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Operating Instructions 221055E, V 1.5c 09/01

1. 2222er Fig 7 Setpoint potentiometer connection for commissioning Fig 8 Rack mount chassis 84 units wide liiis Fig 9 Wall mount chassis 84 units wide for installation on mounting plate Fig 10 Motor chokes zo odd retra uo euer Figs ie REINER ov sor Sot 265 2054 Nite be Sie DASE Dd DS 8 Disp VUES Oe Fig 12 Location of the jumpers on the right hand board 2222 22 Fig 13 Location of the solder bridges on the customer module Fig 14 Solder bridges on the Z1 module 0 0000 eee Fig 15 Solder bridges on the Z2 module 0002 eee eee Fig 16 Solder bridges on the Z4 module 00 020 eee Fig 17 Solder bridges on the P1 and P2 modules 05 Es ESL ESTEE EST ESI EJEJETE GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 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 3HE servo amplifiers designed as 19 plug in modules 3 units height with connection on the front panel e the associated power supplies 19 plug in module design 3 units height for the connection to 90 V AC or 3 x 90 V three phase current e the mains transformers for
2. Lssn 8 7 Setting the current limit orare x RR RUE EG eK Ea a We aree WR s 8 8 Setting the OSCR cosi Sunt eo EVER Dedi Ut Disi eu eco die Ede iet 8 9 Setting the holding control loop amplification Chapter 3 Power supply and accessories 9 Power supply of the servo amplifiers 000005 9 1 Load TaclOR zes Ze aaa cul rane Ea Pee GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 6 Operating Instructions 221055E V 1 5c 927 PGOWEF SUDO cf oerte Ei ER te tne Ex fatale etna ded te 9 2 1 DESIGN sack ar Glad eR Bul She pul ar Natur Sle c P 9 2 2 SHURETSOUAIOE e oce ior cete oor ec earns ea etre eee ee 9 2 3 Connection assignment terminal block X5 9 2 4 So Oe eee Re EHRE EIN Re RUSO E REDE rd 9 2 5 Technical specifications of the power supply 9 2 6 Externalsshiunbresisior 24 5 0 t acra een dea ee TR eae 9 3 Mains transformers sender p ace tad naar re ruhen 9 3 1 General information llle 9 3 2 GONNECHONS rod ror d dte a ot ese ate GU eR eoi oh Ere Ere oil e dd 9 3 3 Technical specifications of the mains transformers 9 3 4 Shielg fOlL A serere ee edet Cao ESO de be ie bd oa 10 ACCESSONGS Zu ur rare Xue ee ee dora Qo qp tue Ca pd e ouf s 10 1 Available accessories and order numbers 2222222 cn 10 2 Description of accessories zu saugen ER Zr SS IS a re ee RE
3. GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 63 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 83 8 6 Setting the feedback with Z4 add on module Tip For the purpose of commissioning a special module is available on which e potentiometers for the time 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 i
4. GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 76 Operating Instructions 221055E V 1 5c 10 2 4 Motor connection cables 535246 Z and 535264 Z The motor must be connected with a shielded cable Characteristics of our motor connection cable 4 core shielded e cross section 1 5 mm in the case of 535246 Z e cross section 2 5 mm in the case of 535264 Z e suitable as trailing cable Choose the appropriate cable according to the required cross sec tions given in table Technical specifications on page 16 Technical specifications Motor connection cable 535246 Z 535264 Z Cable code KWLifPETPC11Y JZ KWLifPETPC11Y JZ 4 x 1 5 mm 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 5 Resolver Encoder connection cable 535245 Z The resolver encoder connection cable is suitable for connecting the position sensor resolver as well
5. 1 5c In accordance with the data given the transformers can also be ordered by the user from a local manufacturer in order to save the comparatively high costs of post and packaging 9 3 2 Connections The connections are clearly labeled on the terminals of the trans formers The secondary neutral point of the mains transformer must not be earthed and also none of the phase pins The negative connection of the bus voltage is earthed in the power supply 9 3 3 Technical specifications of the mains transformers 038112010Z 038104010Z 038105010Z Type of connection single phase three phase three phase Suitable for amplifier or combi KSV 5 15 KSV 10 730 2 x KSV 10 30 nations or or 2 x KSV 5 15 4x KSV 5 15 or others or others Mains connection primary 3 x 400 V 3 x 400 V Output voltage Load factor power supply dimensioning Rated output 750 VA 1 5 kVA 2 7 KVA Primary side back up fuses 4AT 3x4AT 3x6AT Wiring Recomm 2 5 mm 2 5 mm 4 0 mm secondary cross section side T Minimum cross section Necessary RFI filter 002057030Z 002057020Z Dimensions 113 x 130 x 225 x 148 x 245 x 210 x Lx W x H in mm Iam Er Ta 195 160 weight tg ht 10k 19 kg 24 kg The following applies for combinations The load factors of the amplifiers working simultaneously on one power supply at full load are added and the proportionally re duced load factors of the amplifiers working under part l
6. 75903 0 fax 49 0 711 75903 53 32 Operating Instructions 221055E V 1 5c 4 3 2 Connector X2 control signals PLC compatible The following figure shows the interface details internal circuit at the 15 pin SUB D male connector for the control signals section 4 1 2 2 page 20 e for the version with polarity module PLC compatible version forthe version with Z1 add on module 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 Analog output Current monitor Switching output Overload Analog output Speed monitor Switching output Fault or Ready Switching output Motor standstill or Power circuit ready Input 24 V for polarity module and if option E1 Switching input Reset fault 100ka n 7k 100ko ee nE Zw 47kn Oka I 100kn 47kn L Ps 47kn 100ka Lie pe 10ka 10ka CJ C Switching input Limit switch 2 Switching input Limit switch 1 Switching input Con troller enable Input setpoint E Input setpoint E Output auxiliary voltage 15 V Output auxiliary voltage 15 V 0 Volt BN 6646 0000 00A 052 Fig 2 Control signals PLC compatible interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
7. For this reason a motor choke must be fitted in the motor cable if Check the cable is longer than 10 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 10 shows the mounting dimensions the connection please note the connection of the shield and the marking of the terminals GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 78 Operating Instructions 221055E V 1 5c 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 12 A For cable lengths when using 10t050 m 50 to 70m KSV 3HE amplifiers Internal design partially compensated 3 single chokes triple choke by zum Motor Ej tothe motor vom Verst rker _from the amplifier BN3845 0000 00 A 050 Dimensions Distance X Housing height Internal choke Input Output 0380000107 I 0380970102 y 3 W Z Fig 10 Motor chokes 10 2 8 RFI filters 002057030Z and 002057020Z As described in section 4 4 4 a RFI filter has to be connected on the line side of the mains transformer in any case The p
8. GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 13 e since in case of earth leakage a part of the direct current flows in the protective earth conductor 2 5 Hazard warnings i Due to their design and connection system the servo amplifiers and Caution the power supplies e may only be operated in closed housings control cabinet e may only be operated with a fixed connection to the mains Do not introduce any objects screwdrivers wires into the interior of the device through the ventilation holes Before you remove a device from the chassis and before you discon nect or reconnect a connector e switch off mains voltage Power off The charging capacitor of the power supply retains the voltage even after it has been switched off Before working at or in the device wait gt 1 min 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 CE marking The KSV 3HE servo amplifiers meet the requirements of e the EMC directive 89 336 EEC and e the low voltage directive 73 23 EEC C They thus conform to the currently valid EU regulations and bear the CE marking The CE marking only applies CE EMC e when all installation and connection requirements of these operat
9. Operating Instructions 221055E V 1 5c 33 4 3 3 Connector X4 encoder signals 5 volt version The following figure shows the interface details internal circuit at the 15 pin SUB D connector for the encoder signals section 4 1 4 on page 22 e 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 9 is not connected Please note e the electrical isolation of the 3 signals via optoelectronic coupler e the separate voltage supply of the output sc n kompatibel inter ee Bie compatib i v 0 0 Volt Switching input Hold only with option F1 Holding control loop Supply 0 V Voltage supply 5 V Pulse output phase 1 inverse Pulse output phase 1 Pulse output phase 2 inverse Pulse output phase 2 Pulse output index pulse in verse Pulse output index pulse BN 6646 0000 00A 053 Fig 3 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 34 Operating Instructions 221055E V 1 5c 4 3 4 Connector X4 encoder signals 24 volt version The following figure shows the interface details internal circuit at the 15 pin SUB D connector for the encoder signals section 4 1 4 on page 22 e forthe 24 volt version e viewing the connector from the front that is looking at the
10. To switch on again first close the motor line then enable the controller Delay necessary depending on the power contactor for example 20 ms or more GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 59 If the braking time is too long with the selected manner of shutting down the motor the motor can be fitted with a magnetic brake which acts using spring power when the current is switched off 7 2 Estimating the braking distance The braking distance of the connected machine part depends on the moment of inertia of the drive and on the mass of the part to be moved e g of the machine carriage Example assumed values e Braking time for active braking limit switch or zeroing of setpoint 0 1 seconds e linear braking from a velocity of 10 meters per minute e results in a braking distance of approx 8 millimeters This means that with the values of this example the setpoint must be set to zero at least 8 millimeters before the mechanical limit stop if the stop is not to be struck hard 7 3 Emergency stop and safety regulations The safety regulations to be derived from the machinery directive do Do not not allow safety functions to be carried out by electronic circuits since the risk of failure cannot be fully ruled out e An emergency stop or any other safety circuit must not only be effected by zeroing the s
11. Zusatzmodul e Polarity module Polaritatsmodul e Encoder module Gebermodul e Function module Funktionsmodul e External supply for control circuit Not all modules are real boards variants that have been implemen ted differently are also possible 6 1 Customer module Kx Tip The pluggable customer module contains e all assemblies to be set during installation e assemblies for special features such as current control or speed control When an amplifier is replaced the customer module can be trans ferred to the new amplifier Readjustment is therefore not necessary The customer module is fitted in all versions To replace the customer module e loosen the two upper fixing bolts of the front panel and e tilt the front panel forwards 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 221055E V 1 5c 49 6 2 1 Add on module Z1 Additional characteristics when fitted with the Z1 add on module e 2 limit switch inputs dir
12. area earthed with a cable clamp of the shield connection plate on the RFI filter e Unshielded cable ends must not be longer than 5 cm Therefore the shield must not end at the earthing clamp but has to continue Follow the same directions for the connection between transformer and power supply The cable ends must not be longer than 50 cm from the earthing clamps 4 4 4 3 Connection servo amplifier power supply The power supply has terminals to connect the amplifiers installed in the chassis section 9 2 3 page 67 Connect e the positive and negative operating voltage e inside the wiring duct as shown in fig 5 e via short two core wiring connections for the necessary cable cross section see table Technical specifications page 16 e Do not lay other cables motor cables control cables parallel to this connection in the wiring duct e Lead both wires through a ferrite ring 042103010 section 10 2 6 page 77 directly at the amplifier input as shown in fig 5 e Connect PE to the central zero point GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 41 4 4 5 Motor connection general information Check Danger CE EMC For the motors supplied by Georgii Kobold the connection is given in the motor connection sheet shipped with each motor To connect other motors not supplied by us please contact us The 3 motor
13. as for connecting a positioning controller to the sensor signals output Characteristics of our resol ver encoder connection cable 535245 Z e 8 core shielded e twisted pair e Suitable as trailing cable GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 77 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 8596 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 6 Ferrite ring 042103010 The ferrite ring damps the high frequency interference immediately at the terminal For application see connection directions in section 4 4 on page 35ff Dimensions ferrite ring 042103010 Outer diameter 16 mm Inner diameter 8 5 10 mm 10 2 7 Motor chokes 038096010Z and 038097010Z Longer motor cables can overload the device and cause unacceptably CE EMC high interference emission e
14. changed the factory settings it is essential that you should document the new switch position in the table in section 12 page 89 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 47 5 3 LEDs There are three LEDs on the front panel of the amplifier Cn G9 Up Fault red lights up when fault is stored rung 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 e flashes when amplifier is disabled e flashes when fault is stored E yellow EBENE up when switched from peak current to con E tinuous current in BT event of an overload When the mains ae is switched on the amplifier remains dis abled until all voltages are stable During this time which lasts for some tenths of a second the red LED lights up GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 48 Operating Instructions 221055E V 1 5c 6 Modular fittings and expansions This section describes the functions of the modules The modules of a special KSV 3HE 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
15. 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 Or observe pulse output if an encoder module is fitted Set offset trimmer so that the motor comes to a standstill as well as possible GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 65 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 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 66 Operating Instructions 221055E V 1 5c Chapter 3 Power supply and accessories 9 Power supply of the servo amplifiers 9 1 9 2 9 2 1 Load factor The load factor gives the number of amplifiers that can be connected You will find it in the technical specification
16. e the RFI filter with mounted shield connection plate for further details on the shield connection plate 089159 see section 10 2 8 page 78 e the mains transformer 4 4 1 Installation on the mounting plate For the installation on a mounting plate use a chassis specially de signed for this purpose To install the chassis on the mounting plate in the control cabinet screw the chassis onto the bare metal e g zinc plated mounting plate e with the bare metal mounting flange of the chassis or CE EMC e with the bare metal rear wall of the chassis in case of the chassis for 19 control cabinets The mounting plate has to be earthed and therefore e either carry the central zero point on its own or GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 36 Operating Instructions 221055E V 1 5c Positioniersteuerung Position controller Sollwertqueile ipoint source Netzger t Power supply Achse I Axisl Achse II AxisII Steuersignale Gebersignale Control signals Encoder signals Up PE intern verbunden connected internally Schirm Anschlufiplatte Shield connection plate E L3 L2 Entst rfilter LJ RFI filter CH ib b s NN Netz Mains ZIN Trafo lv w Transformer 10 mm 4 ap 9 PE ZentralerNullpunkt im Schaltschrank Central zero point in the contr
17. fax 49 0 711 75903 53 26 Operating Instructions 221055E V 1 5c 4 2 3 6 Switching output Motor standstill or Power circuit ready The Motor standstill output is available only e if the standard version of the Z1 or Z2 add on module is used If the servo motor is operated at a speed greater than 196 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 e 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 80ff 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 th
18. fittings and expansions 0 000 eee Bl Qustomer module Kx zit Busen 5 2 Add on modules Zx zur 8 2 fete Bee Er 6 2 1 Add on module ZT rei trat dc et otra od Rc 6 2 2 Addson iodulgu2 cce exces euo Eon ae wok oe eee poe optet artt 6 2 3 Add on module ZA 000 eee 6 2 4 Further add on modules 00 0 eee eee eee 6 3 Polarity module PX iritis naera erga ee eee eee ee eee er 6 4 Encoder modules G1 to G4 0 ee 6 4 1 POIRSSEIING cg ey te ose ee eee mere ee eee 6 4 2 Index pulse adjustment siue eu RE et 428 CHE ae 8 3 Function module EX 23 crai quei aee Bare Leg Ne nin By elie aln ty Sere d 6 5 1 Hold treo sans ea Sis es exce ero Ent 6 5 2 Field weakening mode F2 022 cee eee eee 6 6 Option E1 external supply of control circuit 2 000005 7 Shutting down the motor and safety shutdown 7 1 9h tling down Options 3 ee ie Bere 7 2 Estimating the braking distance 0 000 eee nn 7 3 Emergency stop and safety regulations 00000085 8 GOMMISSIONING aeran e oa e riet ST R a E1 OOT E EE AA b ER ee e E G 8 2 Switching on for the first time ass er De Dee 8 3 Setting the speed essen en ee ee 8 4 Setting the feedback normal case 00 0c eee cece eee 8 5 Setting the feedback critical applications 2020000 eee 8 6 Setting the feedback with Z4 add on module
19. ing instructions have been exactly complied with and e when the requirements in the notes next to the CE EMC marks have been met GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c If this is not possible then e you must have the installation in which the amplifiers are being operated tested at your own discretion for compliance with the EMC limits 2 7 Preconditions for commissioning In addition to the low voltage and EMC directives applicable to the servo amplifiers the e machinery directive 89 392 EEC applies to machines The machinery directive 89 392 EEC applies to the final product that is the machine containing the servo amplifier The machine manufacturer must comply with the machinery directive 89 392 EEC Commissioning is forbidden until the requirements of the machinery directive have been met 2 8 Opening the housing To replace modules or to carry out matching or other work e first disconnect the device from the mains e pull off the connector and remove cables from the terminals and e remove the device from the chassis after loosening the front panel screws Never operate the device when it is removed from hte chassis GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 15 Chapter 2 Servo amplifier 3 T
20. 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 221055E V 1 5c 6 2 2 Tip The ramp function is effective in all 4 quadrants It is also effective e when actuating a limit switch and e when actuating the controller enable Please note the Z1 add on module is practical only for speed con trolled drives In a KSV 3HE 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 89 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 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 lim
21. 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 Housin TT 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 22 Operating Instructions 221055E V 1 5c 4 1 4 Encoder signals Gebersignale SUB D male connector X4 15 pin The 15 pin SUB D connector Encoder signals is only connected when one of the encoder modules options G1 to G4 is installed Pin Assignment 0 Volt connected to 0 volt of the internal auxiliary voltage not assigned not assigned not assigned Voltage supply encoder module 5 V or 24 V 5 V with option G1 or G3 pulse output 5 V push pull 24 V with option G2 or G4 pulse output 24 V Pulse output phase 1 U Pulse output phase 2 U NIE Switching input Hold only with option F1 Holding control loop 9 not assigned 1 Js 1 not assigned 12 13 Pulse output phase 1 inverse U for 24 V vers not assigned Zero for voltage supply encoder module Pulse output index pulse Ua 14 Pulse output phase 2 inverse U for 24 V vers not assigned 15 Pulse output i
22. phases must be connected with the correct assignments otherwise e the motor blocks e the motor runs roughly e the motor runs with a low torque or e the motor runs uncontrolled at full speed This causes no damage either to the motor or to the amplifier but there is a risk for the machine and the installation personnel As shown in fig 5 the motor is connected using a 4 pin shielded cable Use the motor supply cable described in the accessories for fur ther details see section 10 2 4 on page 76 Lead the three motor cables through a ferrite ring 042103010 section 10 2 6 page 77 directly at the amplifier input as shown in fig 5 e Establish the earthing of the motor cable shields at the shield connection plate where the RF I filter is installed as described above in the context of figures 5 and 6 Establish a large area connection between the shield and earth at the motor in a suitable manner At all places avoid earthing the shield using twirled strands pigtails of the shield Connect the machine earth to the central zero point of the control cabinet using an potential equilization cable with an adequate cross section The shield of the motor cable must not be interrupted e f 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 clam
23. switching inputs and switching outputs the servo ampli fier works together with e with external switches e with the primary controller 4 2 3 1 Properties of the switching inputs and outputs Two possible polarities by means of polarity module P module see also type code e Switching towards zero when no polarity module is used PO in type code e Switching towards positive PLC compatible when polarity module is used P1 in type code Positive is either the externally supplied PLC operating voltage 15 35 V preferably 24 V orthe internal auxiliary voltage of 15 V The outputs are applied via PTC resistors and are thus e 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 24 Operating Instructions 221055E V 1 5c 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 op
24. the RFI filter accord ing to fig 5 The cable between mains and the RFI filter e is led through line side fuses see the table on page 70 for values e must have an adequate cross section for the chosen mains trans former given in the same table must have a fixed connection e Shielding is not required 4 4 4 2 Connections RFI filter mains transformer power supply The mains transformer e is chosen corresponding to the technical specifications of the trans formers in section 9 3 3 page 70 e has to be equipped with a double shield foil like the transformers delivered by us GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c Caution CE EMC e has to be connected well conducting with the mounting plate either via parts of the control cabinet or using a short connection to frame copper braiding of 10 mm cross section The connections are clearly labeled at the terminals of the transform ers The secondary neutral point of the mains transformer must not be earthed and also none of the phase pins The negative connection of the bus voltage is earthed in the power supply The connection between RFI filter and transformer must not be longer than 50 cm e must have an adequate cross section for the chosen mains trans former see the table on page 70 e has to be shielded the shield is large
25. unit All are 3 height units high corresponding to the height of the plug in modules e 84 units wide for installation in 19 racks fig 8 in common 19 design mounting flanges and handles at the front order number e 84 units wide for installation on mounting plate fig 9 mounting flanges at the rear without handles order number e 54 unites wide for installation on mounting plate mounting flanges at the rear without handles order number e other widths as special design on request 10 2 2 Compact enclosures 089163 Z and 089180040Z The compact enclosure is used for installation of one single plug in module KSV 5 15 or KSV 10 30 in a control cabinet It includes an appropriate power supply There are 2 versions e 089163 Z for single phase connection up to 0 5 kW power e 089180040Z for three phase connection up to 1 kW power 10 2 3 Connector sets 099075010Z and 099073010Z The amplifiers are supplied without mating connectors The connector set comprises all necessary connectors e The connector set 099075010Z includes connectors for the version without encoder module GO two SUB D connectors with screwable housings and one 7 pole Combicon female connector e The connector set 099073010Z 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
26. voltage for amplifier Check input voltage of power supply and its fuse Fuse in amplifier defective Replace fuse Green Ready LED flashes Controller enable or limit switch open Check cables connections limit switches Red Fault LED lights up and green No supply voltage this display only in case of Switch on operating voltage check Ready LED flashes option E1 emergency stop circuit Operating voltage too low Measure operating voltage must be gt 50 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 Short circuit or earth fault in motor cables or Check wiring and motor for short circuit in motor and earth fault Customer module missing or incorrectly in Customer module forgotten or incor serted rectly inserted after amplifier replace ment Blocking protection device triggered Electrical fault motor or resolver ca bles transposed Mechanical fault mechanism jammed or faulty Operating voltage increases excessively due Check shunt circuit shunt resistor to fault in shunt circuit missing or defective many axes brak ing at the same time GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 92 Operating Instructions 2210
27. 3HE servo amplifier with encoder module option 099073010Z ih Synchronization unit see separate operating instructions 086046010Z Connector set for 2 KSV 3HE amplifiers and one synchronization unit 099074010Z Screwable connector for connecting the resolver at motor type 310 320 099073010Z 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 535245 Z Ferrite ring for interference suppression of supply cables Motor choke with terminals and enclosure for medium length cables up to 50 m 038096010Z Motor choke with terminals and enclosure for longer cables more than 50 m RFI filter single phase 0020570302 RFI filter three phase 0020570202 Shield connection plate 089159 10 2 Description of accessories 10 2 1 Chassis 10 2 1 1 Multi axis servo amplifier i Using the chassis described in the following we construct the multi Tip axis servo amplifier KSV M2 matched to your application Use these operating instructions for connecting and commissioning The device comes with a form Multi axis servo amplifier where you can find among other specifications e number and designation of the power supplies e number and designation of the amplifier plug in modules e equipment of the amplifiers and specification of the associated motor GEORGII KOB
28. 5 V push pull signals RS 422 signals RS 422 G2 pulse outputs 24 V push pull signals G4 pulse outputs with index pulse shift 24 V GK _ customer specific Additional equipment through function modules FO FO none standard F2 field weakening operation F1 holding control loop Supply of control circuit cannot be refitted EO EO internal supply from DC bus standard E1 through external 24 V e g for position retention Special equipment customization SO So none standard SK customer specific explained by text S1 for connection of a synchronization unit Front panel wo WO standard For further details on the modular expansion options please refer to section 6 page 48 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 16 Operating Instructions 221055E V 1 5c 3 2 Technical specifications Servo amplifier KSV 5 15 KSV 10 30 Minimum bus voltage 50 V DC 50 V DC Maximum permissible bus voltage 170 V DC 170 V DC Rated input voltage 125 V DC 125 V DC Maximum continuous current rms value 5A 10A Maximum peak current crest value 15A 30A Current limiting adjustable from to 1 25 A 5A 2 5A 10A Load factor in conjunction with power supply Integration time of the I t circuit at max peak current approx 2 s Setpoint value 10 Vat20kQ Operating range of speed trimmer 1 7 Speed range 3500 r p m 2 V 1000 r p m Ra 10 KQ Speed range 10 500 r p m 0 67
29. 55E V 1 5c Red and green LEDs flash alternately Sensor 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 Red LED lights up continuously green LED flashes Amplifier motor has cooled down temperature sensor has switched back fault can now be reset Yellow Overload LED lights up Motor is overloaded or blocked Check mechanical system Current limit set too low Compare nominal motor data with set ting Motor is not connected or a motor lead is Check motor wiring interrupted Setpoint missing setpoint lead interrupted or Check setpoint lead 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 Ug not is ear
30. Fl filters e 19 chassis and compact enclosures We construct the multi axis servo amplifier matched to your applica tion using chassis Use these operating instructions for connecting and commissioning Using compact enclosures we construct the servo amplifier one axis in compact design matched to your application For connecting and commissioning use these operating instructions and the operating instructions of the compact enclosure We evaluate the servo drive matched to your application and e deliver the matching servo motor They have separate operating instructions and terminal connec tion diagrams As well as the series with the connection on the front panel there is also a series with the connection on the rear via an indirect connector to 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 221055E V 1 5c 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 P
31. KSV 3HE Servo Amplifier for Brushless Motors KSV 5 15 and KSV 10 30 19 inch 3 height units front connection Operating Instructions 221055E V 1 5c 09 01 These operating instructions apply to e KSV SHE KSV 5 15 and KSV 10 30 servo amplifiers 19 plug in module e 2800200000 power supply 19 plug in module e KSV M2 multi axis servo amplifiers 19 chassis with modules as above e 0381120102 038104010Z and 038105010Z 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 221055E V 1 5c Versions of the document 28 09 95 V 0 1 Original from translator 10 02 96 V 1 0 First revision similar to German version V 1 1 03 11 98 V 1 0a Fo adapted to WP 8 PS Printer prepared for pdf conver sion 20 05 99 V 1 4e MH English terms correct Georgii Kobold dictionary CE references included new versions of customer mod ules Kx Z1 and Z2 add on modules similar to German version V 1 4e 03 11 99 V 1 5 MH English terms correct Georgii Kobold dictionary Z4 add on module new tolerances ferrite ring dimen sions added similar to German version V 1 5 11 01 00 V 1 5b MH values for time constant on Z4 add on module ad justed figures 12 and 13 new mains connection sum marized in s
32. Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 68 Operating Instructions 221055E V 1 5c 9 2 4 LEDs For single phase connection use U and V leave W open For details on the laying of cables see fig 5 and section 4 4 4 pa ge 39 Please note that the terminals are in reverse order compared with the connections on the amplifier There is a fuse for the operating voltage on the board For dimensions and value of the fuse link see section 9 2 5 Technical specifications of the power supply The three LEDs have the following meanings Marking Color Display Fault e lights up when fuse is defective St rung e lights up when shunt resistor is overheated e lights up when shunt circuit is short circuited Ready green lights up when output voltage gt 40 V and Bereit there is no fault Shunt yellow lights up when the shunt circuit for accepting Ballast the energy returned when the motor is brak ed is switched on GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 69 9 2 5 Technical specifications of the power supply Power supply 2800200000 Mains connection via isolating transformer alternating voltage only up to 0 5 kW 1x90VAC three phase voltage 3 x 90 V AC Nominal bus voltage Response threshold of shunt regulator 155 V DC Load facto
33. OLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 73 10 2 1 2 General characteristics The Georgii Kobold chassis are made of chromated aluminum and zinc plated sheet steel They are unlike anodically oxidized alumi num conductive to establish large area connections of the different parts to each other and to the mounting plate The air must be able to flow through the chassis undisturbed If you install additional chassis above or below they must not obstruct the air flow Note that the air leaving the chassis is heated up e this may disturb devices sensitive to heat Figure 8 shows a rack mount chassis 84 units wide for installation in 19 racks fig 9 a wall mount chassis of the same width for installation on a mounting plate both fully equipped with one power supply and 6 amplifiers The wall mount chassis control cabinet installation have an open back The shielding will be closed by the mounting plate Therefore these chassis must have large area conductive contact atthe mount ing flanges to the varnish free mounting plate 6 standard types of chassis are available 3 with and 3 without fan units 10 2 1 3 Chassis with fan unit All are 4 height units high 3 height units for the plug in modules 1 height unit for the fan unit e 84 units wide for installation in 19 racks fig 8 in common 19 design mounting flanges and han
34. TTET 10 2 1 1 Multi axis servo amplifier 10 2 1 2 General characteristics 0000 10 2 1 3 Chassis with fan unit sau bred dme ons 10 2 1 4 Chassis without fan unit 10 2 2 Compact enclosures 089163 Z and 089180040Z 10 2 3 Connector sets 099075010Z and 099073010Z 10 2 4 Motor connection cables 535246 Z and 535264 Z 10 2 5 Resolver Encoder connection cable 535245 2 10 2 6 Ferrite ring 042103010 4 2 ee 10 2 7 Motor chokes 038096010Z and 038097010Z 10 2 8 RFlI filters 002057030Z and 002057020Z 10 2 9 Shield connection plate 089159 Llllslsuus Chapter 4 Notes for specialists 11 Modifications to the servo amplifier 2 000002 eeee Modifying the controller circuitry llli 11 1 11 2 11 1 1 Speed control range ss cedunt re rS x 11 1 2 Number of motor pole pairs llle 11 1 3 Current control instead of speed control Modifications to the feedback 0 ccc eee ec cece tees ences 11 2 1 Resettime Sec csc y clench heed ee Se eid tate tents ae 11 22 Dirceu areas esta d Rad 11 3 Modifications to 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 221055E V 1 5c 7 11 3 1 Location of the s
35. V 1000 r p m Speed range 14 000 r p m 0 5 V 1000 r p m Output current monitor R 10 kQ 10 V for 15 A 10 V for 30 A Switching frequency 16 kHz Frequency of current ripple 32 kHz Auxiliary voltage outputs 15 V and 15 V 10 Load capacity of auxiliary voltages 10 mA each For option E1 external control circuit supply 24 V DC 15 25 approx 200 mA at 24 V Climatic category DIN EN 50178 oper stor transp 3K3 1K4 2K3 Permissible continuous current rms with convection cool ing and 40 C ambient temperature Permissible switching duration at max current cycle time 10 min convection cooling 40 C ambient temp Permissible ambient temp in cont operation ventilated Required minimum cooling air flow for continuous duty at 50 C ambient temperature Wiring to Combicon Recommended cross section 1 5mm 2 5 mm connectors Minimum cross section Fuse link on the board size 5 x 20 mm 10AT 16AT Widin standard Height 3 height units 128 mm Depth without connectors 165 mm Weight 0 6k 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 66 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 17 3 3 Details 3 3 1 Design 3 3 2 Chassis KSV 3HE
36. ady signal see section 11 3 page 84 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 84 The ramp rise can be set with a potentiometer on the add on module The potentiometer is marked with two ramp symbols e Left hand limit slope of 7 ms per 1 V of setpoint voltage e right hand limit slope of 70 ms per 1 V of setpoint voltage that means a setpoint jump of 10 volts leads to a linear rise of the internally effective setpoint within 0 7 seconds 6 2 3 Add on module Z4 The customer module labeled P I I 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 221055E V 1 5c Tip Tip The speed control loop is divided e in the P component P controller adjustable with the Feedback Verst rkung potentiometer on the front panel e and the component I controller Theltime constant can be sel
37. aintenance 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 RFI filter must in accordance with DIN VDE 0160 like the protective earth conductor have a cable cross section of at least 10 mm Cu The other potential equilization cables must have a cross section of at least 2 5 mm or preferably 4 mm GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 39 It is true that drives can run without potential equilization cables without shielded cables and without compliance with safety regula tions However this e is contrary to elementary safety requirements Do not e violates statutory regulations and endangers the safety of persons endangers the operational safety of the system and may lead to faults from and in other parts of the system 4 4 4 Mains connection 4 4 4 1 Connection mains RFI filter In any case as shown in fig 5 switch in the mains connection a RFI filter matching the chosen transformer see table Technical CE EMC specifications of the mains transformers page 70 e The mounting of the RFI filter is described above Connect PE to earth cable cross section according to DIN VDE 0160 of min 10 mm The connections are labeled at the terminals of
38. arked 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 Speed control or current control the set control mode is marked with a cross Speed control n Current control M Reset time the set time constant is marked with a cross t0 10 ms open 20 ms t1 30 ms t2 40 ms t1 t2 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 I5 Active braking off aktive Bremse Aus BR1 Ramp function on Sollwer Rrampe Ein Ein Modifications to Z4 add on module Feedback time constant the set time constant is marked with a cross Limitation of the speed controller component the set limitation is marked with a cross 10096 open 10 lim1 20 lim2 30 lim3 Modification to polarity module marked with a cross when solder bridge closed GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 90 Operating Instructions 221055E V 1 5c 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 p
39. below To do this the offset trimmer on the front panel is required as well as the SMD potenti ometer on the right hand board which is marked P3 n OFFSET See also fig 12 There are two options for offset adjustment e With measuring device Switch off the controller enable GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 81 measure the voltage at the analog output Speed monitor and then make this voltage zero using the SMD potentiometer P3 n OFFSET 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 SMD poten tiometer P3 n OFFSET 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 right hand board Modify by relocating the jumpers on th
40. between power supply and amplifier in the wiring duct 4 4 8 Setpoint connection When connecting the setpoint source top right in fig 5 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 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 43 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 Ti Always use the differential input Ip 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 9 Connection of the encoder signals Figure 5 top right shows the connection of the encoder signals to a positioning controller Please note e Choose twisted pair cables for the 5 volt version e Use a shielded cable forexample the resolver encoder connecting cable mentioned in the accessories for further details see section 10 pag
41. ble 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 14 15 or 16 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 14 or 15 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 0 711 75903 53 88 Operating Instructions 221055E V 1 5c Figure 16 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 eo 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
42. 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 17 453 GHG U X Rasen sae ee tco BB BARES TEE BEBBSERSL IL tree BN 6661 0000 00B 063 INGOW d Fig 17 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 221055E V 1 5c 89 12 Documentation of the settings Copy this page and enter into the following tables the nameplate Tip information and all of the settings and modifications you have carried out Keep these sheets with your documentation If you should later require a similarly configured or modified device send us a copy of these tables Nameplate information In case of multiple devices Device No SN Current setting the switch setting is marked with a cross Lep ele 4 sp cep v s el alec a ee Encoder pulse setting the switch setting is marked with a cross re Ee eo eee aes Speed control range the range set is m
43. de 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 221055E V 1 5c 57 6 6 Option E1 external supply of control circuit In the standard version the E1 module External supply of control circuit module is not fitted When the supply voltage is switched off e the position information disappears The version with the E1 module External supply of control circuit has an input for the separate feeding of a supply voltage of 24 V see table Technical specifications page 16 for connection see section 4 1 2 page 19 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 221055E V 1 5c 7 Shu
44. dingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 38 Operating Instructions 221055E V 1 5c e If you cannot use the shield connection plate install cable clamps on the mounting plate as close as possible to the RFI filter 4 4 2 Installation in a 19 rack system For the installation in a common control cabinet with 19 system use a chassis specially designed for this purpose Install the chassis by e screwing its bare metal mounting flange on the bare metal rack CE EMC made of chromated aluminum or made of zinc plated sheet steel with low resistance earthing i e connected to the central zero point via a shortest possible potential equilization cable of cross section 10 mm or more or better using a wide copper braiding earth strip Do not use varnished or anodized racks Follow the instructions given in the preceding section correspondingly e to install and earth the RFI filter e to earth the cable shields 4 4 3 Potential equilization cables Figure 5 shows potential equilization cables They come from the central zero point of the control cabinet Their tasks are e they forma low 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 ensures protection of the operating and m
45. dles at the front order number 089074010Z e 84 units wide for installation on mounting plate fig 9 mounting flanges at the rear without handles order number 089074020Z 54 unites wide for installation on mounting plate mounting flanges at the rear without handles order number The chassis 84 units wide can accommodate 6 amplifiers and 1 power supply or 5 amplifiers and 2 power supplies The chassis 54 units wide can accommodate 3 amplifiers and 1 power supply The chassis with fan units provide at the lower part of the front e wiring duct to accommodate the DC bus connections between power supply and servo amplifiers GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 74 Operating Instructions 221055E V 1 5c NE E 4 eas o 3 EZ m dm zi in ER Sr l kl Kabelkanal Wiring duct 40x40 mm BN 9135 0000 00A 050 483 UM Kabelkanal Wiring duct 40x40 mm Sa YN BN 9135 0000 004 051 Fig 9 Wall mount chassis 84 units wide for installation on mounting plate GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 75 At the same location there is a 3 pin Combicon connector for supply of the fans e Supply 230 V mains voltage Assignment from left to right Le In ee 10 2 1 4 Chassis without fan
46. e Power circuit ready output is set to 1 When the servo amplifier e is faulty or e disabled then the Power circuit ready output switches to 0 For further details on fault monitoring please refer to section 4 2 10 Fault memory page 29 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 27 4 2 4 Analog outputs The analog output Speed monitor supplies a e voltage proportional to the motor speed the polarity corresponds to the direction of rotation for example to connect a measuring instrument to display the speed The analog output Current monitor supplies a e voltage proportional to the current flowing in the motor the polarity corresponds to the direction of the torque Preconditions e Motor correctly connected Motor operating within the voltage limits of the amplifier For values of both outputs see table Technical specifications on page 16 4 2 5 Encoder signals holding function Encoder signals are available 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 53 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 s
47. e field X 13 labeled MOTOR TYP motor type There are 4 positions for each jumper The positions are labeled 2PP 4PP Sel1 and Sel2 Figure 12 shows the location of the jumpers and the locating options Jumper in position 2PP motor with 2 pole pairs e no jumper plugged in motor with 3 pole pairs e jumper in position 4PP motor with 4 pole pairs e jumper in position Seli or Sel2 special motor further details on request The number of pole pairs is factory set for the used motor see type code page 15 Kx option GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 82 Operating Instructions 221055E V 1 5c P3 Zusatzmodul Funktionsmodul Gebermodul Add on module Function module Encoder module n offset ZUSATZMODUL GEBERMODUL 8 Sinustabelle n urn 1 GJ I LEISTUNGSVERSTHRKER FUR _BURSTENLOSE MOTOREN oe oe en Tee ur 2 Polpaare Strom Drehzahlbereich ss 500 3500 min Motortypl Io Sell 2 ie pairs Current bei 10 V Sollwert ERI Motor type 22 5812 Speed range Em at 10 V setpoint Tal 1000 7000 min 3 Polpaare aS 3 pole pairs oa u A al jm 1500 10500 min 4 Polpaare 4 pole pairs Jen 2000 14000 min BN 6646 0000 00B 062 Sam Fig 12 Location of the jumpers on the right hand board 11 1 3 Current control instead of speed control Whether the servo amplifier is set for speed control or for current contro
48. e 72ff Connect the shield at the amplifier to the earthed amplifier hous ing using the metal plated SUB D housing Additionally earth the shield at the controller follow the recommendations of the controller manufacturer concerning earthing and shield connection 4 4 10 Connecting the position sensor resolver The connection cable to the position sensor resolver must be laid separate from the motor cable e be connected exactly according to the instructions otherwise Check the motor blocks the motor runs roughly the motor runs with a low torque GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 44 Operating Instructions 221055E V 1 5c 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 Danger but there is a risk for the machine and the installation person nel To connect up the resolver as shown in fig 5 e use twisted pairs of leads for channel 1 channel 2 and excitation forexample the resolver encoder connection cable mentioned in the accessories for further details see section 10 2 5 page 76 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 stra
49. e 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 14 and 15 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 14 or 15 e Signal End Bereit on the Z1 module e Be on the Z2 module The Z4 add on module provides the Power circuit ready signal GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 87 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 14 15 or 16 e Impulsstrom Aus on the Z1 and Z4 modules e I on the Z2 module 11 3 5 Switching off active braking at controller disa
50. e 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 89 11 4 Modifying the controller circuitry The controller circuit is defined by the name of the customer module see type code section 3 1 page 15 In some cases it is implemented on the customer module itself in some cases through jumpers on the right hand 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 DREHZAHLBEREICH speed range 2 jumpers must always be placed at the same time The positions are marked 1 and 2 Figure 12 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 f 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
51. e of instruction a icotugrotesqtetoon oclta Ore tg ana iad taal os sacra ta odio 22 lechnicalstall 22e oo ono hehe Sebo Se he ti hi be eee s Manami 2 3 Use for the intended purpose 0c eee ee 2 4 Protective earthing stars sera stetige 2 5 Hazard warnings a2 erzeugen 2 6 GE making nn erregen 2 7 Preconditions for commissioning 2 op dpi eh oed e UR us 2 8 Opening the Housing virrie cee se oe sa eee as ees Chapter 2 Servo amplifier 3 Technical Specilications n risa ag dea Re Pe ee Pe X Ros Y ROC XC RO x 3 1 3 2 3 3 4 1 Typ code 22024 rp TE Technical specifications 1 4 ET ERAN rer por v 3 3 1 DESIGN easacme dees eeee ES RES ER ES RES ERES RES ERU eee ex 3 3 2 S ae E e urea avatars auta ria Fato ahaa a ua ara ah dea a ua Pa ha ud Pu EE 3 3 3 Compact enclosufe ss 2473 4 352 3 Gund 2 15 debi hir ea 4 Connection Assignment of connectors and details Connector assignments sea socii eor u eee ne GLAS QS 4 1 1 Motor and power supply Combicon connector X1 4 1 2 Control signals Steuersignale SUB D fem connector X2 15 pin 4 1 2 1 Version without add on module 4 1 2 2 Version with Z1 add on module 4 1 2 3 Version with Z2 add on module 4 1 2 4 Version with Z4 add on module 4 1 3 Position sensor Lagegeber SUB D female connector X3 9 pin 4 1 4 Encoder signals Gebersignale SUB D male co
52. echnical specifications 3 1 Type code The type code clearly identifies a servo amplifier equipped in a certain way The type code also applies for devices of the series with rear connections Example gt KSV 5 15 K2 Z1 P1 GO0 F0 E0 S0 WO Power 5 1 5 5 15 125 V DC bus output 5 A ms rated current 15 A peak current 10 30 125 V DC bus output 10 Ams rated current 30 A peak current Controller switching customer module and jumpers K2 KO none device not ready for operation K5 3 pole pair motor speed control 7 000 min K1 2 pole pair motor speed control 3 500 min K6 3 pole pair motor current control K2 2 pole pair motor speed control 7 000 min KA 3 pole pair motor speed control 10 500 min K3 2 pole pair motor current control KB 3 pole pair motor speed control 14 000 min K4 3 pole pair motor speed control 3 500 min KK customer specific Additional equipment through add on modules Z1 zo none standard Z4 limit switch P I I lim controller inhibit braking Z1 limit switch ramp controller inhibit braking ZK customer specific Z2 external current limiting rotation reversal Input output polarity polarity module P1 PO switching towards zero standard P2 PLC compatible ready output P1 PLC compatible fault output PK customer specific Additional equipment through encoder modules GO incremental encoder emulation GO no pulse outputs standard G3 pulse outputs with index pulse shift 5 V push pull G1 pulse outputs
53. ected by solder bridges on the Z4 add on module for further details see section 11 3 7 page 87 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 87 For the purpose of commissioning a special module is available on which e potentiometers for time constant and limitation threshold are mounted The special module is not suitable for normal operation because the potentiometers e jut out of the amplifier and 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 84 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 84 It is essential that you should document all changes in the table in section 12 page 89 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 53 6 2 4 Furthe
54. ection 4 4 4 corrections document styles similar to German version V 1 5b 24 09 01 V 1 5c MH OEM preparation corrections similar to German version V 1 5c 0 pdf Vorlagen GK 221055E_15c 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 221055E V 1 5c 3 Contents Chapter 1 General information 1 Preliminary remarks 2x Ru lo 1 1 About this description soe recte to een 1 2 KSV 3HE Servo Drive Packages sss so 405 bom nsus bom REESE ERES s 2 Safety Inslr clions e dns to Re NU M oat eta E Ie RR IS 2 1 Typ
55. ectional braked e controller enable braking in case of shutdown can be switched to non braking using a solder bridge switching output internally selectable Motor standstill or Power circuit ready e peak current can be switched off by means of a solder bridge e ramp function can be switched on by means of a solder bridge Using the limit switch inputs the motor is e shut down depending on the direction of rotation and is actively braked by reversal The Controller enable input also e actively brakes the motor by reversal Active braking can be switched off For conversion by the specialist see section 11 3 page 84 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 84 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 84 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 84 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
56. en or open or lt 2 V gt 13 V Logic level for logical 1 lt 2 V Permissible PLC signal 15 35 V voltage 4 2 3 2 Switching input Controller enable At the switching input Controller enable the logic level for e 1 leads to amplifier enabled motor can run the green Ready LED lights up e 0 leads to amplifier disabled the motor decelerates brakeless the green Ready LED flashes Disabling through the Controller enable switching input does not meet the safety requirements of the machine directive 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 29 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 25 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 th
57. ent of the speed controller can be switched off Figure 13 shows the location of the solder bridges The following applies GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 84 Operating Instructions 221055E V 1 5c 11 2 2 D circuit Solder bridge Reset time none 10 ms i t2 30 ms TET standard factory setting On former versions of the module the t0 solder bridge is missing I component cannot be switched off and the location of the other solder bridges is slightly different from the one shown in fig 13 With the Z4 add on module the time constant can be adjusted on the add on module itself 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 13 The values must be determined by experiment 100 nF and 100 kQ can be regarded as guide values D circuitry connection is not provided with the customer module be longing to the Z4 add on module 11 3 Modifications to the Z1 Z2 and Z4 add on modules 11 3 1 Location of the solder bridges The following figures show the position of the solder bridges on the Z1 Z2 and Z4 add on modules GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 85 Zusatzmodu
58. ere is a fault then e the Fault output switches to 1 For further details on the fault signal and on the fault memory see section 4 2 10 page 29 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 29 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 80ff 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
59. ersion 4 3 4 Connector X4 encoder signals 24 volt version 4 4 Connection directions s Er Berne FTSE ER ds 4 4 1 Installation on the mounting plate 2000000 4 4 2 Installation in a 19 rack system lslselllesssn 4 4 3 Potential equilization cables lsllssssless AAA Mains connection s sec dens Ee pee ERRRESERSOE EETENS 4 4 4 1 Connection mains RFHfilter 222 22 4 4 4 2 Connections RFI filter mains transformer power suppl TEPORE T TE 4 4 4 3 Connection servo amplifier power supply 4 4 5 Motor connection general information 4 4 6 Motor choke u teen teen es 228 C8 ee oe 4 4 7 Connection shielding and laying of the control leads 448 Setpoint connection ics cum sssaaa snarer Ace e peor 4 4 9 Connection of the encoder signals 2 0 000 4 4 10 Connecting the position sensor resolver 4 4 11 X 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 221055E V 1 5c 5 5 Adjustment and display elements 000 cece een 5 1 Trim potentiometers 0 002 eee 5 2 Current limiting and Current rotary switch 2222222 Bo LEDS 24 En en el eae Old Re A A RA a EO She es A Lore ie d 6 Modular
60. etpoint or by using the controller enable With emergency stop switches or other functions important for the safety of persons or property it must therefore be ensured that the shutdown e is effected directly by positively driven contacts which shut down either the motor supply line or the power supply to the amplifier For further details see the relevant regulations including DIN VDE Do not Caution 0113 EN 60204 Safety of machines electrical equipment in ma chines e The operating voltage must not be switched off and on on the DC side because the charging capacitor of the power supply would be switched directly onto the input capacitor of the amplifier GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 60 Operating Instructions 221055E V 1 5c this would result in current peaks of more than 1000 A which would destroy the relay contacts and overload the capacitors e Therefore switch the operating voltage off and on before the power Tip supply GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 61 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 disengage the motor from
61. f the user ueensessessnnsssnnnenennnesnnsensnnnenannennensenennensnnnennnnsnnnsnnsnnnennannnnnnene Dok Nr Ausgabestand erstellt ge ndert Seite Schilhab Datum Signum 47 f 7 10 4 34 4 18 Januar 2000X 1 Mrika Datum Signum 48 Januar 2000 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 91 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 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
62. 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 89 if you have changed the factory settings GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 55 6 4 2 Index pulse adjustment Tip With the G3 and G4 encoder modules adjustable index pulse the position of the index pulse can be shifted within a motor revolution Forthis purpose the encoder module has two rotary switches Rough and Fine and three LEDs 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 circumfe
63. front panel If the option F1 Holding control loop is missing connection point 9 is not connected Please note e the separate voltage supply of the output f schaltend SPS kompatibel intorn 0 Volt ching towards PLC compatible swit Switching input Hold only with option F1 Holding control loop Supply 0 V Voltage supply 24 V Pulse output phase 1 Pulse output phase 2 Pulse output index pulse BN 6646 0000 00A 054 Fig 4 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 221055E V 1 5c 35 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 3HE drive package is connected in accordance with the directions given here 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 5 shows for one axis of the KSV 3HE 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 using the shield con nection plate Figure 6 shows the arrangement of e the chassis
64. in the case of the external supply of the control circuit module E1 This also resets resolver faults Before switching back on wait until the Fault LED has gone out n 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 30 Operating Instructions 221055E V 1 5c 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 67 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 itd
65. isappears when the correct operating voltage has been reached again GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 31 4 3 Interface details 4 3 1 Connector X2 control signals switching towards zero The following figure shows the interface details internal circuit at the 15 pin SUB D male connector for the control signals section 4 1 2 2 page 20 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 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 Option Output auxiliary voltage 15 V Switching input Reset fault 0 Volt BN 6646 0000 00A 051 Fig 1 Control signals switching towards zero interface details GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711
66. it has the effect which has been set at the Cur rent selector switch e If there is a voltage of less than 10 V at the input the current limit is reduced proportionally First only the peak current is reduced Only when the current limit is lowered by the external setpoint below the peak current value the continuous current is also reduced e Values of over 10 V do not cause a higher current than 100 and values of less than 0 1 V do not cause a lower current than 196 of the set value The peak current rise can be switched off e for conversion by the specialist see section 11 3 page 84 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 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 84 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 re
67. l Z1 Z1 add on module Oo Impulsstrom aus Peak current off Je Inpuls strom Aus aktiv Aktives Bremsen aus Dy Brense Aus Active braking off BN 6661 0000 00B 061 Z1 Modul 9 E m Rampenfunktion ein o weri Rompe Ea 4 Ramp function on Endcderei 198 Endstufe bereit an statt Motor steht Power circuit ready instead of Motor standstill Fig 14 Solder bridges on the Z1 module Z2 add on module Zusatzmodul Z2 O ar Impulsstrom aus I 7 Ip Peak current off Endstufe bereit an ti statt Motor steht Power circuit ready instead of Motor standstill Jo BN 6661 0000 00C 062 o Fa Rampenfunktion ein Eis 4 Ramp function on BPI Aktives Bremsen aus EB Active braking off e Fig 15 Solder bridges on the Z2 module GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 86 Operating Instructions 221055E V 1 5c Zusatzmodul Z4 Z4 add on module Oo o zi Z4 Modul EEE EN N l Zeitkonstante ol time constant Peak current off gt jea laele 1 il E n ktiv E Aktives Bremsen aus 9 s Brense Aus d Sp Active braking off H i Begrenzungsschwelle sl Limitation threshold A i i un Npe eje eii Kiil 7 ral p a n X Potentiometer nur auf Sondermodul BN 6661 0000 00A 064 Potentiometer on special module only Fig 16 Solder bridges on th
68. l is implemented on the customer module module K3 for 2 pole pair or K6 for 3 pole pair motors To switch the servo amplifier from speed control as supplied to current control e open the solder bridge n e and close the solder bridge M GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 83 Figure 13 shows the location of the solder bridges The following then applies e 10 V setpoint corresponds to the peak current set at the Current rotary switch S1 L tbr cken Solder bridges Drehmomentregelung Torque control Drehzahlregelung Speed control L tbr cke t0 Solder bridge tO KUNDENMODUL L tbr cke t1 f r BN664 x Solder bridge t1 E l and L tseite Best ckungsseite L tbr cke t2 Solder side Component side Solder bridge t2 BN 6646 0000 00B 063 Fig 13 Location of the solder bridges on the customer module Current control is not provided with the customer module belonging to the Z4 add on module 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 solder bridges t1 and t2 Using the t0 solder bridge the compon
69. lowly For further details see section 6 5 1 page 55 4 2 6 Position sensor The input for the position sensor is dimensioned for the common servo drive type e 2 pin resolver 1 pole pair with a gear ratio of 1 0 5 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 28 Operating Instructions 221055E V 1 5c 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
70. n section 11 3 page 84ff 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 tO 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 64 Operating Instructions 221055E V 1 5c e 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 the current limit at the open device through the Current rotary switch see section 5 2 page 45 It is essential that you should document the new switch position in the table in section 12 page 89 if you have changed the factory settings Never set the continuous current higher than permissible for the motor Otherwise may
71. nction protects the motor and the amplifier From the unloaded state a maximum current equivalent to the preset peak current is possible e 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 current limit is located on the right behind the front panel between the two plug in connectors 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 lp as rms GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 46 Operating Instructions 221055E V 1 5c Tip value and peak current as crest value is shown in the following table Servo KSV 5 15 KSV 10 30 amplifier Current Continuous Peak current Continuous Peak current switch current lp A I A current lp A I A SL TZ mum tek 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 F maximum current If you have
72. ndex pulse inverse U for 24 V vers not assigned Housin Connect cable shield to the housing of the SUB D connector Tu 1 4 2 Details about the signals This section describes details about the signals named in the connec tion assignments The sequence corresponds to the sequence of connectors given above 4 2 1 Auxiliary voltage outputs The two auxiliary voltage outputs are primarily for connecting an external setpoint potentiometer for initial tests see fig 7 page 62 The auxiliary voltage outputs must not be short circuited For height tolerance and load carrying capacity of the auxiliary voltages see the table Technical specifications page 16 The auxiliary voltages are only roughly stabilized their voltage values vary within the given tolerances when the amplifier output is placed under load GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 23 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 8 page 42 you avoid faults caused by neutral loops with the differential input f A positive setpoint E positive against E results in a clockwise Tip rotation of the motor shaft when looking towards the bearing plate 4 2 3 Switching inputs and switching outputs Through the
73. nds pigtails of the shield e Do not connect the shield at the motor side 4 4 11 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 221055E V 1 5c 45 5 Adjustment and display elements The adjustment and display elements contained in all KSV 3HE ver sions are described here Special information for the versions with expansion modules is given with the appropriate options 5 1 Trim potentiometers 3 or 4 trim potentiometers are accessible on the front panel of the amplifier Their significance is in the sequence from top to bottom Schematic Effect with clockwise Feedback Amplification speed A P 1 ER Verst rkung control circuit I rises Speed Drehzahl E Speed adjustment Speearises rises Offset Nullpunkt Offset adjustment Lu eee i spas 7 LN holding Kr el control loop Ampiiicton ses rises The Hold trim potentiometer is implemented only with option F1 holding control loop 5 2 Current limiting and Current rotary switch A current limiting device with I t fu
74. nection 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 221055E GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53
75. ngen phone 49 0 711 75903 0 fax 49 0 711 75903 53 62 Operating Instructions 221055E V 1 5c 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 80 8 4 Setting the feedback normal case How to proceed with a speed controller 3 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 Observe motor behavior at different speeds and at standstill if the feedback is set too hard the motor runs loud and rough ifitis 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
76. nnector X4 2s DUE UTE ET e a a Ohne ee a oy a oes 22 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 4 Operating Instructions 221055E V 1 5c 4 2 Details about the signals xxxi I RR RE REPRE 4 2 1 Auxiliary voltage outputs s s 5 RR eh ee eed SERE REESE 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 222220 4 2 3 4 Switching output Fault or Ready 4 2 3 5 Switching output Overload 224 4 2 3 6 Switching output Motor standstill or Power circuit ready 4 2 4 Analog oH DIS nee tne aie ee ae ee eS AS ee et 2 4 2 5 Encoder signals holding function 22222222220 426 POSING Sensor ee ee teda 4 2 7 Motor temperature sensor 2 eee 4 2 8 Sensor fault detection oonan ee ee eie het 4 2 9 Block protection ses sospes eoo ob do o obo ope a Saa 42 10 Fault memory oci a eb ar FUE RU en a RE SER eee as 4 3 interiace details udn reas e re p ru eR Pv 4 3 1 Connector X2 control signals switching towards zero 4 3 2 Connector X2 control signals PLC compatible 4 3 3 Connector X4 encoder signals 5 volt v
77. normal operation e If the motor is at a standstill for longer than about 10 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 221055E V 1 5c 29 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 10 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
78. ntrol 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 A pre sensor reduces the speed of the motor in good time before the position so that later no more than a single revolution will be needed to brake the motor asensor 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 mo
79. oad are added The total load factor thus calculated determines the transformer required e Check to make sure that the load factor of the power supply is not exceeded GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 71 If itis exceeded several power supplies and possibly several transformers must be used Never connect several power supplies to one transformer winding Caution Equalizing currents from the common zero endanger the rectifier diodes the power circuits of the setpoint sources and the setpoint inputs 9 3 4 Shield foil To comply with the EMC directive CE EMC TI e the transformers supplied by us are equipped with a shield foil between the primary and the secondary winding and with a shield foil covering the outer winding GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 SQ N Operating Instructions 221055E V 1 5c 10 Accessories 10 1 Available accessories and order numbers Accessories Order number Chassis 54 and 84 units empty with and without fan units see pages 73 75 Compact enclosure with installed power supply single phase connection 089163 Z Compact enclosure with installed power supply three phase connection 089180040Z Connector set for KSV 3HE servo amplifier without encoder module option 0990750102 Connector set for KSV
80. ol cabinet BN 6646 0000 004 055 Fig 5 Connection directions GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c Chassis on mount ing plate Shield connection plate All shields are connected here as RFI filter on mount ing plate Wiring duct for mo tor cable Fig 6 Spatial arrangement in the control cabinet shown also in fig 5 Mains transformer on bot tom of control cabinet BN 6646 0000 00A 056 be connected to the central zero point via a shortest possible potential equilization cable Of cross section 10 mm or more or better using a wide copper braiding earth strip To ensure a well conducting connection for high frequencies between the housing of the RFI filter the mounting plate and the chassis e install the RFI filter directly on the bare mounting plate below the chassis Establish the earthing of the motor cable shields at the shield connec tion plate where the RFI filter is installed by e removing a ring shaped part of the isolating cable sheath and clamping the bare shield on the shield connection plate The length of the remaining cable between the earthing point of the shield and the connector at the amplifier has to be no longer than 50 cm It remains shielded The shield is not connected at the cable s end GEORGII KOBOLD D 70771 Leinfelden Echter
81. older bridges sssus 11 3 2 Former versions of modules Z1 and Z2 11 3 3 Power circuit ready signal instead of Motor standstill signal 11 8 4 Switching off the peak current rise 22 222 o seen 11 3 5 Switching off active braking at controller disable 11 8 6 Activating the ramp function 0200 cece eee 11 3 7 Adjusting and limiting the component of the speed controller 11 4 Modifications to the polarity module 2 000 cee eee 11 4 1 Ready signal instead of Fault signal 12 Documentation of the settings 2 20 ccc ee Appendix Appendix A EC Declaration of Conformity 2222 Appendix B Terms of warranty slslllsell eee Appendix C Table of faults llsss e GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 8 Operating Instructions 221055E V 1 5c Figures Fig 1 Control signals switching towards zero interface details Fig 2 Control signals PLC compatible interface details llli Fig 3 Encoder signals 5 volt version interface details 0055 Fig 4 Encoder signals 24 volt version interface details 05 Fig 5 Connection dire clleis cuc xe ver teo ee oe mur xe oe xc mr eot Fig 6 Spatial arrangement in the control cabinet
82. ower off 1 minute until the DC bus capacitors have discharged before carry wait 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 ENC directive 89 336 EEC low voltage directive 73 23 EEC machinery directive 89 392 EEC CE EMC GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c VDE regulations such as DIN VDE 0100 DIN VDE 0113 EN 60204 gt DIN VDE 0160 EN 50178 safety rules may the
83. p as described above The motor cables e have to leave the control cabinet at shortest possible distance GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 42 Operating Instructions 221055E V 1 5c e must not be laid parallel to sensible control leads or unshielded mains cables lf parallel arrangement cannot be avoided ensure a distance of min 25 cm to the other cables 4 4 6 Motor choke Longer motor cables can overload the device and lead to intolerable CE EMC high emission e f the motor cable is longer than 10 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 7 page 77 4 4 7 Connection shielding and laying of the control leads These notes on connection shielding and laying of the control leads CE EMC apply for the following three sections Use only shielded leads e The SUB D connectors must have metal plated housings like the connectors supplied by us There the shield is connected with a low resistance to the hous ing via the strain relief e This allows you to achieve the necessary large area earth connec tion for the shield and to avoid earthing the shield using twirled strands pigtails of the shield Do not lay control leads parallel to motor cables or to connections
84. plifier in a different way e itis your responsibility to check the installation for complying with the EMC limits GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 18 Operating Instructions 221055E V 1 5c 3 3 3 Compact enclosure The compact enclosure is used when the application requires one single KSV 3HE servo amplifier It includes one power supply and offers space to install the KSV 3HE servo amplifier See also section 10 2 2 page 75 Further details can be found in operating instructions 221051 Compact Enclosures GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 c Operating Instructions 221055E V 1 5c 1 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 power supply Combicon connector X1 Marking Assignment Motor connection U o Q c Motor V Motor connection V Motor connection W PE PE for motor cable Negative pole of bus voltage from power supply Us Positive pole of bus voltage from power suppl 4 1 2 Control signals Steuersignale SUB D fem connector X2 15 pin 4 1 2 1 Version without add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Inp
85. r 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 23 it ensures that the switching inputs and outputs are PLC compatible that is that they switch towards 24 V If it is not implemented these inputs and outputs switch towards zero 6 4 Encoder modules G1 to G4 Application of the encoder signals e Connection of positioning controls e Connection of a digital speed counter for monitoring the motor speed For all encoder modules 16 different pulse numbers can be set Encoder signals are available only if the encoder module is fitted For the various encoder modules see type code section 3 1 on page 15 e Standard G1 encoder module outputs like standard incremental encoder 5 volt push pull RS 422 interface with SN 75114 line driver phase 1 phase 2 index pulse and corresponding complement that is 6 lines electrically isolated from the remaining circuit via optoelectronic coupler external supply as with incremental encoders with 5 V 5 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 55 e G2 encoder module pulse output for 24 volts inte
86. r in case of single phase connection Load factor in case of three phase connection 12 Maximum continuous braking power 30W Peak braking power 296 switching cycle 2 sec 200 W Fuse link 6 x 32 mm 25AT Climatic category DIN EN 50178 operation stora 3K3 1K4 2K3 ge transport Dimensions Width Height Depth without connector 10 units 51 mm 3 height units 128 mm 165 mm 9 2 6 External shunt resistor The plug in power supply can be supplied as a special version for an external shunt resistor The resistor is connected to an additional terminal at the rear edge of the board of the power supply Further details on request 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 Please contact us if you wish to operate the unit in this way 9 3 Mains transformers 9 3 4 General information Mains transformers for operating plug in power supplies e single phase connection for up to 0 5 kW power e three phase connection for higher power As well as the standard transformers shown in the following table we can also supply special versions further details on request GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 70 Operating Instructions 221055E V
87. recise installation instructions can be found there The filter has to be dimensioned GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 79 e according to the power of the power supply or the mains trans former respectively You find the suitable filter e in the table of the technical specifications of the mains transform ers page 70 Figure 11 shows the dimensions of the RFI filters BN 3841 2302 00A 050 Dimensions in mm A B C D E F 002057030Z 99 105 58 51 95 4 3 0020570202 115 Fig 11 RFI filter 10 2 9 Shield connection plate 089159 To establish earthing of the motor cable shield in compliance with CE EMC EMC the shields have to be connected close to the RFI filter The shield connection plate 089159 which can be supplied as acces sories simplifies this procedure It will be screwed together with the HFI filter 8 cable clamps are attached at the shield mounting side allowing the correct earthing of the shields of 6 motor cables and the shields of the connections between mains filter and transformer and between transformer and power supply GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 80 Operating Instructions 221055E V 1 5c Chapter 4 Notes for specialists 11 Modifications to the servo amplifier This section describes how th
88. refore e install e commission e maintain and Service these units They must read these operating instructions carefully beforehand and always follow the safety instructions while working 2 3 Use for the intended purpose The servo amplifiers and the power supplies have been developed manufactured tested and documented in accordance with the rele vant standards If used for the intended purpose the devices do not cause any danger to persons or property Use for the intended pur pose requires that the device should be used only in the manner described here and that the safety regulations mentioned are adhered to When using the devices use for the intended purpose includes com pliance with the relevant regulations with respect to safety machinery directive and electromagnetic compatibility EMC directive Dispose of the apparatus at the end of its useful service life in accor dance with the current regulations GEORGII KOBOLD AUGUST HEINE GmbH amp Co can accept no liability for direct or indirect damage resulting from abuse of the de vices 2 4 Protective earthing On account of leakage current from the RFI filter to bebuilt in the protective earth conductor in accordance with DIN VDE 0160 must e either be run double to the amplifier or e have a cable cross section of at least 10 mm Cu Operation using an earth leakage circuit breaker is not possible e due to the leakage current of the RFI filter and
89. rence When a pulse figure of over 256 is set then the index pulse is narrower than 1 256 of the circumference For this reason the Zero LED does not light up within the entire adjust ment window of 1 4 For it to light up the motor shaft must be rotated within the window to the exact zero point 6 5 Function module Fx Various functions including customer specific functions are imple mented on the function module So far there are the hold function and the field weakening mode which will be described in the follow ing 6 5 1 Hold function F1 Disadvantages of conventional servo drives when the motor is at a standstill e If the controller enable is canceled the motor is at a standstill without torque e If the 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 GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 56 Operating Instructions 221055E V 1 5c 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 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 co
90. rface push pull outputs actively switching towards zero and towards 24 volts phase 1 phase 2 and index pulse without complement over 3 lines GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 54 Operating Instructions 221055E V 1 5c outputs electrically connected to the amplifier circuit outputs short circuit proof external supply as with incremental encoders with 24 V 20 e G4 encoder module characteristics like G2 but in addition with adjustable index pulse The index pulse can be shifted in 256 steps within one motor revolution For further details see section 6 4 2 page 55 aK 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 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 Bi Pulsesper per Switch setting setting Pulses per revolution revolution im 1024 180 100 E CI cHOERS standard factory setting ale jolwm o oOIo l u I gt o o p specially intended
91. roducts Product GEORGII KOBOLD Type KSV 3HE front connection Series KSV Servo Amplifier correspond to the EC directives standards and regulations below and are designed for installation in a ma chine According to EC directive Machines commissioning is prohibited until it has been ascertained that the machine in which the above product is installed meets the provisions of the EC directive The requirements of the EC directives standards and regulations will only be met if the directions for instal lation and cabling given in the operating instructions are observed Operating instructions 22 10 55E The products are developed constructed and produced in accordance to EC Directive EMC directive 89 336 EWG amended by 91 263 EWG 92 31 EWG 93 68 EWG Low voltage directive 73 23 EWG amended by 93 68 EWG of exclusive responsibility of company GEORGII KOBOLD Postfach 10 01 54 D 70745 Leinfelden Echterdingen Fasanenweg 6 8 D 70771 Leinfelden Echterdingen AUGUST HEINE GmbH amp Co Telefon 0711 75903 0 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 o
92. s for the amplifiers the power supplies and the mains transformers The following applies When all amplifiers are being operated simultaneously at full load the sum of their load factors must not exceed the load factor of the power supply and the one of the mains transformer When not all amplifiers are being operated simultaneously at full load which is frequently the case with servo drives the total load factor is the sum of the load factors of the amplifiers being oper ated simultaneously When amplifiers are operated under part load only their load fac tors are reduced for purposes of the calculation in proportion to the part load Example The KSV 5 15 KSV 3HE amplifier has a load factor of 3 the 2800200000 power supply has a load factor of 12 this means that this power supply can run 4 of these amplifiers simultaneously at full load Power supply Design The servo amplifiers the power supply and the mains transformers are well matched Design of the power supply order number 2800200000 19 plug in module designed in the same way as the servo ampli fier for installation into the 19 chassis together with servo amplifi ers The power supply contains the mains rectifier the charging capacitors the monitoring circuit and GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 67 e the shunt regulator wi
93. servo amplifiers are manufactured as 19 plug in modules They consist of two printed circuit assemblies PCAs in euroboard format 100 x 160 mm with heat sink arranged in parallel the cus tomer module and the front panel The PCA on the right has slots for the modules explained later All connections trim potentiometers and LEDs are located at the front panel e control signals 15 pin SUB D female connector e motor and operating voltage input 7 pin Combicon connector e position sensor resolver 9 pin SUB D female connector e output for encoder signals 15 pin SUB D male connector connected only if encoder module is mounted For continuous currents up to 3 A KSV 5 15 or 3 5 A KSV 10 30 the devices work e with natural convection At higher continuous currents e they need fans like the ones included in our chassis with fan units For currents and temperatures see table Technical specifications page 16 for chassis see section 10 page 72 Use chassis to combine multiple KSV 3HE amplifier plug in modules with the power supply or several power supplies For further details refer to section 10 2 1 page 72 The requirements of the EMC directive are fulfilled if the KSV 3HE servo amplifiers are built into an Georgii Kobold chassis and e if the installation follows the connection directions given on pa ge 35ff The CE marking is valid only when the EMC limits are complied with If you install the am
94. tching 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 Der Analog output Current monitor Connect cable shield to the housing of the SUB D connector GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 Operating Instructions 221055E V 1 5c 2 4 1 2 4 Version with Z4 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E 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 D connector 4 1 3 Position sensor Lagegeber SUB D female connector X3 9 pin Pin Assignment 0 volt connect
95. th a shunt resistor sufficient for common servo applications For the power supply various mains transformers are available both for single phase connection to 230 V and for three phase connection to 3 x 400 V 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 prevents that the power transistors are destroyed by that 9 2 3 Connection assignment terminal block X5 12 terminals in 3 blocks are located on the front panel of the power supply Upper block 4 terminals connected in parallel for the positive pole of the bus voltage labeled U e central block 4 terminals connected in parallel for the negative pole of the bus voltage labeled U e lower terminal block with larger terminals connection of mains transformer Terminal assignment 4 terminals connected in parallel for positive pole of bus volt age This allows a separate line to be laid to each of 4 con nected amplifiers age This allows a separate line to be laid to each of 4 con nected amplifiers 4 terminals connected in parallel for negative pole of bus volt PE Power safety ground external connection Phase 1 secondary side transformer V Phase 2 secondary side transformer Phase 3 secondary side transformer GEORGII KOBOLD D 70771
96. the connection to 3 x 400 V three phase current and the RFI filter 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 3HE Servo Drive Packages KSV 3HE servo drive packages consist of e the brushless motor with coupled resolver as a speed and position sensor e the analog servo amplifier e a power supply with mains transformer connected in series The series described here with the connection on the front panel comprises e amplifiers for 2 different currents 5 A and 10 Asn e amplifiers with different specifications optional GEORGII KOBOLD D 70771 Leinfelden Echterdingen phone 49 0 711 75903 0 fax 49 0 711 75903 53 10 Operating Instructions 221055E V 1 5c e power supplies for 19 rack system plug in power supplies e mains transformers for the plug in power supplies e R
97. 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 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 45 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 the auxiliary voltage outputs section 4 2 1 page 22 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 Echterdi
98. thed nected on one side to setpoint source inside the power supply zero volts Check shield check zero connection Motor is at a standstill with power drifts slowly but cannot be controlled 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 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 Motor runs rough or soft after speed Speed adjustment also influences feedback Adjust feedback adjustment at speed potentiometer setting Motor runs roughly or vibrates Feedback too hard 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 begins to turn slowly at setpoint Zero loop e g between amplifier zero and Use differential input see section zero with increasing load control zero 4 4 8 page 42 Supplement for KSV 3HE with F1 option Holding control loop Motor is at a standstill with power with Holding control loop accidentally activated Check Hold signal con
99. tting 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 O volts motor is actively braked by reversal Switch off the supply voltage motor decelerates brakeless the position information is lost When switching off the supply voltage please note the tip on page 60 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
100. ut setpoint E Switching input Controller enable not assigned not assigned Switching input Reset fault Input 24 V for modules P1 P2 and or E1 only if fitted not assigned Switching output Fault or Ready 13 14 Switching output Overload 15 Housin Analog output Speed monitor e 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 20 Operating Instructions 221055E V 1 5c 4 1 2 2 Version with Z1 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Switching input Controller enable Switching input Limit switch 1 Switching input Limit switch 2 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 Deere Analog output Current monitor Connect cable shield to the housing of the SUB D connector 4 1 2 3 Version with Z2 add on module Pin Assignment 1 0 Volt Output auxiliary voltage 15 V Output auxiliary voltage 15 V Input setpoint E Input setpoint E Swi

Operating Instructions 221055E, V 1.5c 09/01

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