating Instructions 221058E V 1 5a 7 Shutting down the motor and safety shutdown 7 1 Shutting down options Options for shutting down the motor Disabling through the Controller enable input without Z1 Z2 or Z4 module the motor decelerates brakeless with Z1 Z2 or Z4 module the motor is actively braked by rever sal Switch off via limit switch only with Z1 or Z4 module directional motor is actively braked by reversal Switch off the speed setpoint set setpoint to 0 volts motor is acti
80. ructions 221058E V 1 5a 19 3 3 2 Installation in the control cabinet For fixing in the control cabinet the amplifier provides e a strap with an opening for locating it on an M 4 bolt at the top of the rear panel and e another strap with two slots for additional attachment at the bottom For notes on installation on a bare metal mounting plate see section 4 4 1 page 36 The device is designed for pollution degree 2 in accordance with EN 50178 1994 Please make sure that it is only exposed to e non conductive dirt f necessary provide for a suitable filter in the ventilation of the control cabinet The KSV 6HE servo amplifiers KSV 1 5 5 compact design to KSV 6 20 compact design are convection cooled To ensure that the air can flow through the housing and the heat sink e leave a gap of at least 80 mm above and below the devices and e leave a lateral gap of at least 20 mm The KSV 6HE servo amplifiers KSV 9 30 compact design and KSV 12 30 compact design are equipped with one or two fans re spectively To ensure that the air can flow undisturbed through the housing and the heat sink e leave a gap of at least 80 mm above and below the devices e Several such devices can be mounted directly beside each other without a lateral gap between the devices A few millimeters of space facilitate installation and subsequent removal and installation of individual devices GEORGII KOBOLD D 70771 Leinfelden Echter
81. ry see section 4 2 10 page 30 On request the Ready output can be switched instead of the Fault output Since the same connector pin on the control signal male connector is used for both options the two outputs cannot be present at the same time The Ready output is inverse to the Fault output It is present e when the polarity module P2 is used When the servo amplifier is working correctly then e the Ready output is set to 1 If there is a fault then e the Ready output is set to 0 For further details on the fault signal and on the fault memory see section 4 2 10 Fault memory page 30 If the amplifier is off circuit then e the output is disabled that is it is at O V The polarity module P1 can be converted into the polarity module P2 using a solder bridge For further information please refer to section 11 Notes for specialists on page 73ff 4 2 3 5 Switching output Overload When the servo amplifier is being operated within the set continuous current limits or when peak current is only drawn briefly then e the output is 0 If the current limiting circuit has switched back from peak current to continuous current due to an overload then e the output switches to 1 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 28 Operating Instructions 221058E V 1 5a 4 2 3 6 Switching
82. s CE EMC e when all installation and connection requirements of these operat ing instructions have been exactly complied with and GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 14 Operating Instructions 221058E V 1 5a e when the requirements in the notes next to the CE EMC marks have been met If this is not possible then e you must have the installation in which the amplifiers are being operated tested at your own discretion for compliance with the EMC limits 2 8 Preconditions for commissioning In addition to the low voltage and EMC directives applicable to the servo amplifiers the e machinery directive 89 392 EEC applies to machines The machinery directive 89 392 EEC applies to the final product that is the machine containing the servo amplifier The machine manufacturer must comply with the machinery directive 89 392 EEC Commissioning is forbidden until the requirements of the machinery Do not directive have been met 2 9 Working with the amplifier To replace modules or to carry out matching or other work e first disconnect the device from the mains e pull off the connectors and remove the right hand panel with the power supply after loosening the 4 cross recessed screws Never operate the device when it is open Danger GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating
83. s former given in the same table e must have a fixed connection e Shielding is not required e Connect PE to earth e The secondary neutral point of the mains transformer has to be earthed The cable between transformer and the built in power supply e must have an cross section as given in table Technical specifica tions on page 15 e Shielding is not required 4 4 4 Connection of the built in power supply The bus voltage supplied by the built in power supply is connected externally to the amplifier using the Combicon terminal strips Connect the power supply and the amplifier by 3 short leads cross section as given in the table Technical sepcifications on page 15 Assignment green yellow for PE blue for U red for U e Avoid unnecessary loops The bus voltages of several compact amplifiers must not be con nected The equalizing currents could damage the power supply 4 4 5 Motor connection general information For the motors supplied by Georgii Kobold the connection is given in the motor connection sheet shipped with each motor To connect other motors not supplied by us please contact us The 3 motor phases must be connected with the correct assignments otherwise e the motor blocks e the motor runs roughly e the motor runs with a low torque or the motor runs uncontrolled at full speed GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax
84. s also reduced e Values of over 10 V do not cause a higher current than 100 and values of less than 0 1 V do not cause a lower current than 1 of the set value The peak current rise can be switched off e for conversion by the specialist see section 11 3 page 77 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 51 The additional switching input Setpoint reversing e reverses the polarity of the setpoint internally lf itis open or set to 0 the setpoint leads to the same direction of motor rotation as without the module If it is switched to 1 the direction of the motor rotation is re versed The Controller enable input e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 77 An additional switching output supplies e the Motor standstill signal or e the signal Power circuit ready as a special version For conversion to the version with the Power circuit ready signal see section 11 3 page 77 The ramp function is not effective as delivered To activate it a solder bridge must be installed e for further details see section 11 3 page 77 The ramp rise can be set with a potentiometer on the add on module The potentiometer is marked with two ramp symbols e Left hand limit slope
85. signals switching towards zero 4 3 2 Connector X2 control signals PLC compatible 4 3 3 Connector X4 encoder signals 5 volt version 4 3 4 Connector X4 encoder signals 24 volt version 4 4 Connection directions a art Ta tA Soh auaa ananena el 4 4 1 Installation on the mounting plate 2 00000ee 4 4 2 Potential equilization cables 0 00 00 AAB Mains COMME CHO 520 ee 4 4 4 Connection of the built in power supply 4 4 4 5 Motor connection general information 4 4 6 Shield connection motor cable 0 0 2 00 e eee 4 4 7 Motor choke suraraser ee ieee aoe er 4 4 8 Shield connection of the external shunt resistor cable 4 4 9 Connection shielding and laying of the control leads 4 4 10 Setpoint connection 23 04 csench anerodhehemekak abe mek okes 4 4 11 Connection of the encoder signals 000005 4 4 12 Connecting the position sensor resolver 4 4 13 Connection of the motor temperature sensor GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 5 5 Adjustment and display elements 00 0c eens 5 1 Trim potentiometers 0 0 2 cee eee 5 2 Current limiting and Current rotary switch 2222222 Bo PEDS Eaa a E
86. t Controller enable At the switching input Controller enable the logic level for e 1 leads to amplifier enabled motor can run the green Ready LED lights up e 0 leads to amplifier disabled the motor decelerates brakeless the green Ready LED flashes Disabling through the Controller enable switching input does not meet the safety requirements of the machine directive If an emergency stop or a safety shutdown of the machine is re quired the instructions given in section 7 3 concerning the safety re quirements of the machine directive must be followed strictly 4 2 3 3 Switching input Reset fault The logic level at the Reset fault condition input e must be set to 0 at rest e is briefly switched to 1 when a stored fault is to be reset For further details on the fault signal and on the fault memory see section 4 2 10 page 30 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 27 4 2 3 4 Switching output Fault or Ready The Fault output is present e when no polarity module PO or polarity module P1 is used When the servo amplifier is working correctly then e the Fault output is set to 0 If there is a fault then e the Fault output switches to 1 For further details on the fault signal and on the fault memo
87. t flows in the protective earth conductor GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 13 2 5 Hazard warnings Due to their design and connection system the servo amplifiers Caution e may only be operated in closed housings control cabinet e may only be operated with a fixed connection to the mains Do not introduce any objects screwdrivers wires into the interior of the device through the ventilation holes Before you remove a device from the chassis and before you discon nect or reconnect a connector e switch off mains voltage Power off The charging capacitor of the power supply retains the voltage even after it has been switched off Before working at or in the device wait gt 1 min e wait at least one minute after switching off Electronic devices are generally not fail safe The user must make Danger sure e that when a device breaks down the drive is switched to a safe state 2 6 Warning The temperature of the heat sink located on the left hand side may if Caution the device is under full load e reach as much as 80 C 2 7 CE marking The KSV 6HE servo amplifiers meet the requirements of e the EMC directive 89 336 EEC and e the low voltage directive 73 23 EEC C They thus conform to the currently valid EU regulations and bear the CE marking The CE marking only applie
88. teristics of our motor connection cable e 4 core shielded e cross section 1 5 mm in the case of 535246 Z e cross section 2 5 mm in the case of 535264 Z e suitable as trailing cable Choose the appropriate cable according to the required cross sec tions given in table Technical specifications on page 15 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 71 Technical specifications Motor connection cable 535246 Z 535264 Z Cable code KWLifPETPC11Y JZ KWLifPETPC11Y JZ 4 x 1 5mm 4 x 2 5 mm Single core 1 5 mm Cu litz 2 5 mm Cu litz bare 192 x 0 1 mm bare 320 x 0 1 mm Structure 4 cores stranded with optimized length of twist Color coding 1 x green yellow PE cond 3 x black Z1 Z3 Total shield Cu braiding tin coated 0 1 mm single wire diameter Total sheath Polyurethane orange RAL 2003 Bending radius for single min 65 mm bend fixed installation Rolling radius for continuous min 95 mm min 120 mm altern bending trailing use Operating temperature 50 to 90 C fixed installation 30 to 80 C trailing use 10 2 3 Resolver Encoder connection cable 535245 Z The resolver encoder connection cable is suitable for connecting the position sensor resolver as well as for connecting a positioning controller to the sensor signals output Characteristics of our resol ver encod
89. vely braked by reversal Switch off the supply voltage motor decelerates brakeless the position information is lost Switch off in the motor supply line without braking resistors motor decelerates brakeless with braking resistors motor is braked by withdrawal of kinetic energy less effective than active braking by reversal Braking resistors effect increases as their resistance value falls the maximum permissible peak current given in the data sheet for the motor may not be exceeded by that If no value is given assume that the limit is three times the continuous current Switching sequence when switching off in the motor supply line first disable the amplifier using controller enable then open the motor line no delay is required between the two operations since the power contactor is slower than the disabling operation To switch on again first close the motor line then enable the controller Delay necessary depending on the power contactor for example 20 ms or more If the braking time is too long with the selected manner of shutting down the motor the motor can be fitted with a magnetic brake which acts using spring power when the current is switched off GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 59 7 2 Estimating the braking distance The braking distanc
90. wer off 1 minute until the DC bus capacitors have discharged before carry wait gt 1 min ing out the measures described CE EMC e The CE marking presumes compliance with the EMC limits in accordance with EN 55011 A and B emissions and EN 50082 1 and 2 immunity The specifications marked with this symbol must be complied with Otherwise the installation in which the amplifier is being run must be checked for compliance with the EMC limits at the discretion of the customer Other instructions given in the margin e Check First check these positions if the drive system does not work as required or if you cannot proceed working with the device for other reasons e Tip Useful hint Check Tip N N Technical staff The servo amplifiers and the power supplies work with voltages which are dangerous in case of contact Touching live parts can cause serious injury or death Danger Only trained technical staff with special knowledge in the fields of e automation e dealing with dangerous voltages e standards and regulations such as EMC directive 89 336 EEC low voltage directive 73 23 EEC machinery directive 89 392 EEC CE EMC GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 12 Operating Instructions 221058E V 1 5a VDE regulations such as DIN VDE 0100 DIN VDE 0113 lt EN 60204 gt DIN VDE 0160 lt EN 501785 safety rules
91. wer supply e the mains transformer The compact series described here comprises e amplifiers for 5 different currents 1 5 A ms to 12 Ams e amplifiers with different specifications optional with built in power supply e mains transformers to feed the amplifiers GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 10 Operating Instructions 221058E V 1 5a We evaluate the servo drive matched to your application and e deliver the matching servo motor They have separate operating instructions and terminal connec tion diagrams As well as the compact series there is a series in 19 plug in module design for installation into 19 rack systems and a matching power supply KSV 1 5 5 to KSV 12 30 amplifiers with separate operating instructions GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221058E V 1 5a 11 2 Safety instructions 2 1 Type of instruction It is essential that you should note the warnings and instructions in the margin Danger for life and limb through electrical shock or motion of the Danger drive system e Caution Disregard can lead to personal injury or death or damage Caution of property e Prohibition Disregard is a violation of safety regulations or statu Do not tory provisions Power off Disconnect the device from the mains and wait at least Po
92. you would like to use an external shunt resistor instead of the inter nal one then e remove the jumper between Rinw and R int e connect the external resistor to the connections Rex and R The external shunt resistor e must be installed in an earthed metal housing to avoid emission and as a protection against contact with live parts and with the hot resistor The cable e must have a cross section of 1 5 mm and must be shielded Note the connection directions section 4 4 8 Shield connection ofthe external shunt resistor cable GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 68 Operating Instructions 221058E V 1 5a The output for the shunt resistor is short circuit proof In case of a short circuit e the shunt circuit will be switched off The red LED indicates the fault As a consequence the bus voltage increases during braking until the connected amplifier switch off due to overvoltage the red LED of the amplifier indicates the fault the Fault St rung output switches on This fault can only be reset e by switching the mains voltage off and on again 9 3 Mains transformers 9 3 1 General information The mains transformers are laid out for three phase connection As well as the standard transformers shown in the following table we can also supply special versions further details on request In accordance

Operating Instructions 221058E, V 1.5a 09/01

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