SERVOSTAR® 300

Digital Servo Amplifier

Product Manual
Edition 10/2007
Valid for Hardware Revision 02.01

Keep all manuals as a product component

during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr300_e.***
Record of Document Revisions:

Revision Remarks
06/04 First edition
04/05 Restart lock -AS-, UL-listing, new pinning for X8, several corrections
04/05a order numbers 400V types for NA updated
Chapter 1 updated, ComCoder wiring corrected, Acuro(BISS)-Interface new, max. station ad-
11/05 dress changed to 127, motor choke changed, SynqNet and EtherCat expansion cards added,
chapter 6 restructured, order codes restructured
12/05 Feedback section, termination resistors X1/X5, CE section
Error messages and warnings updated, additional information (SERCOS), AWG cross-sections
02/06
added, inch dimensions added, analog-in circuit updated, cross section (awg)
CAN baud rate coding updated, LED display structure updated, input analog-in updated, BISS
05/06
interface updated, hardware revision added, Errors/Warnings updated
09/06 New document structure, new cover design, warning n24, Quickstart integrated
New part number scheme, termination resistors CAN interface and X5 corrected, branding upda-
ted, chapter leakance current new, chapter "servo system graphics" expanded and moved,
03/07
chapter "various mains supply networks" moved, trouble shooting reduced, Feedback expanded
and restructured, enc emulation, DC-Link expanded, AS restructured, accessories removed
07/07 Timing diagramm motor brake, standards updated (EMC and LVD)
10/07 Target group, use as directed, standards

Hardware Revision (HR) History

Hardware Revision usable Firmware Revision usable DRIVEGUI.EXE Revision

02.01 >= 2.18 <= 1.30 Build 0056

WINDOWS is a registered trademark of Microsoft Corp.

HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
SERVOSTAR is a registered trademark of Danaher Motion

Technical changes which improve the performance of the equipment may be made without prior notice!
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm
or any other method) or stored, processed, copied or distributed by electronic means without the written per-
mission of Danaher Motion.
Danaher Motion 10/2007 Contents
page
1 General
1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.4 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.5 Abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 Safety
2.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.2 Use as directed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.3 Prohibited use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 Standards
3.1 Approvals of the servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1.1 CE conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1.2 Conformance with UL and cUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2 European Directives and Standards for the machine builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 American Directives and Standards for the machine builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Asian Directives and Standards for the machine builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Handling
4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.4 Maintenance, Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5 Package
5.1 Package supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.3 Part number scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6 Technical description
6.1 The SERVOSTAR 300 family of digital servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.2.1 Technical data for 110/230 V (types S3_ _6_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.2.2 Technical data for 400/480 V (types S3_ _0_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.2.3 Inputs / outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.2.4 Recommended tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.2.5 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.2.6 Ambient conditions, ventilation, mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.7 Conductor cross-sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.3 Motor holding brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.4 LED display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.5 Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.6 Electrical braking (regen circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.7 Switch-on and switch-off behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.7.1 Behavior in standard operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.7.2 Behavior in the event of an error (with standard setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8 Stop- / Emergency Stop- Function to EN 60204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.8.1 Stop: Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.8.2 Emergency Stop: Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.8.3 Implementation of the Stop Category 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6.8.4 Implementation of the Stop Category 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
6.8.5 Implementation of the Stop Category 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.9 Shock-hazard protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.9.1 Leakage current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.9.2 Residual-current circuit breakers (FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.9.3 Isolating transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
7 Mechanical Installation
7.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7.2 Guide to mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

SERVOSTAR ® 300 Product Manual 3

Contents 10/2007 Danaher Motion
page
8 Electrical installation
8.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
8.2 Guide to electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
8.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
8.3.1 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
8.3.2 Shielding connection to the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
8.3.3 Technical data for connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.4 Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.5 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.6 Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
8.7 Connection diagram (Overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.8 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
8.8.1 Connection to various mains supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
8.8.2 Mains supply connection (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.8.2.1 Three phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.8.2.2 Two phase without neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.8.2.3 Single phase with neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.8.3 24V auxiliary supply (X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.8.4 DC bus link (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.9 Motor connection with brake (X9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.10 External regen resistor (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.11 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
8.11.1 Resolver (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.11.2 Sine Encoder with BISS (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
8.11.3 Sine Encoder with EnDat 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
8.11.4 Sine Encoder with HIPERFACE (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.11.5 Sine Encoder without data channel (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
8.11.6 Sine Encoder with Hall (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
8.11.7 ROD (AquadB) 5V (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.11.8 ROD (AquadB) 5V with Hall (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
8.11.9 ROD (AquadB) 5V (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.11.10 ROD (AquadB) 5V with Hall (X5/X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
8.11.11 ROD (AquadB) 24V (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
8.11.12 ROD (AquadB) 24V with Hall (X3/X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
8.11.13 SSI Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
8.11.14 Hall sensors (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
8.12 Electronic Gearing, Master-slave operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
8.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.12.2 Connection to stepper motor controllers (step and direction) . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.12.2.1 Step/Direction with 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
8.12.2.2 Step/Direction with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
8.13 Encoder emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
8.13.1 Incremental encoder output - A quad B (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
8.13.2 SSI encoder output (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
8.14 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.14.1 Analog inputs (X3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.14.2 Digital inputs (X3/X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
8.14.3 Digital outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
8.15 RS232 interface, PC connection (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
8.16 CANopen interface (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
8.17 Personnel safe restart lock -AS-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8.17.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8.17.2 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.17.3 Technical data and pinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.17.4 Enlosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.17.5 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.17.6 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
8.17.6.1 Signal diagram (sequence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
8.17.6.2 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
8.17.6.3 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
8.17.6.4 Mains supply circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

4 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Contents
page
9 Setup
9.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
9.2 Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
9.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
9.2.1.1 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
9.2.1.2 Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
9.2.1.3 Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
9.2.1.4 Operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
9.2.2 Installation under WINDOWS 2000 / XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
9.3 Quickstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
9.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.3.1.2 Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
9.3.1.3 Minimum Wiring for Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
9.3.2 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
9.3.3 Important Screen Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
9.3.4 Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
9.3.4.1 Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
9.3.4.2 Units/Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
9.3.4.3 Motor (rotary) / Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
9.3.4.4 Motor (linear) / Feedback (Encoder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.3.4.5 Save Parameters and Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
9.3.5 Motion Service (Jog Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
9.3.6 More Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
9.4 Multi-axis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.4.1 Station address for CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.4.2 Baud rate for CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.5 Keypad operation / LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.5.1 Keypad operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.5.2 Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
9.5.3 Standard menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
9.5.4 Advanced menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
9.6 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
9.7 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
9.8 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
10 Expansions Cards
10.1 Guide to installation of expansion cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
10.2 Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
10.2.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
10.2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
10.2.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
10.2.4 Entering a motion block number (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
10.2.5 Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
10.2.6 Connection diagram (default) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
10.3 Expansion card -PROFIBUS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
10.3.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
10.3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
10.3.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
10.4 Expansion card -SERCOS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
10.4.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
10.4.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
10.4.3 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
10.4.4 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
10.4.5 Modifying the station address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
10.4.6 Modifying the baud rate and optical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

SERVOSTAR ® 300 Product Manual 5

Contents 10/2007 Danaher Motion
page
10.5 Expansion card -DEVICENET-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
10.5.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
10.5.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
10.5.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
10.5.4 Combined module/network status-LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
10.5.5 Setting the station address (device address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
10.5.6 Setting the transmission speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
10.5.7 Bus cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
10.6 Expansion card -ETHERCAT- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
10.6.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
10.6.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
10.6.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
10.7 Expansion card -SYNQNET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
10.7.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
10.7.2 NODE ID Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
10.7.3 Node LED table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
10.7.4 SynqNet Connection, Connector X21B/C (RJ-45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) . . . . . . . . . . . . . . . . . . . . . . . 113
10.7.6 Connection diagram digital inputs/outputs, connector X21A . . . . . . . . . . . . . . . . . . . . . . . . 113
10.8 Expansion module -2CAN- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
10.8.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
10.8.2 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
10.8.3 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
10.8.4 Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
10.8.5 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
11 Appendix
11.1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
11.2 Order codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
11.2.1 Servo amplifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
11.2.2 Expansion cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
11.2.3 Mating connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
11.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

6 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 General

1 General
1.1 About this manual
This manual describes the SERVOSTAR® 300 series of digital servo amplifiers
(standard version: 1.5A ...10A rated current).
A more detailed description of the expansion cards that are currently available and the
digital connection to automation systems can be found, together with our applications
notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements:
WINDOWS, Internet Browser, Acrobat Reader) in different languages.
Technical data and dimensional drawings of accessories such as cables, regen resistors,
mains supplies, etc., can be found in the accessories manual.
You can print out this documentation on any standard commercial printer. A printed copy
of the documentation is available from us at extra cost.

1.2 Target group

This manual addresses personnel with the following qualifications:
Transport : only by personnel with knowledge of handling electrostatically sensitive
components.
Unpacking: only by electrically qualified personnel.
Installation : only by electrically qualified personnel.
Setup : only by qualified personnel with extensive knowledge of electrical
engineering and drive technology
The qualified personnel must know and observe the following standards:
IEC 60364 or DIN VDE 0100
IEC 60664 or DIN VDE 0110
national accident prevention regulations or BGV A3

The operator must ensure that the safety instructions in this manual are followed.
The operator must ensure that all personnel responsible for working with the servo
amplifier have read and understood the product manual.

1.3 Hints for the online edition (PDF format)

Bookmarks:
Table of contents and index are active bookmarks.
Table of contents and index in the text:
The lines are active cross references. Click on the desired line and the appropriate page
is indicated.
Page/chapter numbers in the text:
Page/chapter numbers with cross references are active. Click at the page/chapter num-
ber to reach the indicated target.

1.4 Symbols used

Danger to personnel
Danger to maschinery, Important
from electricity and its
general warning notes
effects

ð p. see page l special emphasis

SERVOSTAR ® 300 Product Manual 7

General 10/2007 Danaher Motion

1.5 Abbreviations used

Abbrev. Meaning
AGND Analog ground
AS Restart lock
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Europeenne
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground (for 24V and digital I/O)
DIN German Institute for Industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EN European Standard
ESD Electrostatic discharge
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IEC International Electrotechnical Commission
IGBT Insulated-gate bipolar transistor
INC Incremental interface
ISO International Organization for Standardization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
PC Personal computer
PELV Protected low voltage
PLC Programmable logic controller
PWM Pulse-width modulation
RAM Volatile memory
RBallast / RBR Ballast resistor (= regen resistor)
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD digital encoder
S1 continuous operation
S3 Intermittent operation
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriters Laboratories
V AC Alternating voltage
V DC DC voltage
VDE Society of German Electrical Technicians

8 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Safety

2 Safety
2.1 Safety Instructions
l Only properly qualified personnel are permitted to carry out activities such as
transport, installation, commissioning and maintenance. Properly qualified per-
sons are those who are familiar with the transport, assembly, installation, com-
missioning and operation of the product, and who have the appropriate qualifi-
cations for their job. The qualified personnel must know and observe the
following standards and regulations:
— IEC 60364 or DIN VDE 0100
— IEC 60664 or DIN VDE 0110
— national accident prevention regulations or BGV A3
l Check the Hardware Revision Number of the product (see product label). This
revision number must match the Hardware Revision Number on the cover page
of the manual.
l Read this documentation before carrying out the installation and commissio-
ning. Incorrect handling of the servo amplifier can lead to personal injury or
material damage. It is vital that you keep to the technical data and information
on connection requirements (nameplate and documentation).
l Discharge your body before touching the servo amplifier. The servo amplifiers
contain electrostatically sensitive components which may be damaged by in-
correct handling. Avoid contact with highly insulating materials (artificial fab-
rics, plastic film etc.). Place the servo amplifier on a conductive surface.

l The manufacturer of the machine must produce a hazard analysis for the ma-
chine and take appropriate measures to ensure that unforeseen movements do
not result in personal injury or material damage.
l Do not open or touch the equipment during operation. Keep all covers and ca-
binet doors closed during operation. Touching the equipment is allowed du-
ring installation and commissioning for properly qualified persons only. Other-
wise, there are deadly hazards, with the possibility of death, severe injury or
material damage.
— During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
— Control and power connections may be live, even though the
motor is not rotating.
— Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
l Never undo any electrical connections to the servo amplifier while it is live.
There is a danger of electrical arcing with damage to contacts and personal in-
jury.
Wait at least five minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply power. To be
sure, measure the voltage in the DC Bus link and wait until it has fallen below
40V.

SERVOSTAR ® 300 Product Manual 9

Safety 10/2007 Danaher Motion

2.2 Use as directed

l Servo amplifiers are components that are built into electrical plant or machines, and
can only be operated as integral components of such plant or machines.
l The manufacturer of the machine must generate a hazard analysis for the machine,
and take appropriate measures to ensure that unforeseen movements cannot cause
injury or damage to any person or property.
l Servo amplifiers in the SERVOSTAR 300 series can be supplied from 3-phase
grounded (earthed) industrial supply networks (TN-system, TT-system with grounded
neutral point, no more than 5000A symmetrical rated current at 110-10%...230V+10% or
208-10%...480V+10% depending on the amplifier type).
Connection to other types of supply networks (with an additional isolating transfor-
mer) is described on page 48.
l Periodic overvoltages between phases (L1, L2, L3) and the housing of the servo am-
plifier must not exceed 1000V crest.
In accordance with EN 61800, voltage spikes (< 50µs) between phases must not ex-
ceed 1000V. Voltage spikes (< 50µs) between a phase and the housing must not ex-
ceed 2000V.
l If the servo amplifiers are used in residential areas, in business/commercial areas, or
in small industrial operations, then additional filter measures must be implemented by
the user.
l The SERVOSTAR 300 family of servo amplifiers is exclusively intended for driving
suitable brushless synchronous servomotors and asynchronous motors with clo-
sed-loop control of torque, speed and/or position. The rated voltage of the motors
must be at least as high as the DC bus link voltage/ 2 produced by the servo ampli-
fier.
l The servo amplifiers must only be operated in a closed control cabinet, taking into
account the ambient conditions defined on page 21. Ventilation or cooling may be
necessary to keep the temperature within the cabinet below 40°C.
l Use only copper conductors for wiring. The conductor cross-sections can be derived
from the standard EN 60204 (alternatively for AWG cross-sections: NEC Table
310-16, 60°C or 75°C column).
l We only guarantee the conformance of the servo system with the standards cited on
p.12 if the components (servo amplifier, motor, cables etc.) are those supplied by us.
l Consider the specifications on page 77 when you use the restart lock -AS-.

2.3 Prohibited use

l The use of the servo amplifier in the following environments is prohibited:
- potentially explosive areas
- environments with corrosive and/or electrically conductive acids, alkaline solutions,
oils, vapours, dusts
- directly on non-grounded supply networks or on asymmetrically grounded supplies
with a voltage >230V.
l Commissioning the servo amplifier is prohibited if the machine in which it was
installed
- does not meet the requirements of the EC Machinery Directive
- does not comply with the EMC Directive
- does not comply with the Low Voltage Directive

10 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Standards

3 Standards
3.1 Approvals of the servo amplifiers
3.1.1 CE conformance

Conformance with the EC EMC Directive 2004/108/EC and the Low Voltage Directive
2006/95/EC is mandatory for the supply of servo amplifiers within the European Commu-
nity. Product standard EN 61800-3 is applied to ensure conformance with the EMC Direc-
tive. The Declaration of Conformity form can be found on our website (download area).
Concerning noise immunity the servo amplifier meets the requirements to the 2nd envi-
ronmental category (industrial environment). For noise emission the amplifier meets the
requirement to a product of the category C2 (motor cable £ 10m).

This product can cause high-frequency interferences in non industrial

environments which can require measures for interference suppression.

With a motor cable length from 10m onwards, the servo amplifier meets the requirement
to the category C3.
The servo amplifiers have been tested by an authorized testing laboratory in a defined
configuration, using the system components that are described in this documentation.
Any divergence from the configuration and installation described in this documentation
means that you will be responsible for carrying out new measurements to ensure confor-
mance with regulatory requirements. The standard EN 61800-5-1 is applied to ensure
conformance with the Low Voltage Directive.

3.1.2 Conformance with UL and cUL

This servo amplifier is listed under UL file number E217428.

UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S.
and Canadian standard (in this case UL 840 and UL 508C).
This standard describes the fulfilment by design of minimum requirements for electrically
operated power conversion equipment, such as frequency converters and servo amplifi-
ers, which is intended to eliminate the risk of fire, electric shock, or injury to persons,
being caused by such equipment. The technical conformance with the U.S. and Canadian
standard is determined by an independent UL (cUL) inspector through the type testing
and regular checkups.
Apart from the notes on installation and safety in the documentation, the customer does
not have to observe any other points in direct connection with the UL (cUL)-certification of
the equipment.
UL 508C
UL 508C describes the fulfilment by design of minimum requirements for electrically oper-
ated power conversion equipment, such as frequency converters and servo amplifiers,
which is intended to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfilment by design of air and insulation creepage spacings for
electrical equipment and printed circuit boards.

SERVOSTAR ® 300 Product Manual 11

Standards 10/2007 Danaher Motion

3.2 European Directives and Standards for the machine builder

Servo amplifiers are components that are intended to be incorporated into electrical plant
and machines for industrial use. When the servo amplifiers are built into machines or
plant, the amplifier must not be used until it has been established that the machine or
equipment fulfills the requirements of the
l EC Machinery Directive (98/37/EG)
l EC EMC Directive (2004/108/EG)
l EC Low Voltage Directive (2006/95/EG)

Standards to be applied for conformance with the EC Machinery Directive (98/37/EG)

EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 12100 (Safety of Machines)

The manufacturer of the machine must generate a hazard analysis for the machine,
and must implement appropriate measures to ensure that unforeseen movements
cannot cause injury or damage to any person or property.

Standards to be applied for conformance with the Low Voltage Directive (2006/95/EC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 60439-1 (Low-voltage switchgear and controlgear assemblies)
Standards to be applied for conformance with the EMC Directive (2004/108/EC):
EN 61000-6-1 / 2 (Interference Immunity in Residential & Industrial Areas)
EN 61000-6-3 / 4 (Interference Generation in Residential & Industrial Areas)
The manufacturer of the machine/plant is responsible for ensuring that it meets the limits
required by the EMC regulations. Advice on the correct installation for EMC (such as
shielding, grounding, treatment of connectors and cable layout) can be found in this docu-
mentation.

The machine/plant manufacturer must check whether other standards or EC

Directives must be applied to the machine/plant.

3.3 American Directives and Standards for the machine builder

Chapter in process

3.4 Asian Directives and Standards for the machine builder

Chapter in process

12 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Handling

4 Handling
4.1 Transport
l Transport by qualified personnel in the manufacturer’s original recyclable packaging
l Avoid shocks while transporting
l Transport temperature: -25 to +70°C, max. rate of change 20K / hour
l Transport humidity: max. 95% relative humidity, no condensation
l The servo amplifiers contain electrostatically sensitive components, that can
be damaged by incorrect handling. Discharge yourself before touching the ser-
vo amplifier. Avoid contact with highly insulating materials, such as artificial
fabrics and plastic films. Place the servo amplifier on a conductive surface.
l If the packaging is damaged, check the unit for visible damage. In such an event, in-
form the shipper and the manufacturer.

4.2 Packaging
l Recyclable cardboard with inserts
l Dimensions: (HxWxD) 115x365x275mm
l Labeling: instrument label on outside of box

4.3 Storage
l Storage only in the manufacturer’s original recyclable packaging
l Max. stacking height 8 cartons
l Storage temperature -25 to +55°C, max. rate of change 20K / hour
l Storage humidity 5 ... 95% relative humidity, no condensation
l Storage duration:
Less than 1 year: without restriction.
More than 1 year: capacitors must be re-formed before setting up and operating the
servo amplifier. To do this, remove all electrical connections and apply single-phase
230V AC for about 30 minutes to the terminals L1 / L2.

4.4 Maintenance, Cleaning

The instruments do not require any maintenance, opening the instruments invalidates the
warranty.
Cleaning : — if the casing is dirty: clean with Isopropanol or similar
do not immerse or spray
— if there is dirt inside the unit: must be cleaned by the manufacturer
— dirty protective grill on fan: clean with a dry brush

4.5 Disposal
In accordance to the WEEE-2002/96/EG-Guidelines we take old devices and accessories
back for professional disposal, if the transport costs are taken over by the sender. Send
the devices to:
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf, Germany

SERVOSTAR ® 300 Product Manual 13

Package 10/2007 Danaher Motion

5 Package
5.1 Package supplied
When you order an amplifier from the SERVOSTAR 300 series (order numbers ð p.119),
you will receive:
— SERVOSTAR 3xx
— Mating connectors X0, X3, X4, X8
— Mating connector X9 only with SERVOSTAR 303-310 (S3xx6)
— Product manual and online documentation on CD-ROM
— Setup software DRIVEGUI.EXE on CD-ROM

The mating SubD connectors are not part of the package!

Accessories : (must be ordered separately, if required; description see accessories

manual)
— motor cable (prefabricated) with special shield clamp, or both power connectors
separately, with the motor cable as a cut-off length
— feedback cable (prefabricated)
or both feedback connectors separately, with the feedback cable as a cut-off length
— motor choke 3YL, for motor cables longer than 25 meters
— external regen resistor BAR(U)
— communication cable to the PC (ð p.75) for setting parameters from a PC
— power cable, control cables, fieldbus cables (as cut-off lengths)

5.2 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.

Servo amplifier type Serial number Comments Enclosure Rating

Danaher Motion GmbH Customer Support

Wacholderstr. 40-42 Europe Tel. +49 (0)203 / 99790 C UL
® US
D-40489 Düsseldorf Italy Tel. +39 (0)362 / 594260 E217428 LISTED
www.DanaherMotion.com North America Tel. +1 540 633 3400 IND. CONT. EQ.
1VD4
Typenbezeichnung Model Number Ser. Nr Ser. No. Bemerkung Comment

Spannungsversorgung Power Supply Nennstrom Nom. Current Schutzart Encl.Rating

Umgebungstemp. Hardware
Ambient temp. Revision

example example

max. ambient Electrical supply Output current Hardware

temperature Installed load in S1 operation Revision

14 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Package

5.3 Part number scheme

S 3 0 6 0 1 - S E*

Expansions
Family NA no expansion
S3 S300 DN DEVICENET
PB PROFIBUS
SE SERCOS
Current rating EC ETHERCAT
01 1.5A rms SQ SYNQNET
03 3A rms I/O I/O Extension
06 6A rms
10 10A rms

Electr. options
Voltage rating 0 no option
0 208...480V 1 AS
6 110...230V

* additional coding defines customer specific specials

Comparison device name -> part number

Device Name Part Number

SERVOSTAR 303 S30361-NA
SERVOSTAR 306 S30661-NA
SERVOSTAR 310 S31061-NA
SERVOSTAR 341 S30101-NA
SERVOSTAR 343 S30301-NA
SERVOSTAR 346 S30601-NA

SERVOSTAR ® 300 Product Manual 15

Technical description 10/2007 Danaher Motion

6 Technical description
6.1 The SERVOSTAR 300 family of digital servo amplifiers
Standard version
l Two voltage classes with large nominal voltage range
1 x 110V-10% ... 3 x 230V+10% (SERVOSTAR 303-310, S3xx6)
3 x 208V-10% ... 3 x 480V+ 10% (SERVOSTAR 341-346, S3xx0)
l Shielding connection directly on the servo amplifier
l Two analog inputs onboard
l CANopen onboard (default: 500 kBaud), for integration in CAN-bus systems and for
setting parameters for several drives via the PC interface of one of the amplifiers
l Slot for an expansion card
l RS232 and pulse direction interface onboard
l Restart lock -AS- for personnel safety onboard, ð p. 77
l Intelligent position controller onboard
l Multi feedback support
l Synchronous servomotors, linear motors and asynchronous motors can be used

Power section
l Directly on grounded 3-phase supply, 110V-10% or 230V-10% up to 480V+10%
TN-network or TT-network with grounded neutral point, 5000 A max. symmetrical
current rating, connection to other supply types only via isolating transformer, ðp.48
l B6 bridge rectifier, integral supply filter and soft-start circuit
l Single-phase supply operation possible (e.g. for setup)
l Fusing (e.g. fusible cutout) to be provided by the user
l Shielding All shielding connections are made directly on the amplifier
l Output stage IGBT module with floating current measurement
l Regen circuit with dynamic distribution of the regenerated power between
several amplifiers on the same DC bus link circuit. Internal
regen resistor as standard, external regen resistors if required.
l DC bus link voltage 135 … 450 V DC or 260 … 900 V DC,
can be connected in parallel.
l Interference suppression filters are integrated for the electrical supply feed and the
24V auxiliary supply voltage (with motor cable £ 10m for C2 as per EN 61800-3, with
motor cable < 10m for C3 as per EN 61800-3).

Integrated safety
l Appropriate insulation/creepage distances and electrical isolation ensure safe electri-
cal separation, as per EN 61800-5-1, between the power input / motor connections
and the signal electronics.
l Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring.
l Temperature monitoring of the servo amplifier and motor (if our motors and prefabri-
cated cables are used).

16 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Technical description

Auxiliary supply voltage 24V DC

l Electrically isolated, internal fusing, from an external 24V DC power supply unit with,
for instance, isolating transformer or uninterruptible power supply.

Operation and parameter setting

l With our user-friendly setup software, for setup via the serial interface of a PC.
l If no PC is available: direct operation by two keys on the servo amplifier and a 3-cha-
racter LED display.
l Fully programmable via RS232 interface.

Completely digital control

l Digital current controller (space vector, pulse-width modulation, 62.5 µs)
l Adjustable digital speed controller (62.5 µs)
l Integrated position controller, with adaptation possibilities for all applications (250 µs)
l Integrated step/direction interface for connecting a servomotor to a stepper controller
l Evaluation of resolver signals and sine-cosine signals of high-resolution encoders
l Encoder emulation (incremental, compatible with A quad B or SSI)

Comfort functions
l 2 programmable analog inputs
l 4 programmable digital inputs
l 2 programmable digital outputs
l programmable logical combinations of digital signals

Expansions
l I/O-14/08 expansion card, ð p.102
l PROFIBUS DP expansion card, ð p.105
l SERCOS expansion card, ð p.106
l DeviceNet expansion card, ð p.108
l EtherCat expansion card, ð p. 111
l SynqNet expansion card, ð p. 112
l -2CAN- expansion module, separated connectors for CAN-bus and RS232, ð p.114
l Several third-party expansion cards (ModBus, LightBus, FIP-IO etc. please contact
the manufacturer for further information)

SERVOSTAR ® 300 Product Manual 17

Technical description 10/2007 Danaher Motion

6.2 Technical data

6.2.1 Technical data for 110/230 V (types S3_ _6_)

SERVOSTAR
Electrical data DIM 303 306 310
Order Code — S30361 S30661 S31061
1 x 110V-10% … 1 x 230V+10%
Rated supply voltage
V~ 3 x 110V-10% … 3 x 230V+10%
(grounded supply, phase to phase)
50/60 Hz
Rated input power for S1 operation kVA 1.1 2.4 4
Max. DC bus link voltage V= 450
Rated output current (rms value, ± 3%)
at 1x115V Arms 3* 3* 3*
at 3x115V Arms 3.5 8 10
at 3x230V Arms 3 6 10
at 1x230V Arms 3* 4* 4*
Peak output current (rated current x 2 for approx. 5s, ± 3%)
at 1x115V Arms 5* 5* 5*
at 3x115V Arms 9 15 20
at 3x230V Arms 9 15 20
at 1x230V Arms 9* 9* 9*
Switching frequency of the output stage kHz 8 (16**)
Technical data for regen circuit — ð p.23
Threshold for overvoltage switch-off
at 115V VDC 235
at 230V VDC 455
Motor inductance min.
at 1x115V mH 3.7 3.7 3.7
at 3x115V mH 2.1 1.3 1.0
at 3x230V mH 4.3 2.6 1.9
at 1x230V mH 4.3 4.3 4.3
Motor inductance max. mH Consult our customer support
Form factor of the output current
— 1.01
(rated conditions, min. load inductance)
Bandwidth of current controller kHz > 1.2
Residual voltage drop at rated current V 4
Thermal dissipation, output stage disabled W 12
Thermal dissipation at rated current
W 35 60 90
(incl. PSU losses, without regen dissipation)
Mechanical data
Weight kg approx. 2.6
Height, without connectors mm 275 279
Width mm 70
Depth, without connectors mm 171
Depth, with connectors mm < 200
* in single-phase applications nom./peak current is limited to value below nominal
value dependent on the motor constant Kt and the motor speed.
** at reduced current (50%)

18 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Technical description

6.2.2 Technical data for 400/480 V (types S3_ _0_)

SERVOSTAR
Electrical data DIM 341 343 346
Order Code — S30101 S30301 S30601
Rated supply voltage 3 x 208V-10% … 480V+10%, 50/60
V~
(grounded supply, phase to phase) Hz
Rated input power for S1 operation kVA 1.2 2.5 5
Max. DC bus link voltage V= 900
Rated output current (rms value, ± 3%)
at 3x208V Arms 2 5 6
at 3x230V Arms 2 5 6
at 3x400V Arms 1.5 4 6
at 3x480V Arms 1.5 3 6
Peak output current (max. approx. 5s, ± 3%)
at 3x208V Arms 4.5 7.5 12
at 3x230V Arms 4.5 7.5 12
at 3x400V Arms 4.5 7.5 12
at 3x480V Arms 4.5 7.5 12
Switching frequency of the output stage kHz 8 (16*)
Technical data for regen circuit — ð p.23
Threshold for overvoltage switch-off
a 230V VDC 455
a 400V VDC 800
a 480V VDC 900
Motor inductance min.
at 3x208V mH 7.7 4.6 2.9
at 3x230V mH 8.5 5.1 3.2
at 3x400V mH 14.8 8.9 5.6
at 3x480V mH 17.8 10.7 6.7
Motor inductance max. mH Consult our customer support
Form factor of the output current
— 1.01
(rated conditions, min. load inductance)
Bandwidth of subordinate current controller kHz > 1.2
Residual voltage drop at rated current V 5
Thermal dissipation, output stage disabled W 12
Thermal dissipation at rated current
W 40 60 90
(incl. PSU losses, without regen dissipation)
Mechanical data
Weight kg approx. 2.7
Height, without connectors mm 275 278
Width mm 70
Depth, without connectors mm 171
Depth, with connectors mm < 235
* at reduced current (50%)

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Technical description 10/2007 Danaher Motion

6.2.3 Inputs / outputs

Analog inputs 1, 2 (resolution 14/12 bit) V ±10

Max. common-mode voltage V ±10
Digital control inputs V as per EN 61131-2 Type 1, max. 30VDC
Digital control outputs, active high V open Emitter, max. 30VDC, 10mA
V DC max. 30, AC max 42
BTB/RTO output, relay contacts
mA 500
Auxiliary supply voltage, electrically isola- V 20 - 30
ted, without brake/fan A 1
Auxiliary supply voltage, electrically isola- V 24 (-0% +15%)
ted, with brake/fan (check voltage drop !) A 2.5
Min./max. output current to brake A 0.15 / 1.5
Connection technology
Control signals — Combicon connector
Power signals — Combicon connector
Resolver input — SubD 9-pin (socket)
Incremental encoder input — SubD 15-pin. (socket)
PC interface, CAN — SubD 9-pin (plug)
Encoder emulation, ROD/SSI — SubD 9-pin (plug)
Connection technology
Control signals Combicon connector
Power signals Combicon connector
Resolver input SubD 9-pin (socket)
Incremental encoder input SubD 15-pin. (socket)
PC interface, CAN SubD 9-pin (plug)
Encoder emulation, ROD/SSI SubD 9-pin (plug)

6.2.4 Recommended tightening torques

Connector Tightening torque

X0, X8, X9 0.5..0.6 Nm
Grounding bolt 3.5 Nm

6.2.5 Fusing

Internal fusing
Circuit Internal fuse
Auxiliary voltage 24V 3.15 A (slow)
Regen resistor electronic

External fusing
SERVOSTAR SERVOSTAR
Wire fuses or similar
303*, 341*, 343* 306*, 310*, 346*
AC supply feed FN1/2/3 (X0/1; 2; 3) 6 AT (FRx-6) 10 AT (FRx-10)
24V feed FH1/2 max. 8 AF (FRx-12)
Regen resistor FB1/2 (X8/2; 4) 6 AT (FRS-6) 6 AT (FRS-6)
US fuses in brackets, x = S or S-R for 480V applications
x = N or N-R for 230V applications
* order code reference see p. 15

20 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Technical description

6.2.6 Ambient conditions, ventilation, mounting position

Storage hints ð p.13

Transport hints ð p.13
Supply voltage 303-310*: 1x110V-10% …1x230V+10%, 50/60 Hz
3x110V-10% …3x230V+10%, 50/60 Hz
341-346*: 3x208V-10% - 3x 480V+10%, 50/60 Hz
Auxiliary voltage
without brake and fan 20 V DC ... 30 V DC
with brake or fan 24 V DC (-0% +15%), check voltage drop !
0...+40°C under rated conditions
Ambient temperature in operation
+40...+55°C with power derating 2.5% / °C
Humidity in operation rel. humidity 85%, no condensation
up to 1000 meters a.m.s.l. without restriction
Site altitude 1000…2500 meters a.m.s.l. with power derating
1.5% / 100meters
Pollution level Pollution level 2 as per IEC 60664-1, 2.5.1
Vibrations Class 3111 according to IEC 721-3-3
Noise emission max. 45 dB(A)
Enclosure protection IP 20
Mounting position vertical ð p.36
Ventilation 1 A and 3 A types natural convection
all other types built-on fan
Make sure that there is sufficient forced ventilation within the control cabinet.
* order code reference see p. 15

6.2.7 Conductor cross-sections

Following EN 60204, we recommend for single-axis systems:

AC connection 1.5 mm² (14awg) 600V,105°C
1000V, 105°C,
DC bus link
1.5 mm² (14awg) shielded for lengths
Regen resistor
>20cm
600V, 105°C, shielded,
Motor cables up to 25 m 1 - 1.5 mm² (14awg)
capacitance <150pF/m
Motor cables 25m to 50 m, 600V,105°C, shielded,
1 mm² (14awg)
with motor choke 3YL capacitance <150pF/m
4x2x0.25 mm² (22awg), twisted pairs, shielded,
Resolver, motor thermostat
max. 100m capacitance <120pF/m
7x2x0.25 mm² (22awg),
Encoder, motor thermostat twisted pairs, shielded
max.50m
ComCoder, motor thermo- 8x2x0.25 mm² (22awg),
twisted pairs, shielded
stat max.25m
Setpoints, AGND 0.25 mm² (22awg), max 30m twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20awg), max 30m
600V, 105°C, shielded,
Holding brake (motor) min. 0.75 mm² (18awg)
check voltage drop
+24 V / DGND max. 2.5 mm² (12awg) check voltage drop
For multi-axis systems, observe the specific operating conditions for your system.
To reach the max. permitted cable length, observe cable requirements ð p. 43.
* Danaher Motion North America supplies cables up to 39 meters
* Danaher Motion Europe supplies cables up to max. length

SERVOSTAR ® 300 Product Manual 21

Technical description 10/2007 Danaher Motion

6.3 Motor holding brake

A 24V / max.1.5A holding brake in the motor can be controlled directly by the amplifier.

Check voltage drop, measure the voltage at brake input and check brake function
(brake and no brake). This function does not ensure personnel safety!

The brake function must be enabled through the BRAKE setting (screen page: Motor). In
the diagram below you can see the timing and functional relationships between the
ENABLE signal, speed setpoint, speed and braking force. All values can be adjusted with
parameters, the values in the diagram are default vales.

During the internal ENABLE delay time of 100ms (DECDIS), the speed setpoint of the
servo amplifier is internally driven down an adjustable ramp to 0V. The output for the
brake is switched on when the speed has reached 5 rpm (VELO), at the latest after 5 sec-
onds (EMRGTO).
The rise (fbrH) and fall (fbrL) times of the holding brake that is built into the motor are dif-
ferent for the various types of motor (see motor manual). A description of the interface
can be found on page 51. Operation of the brake in a manner that provides personnel
safety requires an additional “make” contact in the brake circuit, and a suppressor device,
such as a varistor, for the brake circuit.
Recommended circuit:

SERVOSTAR

22 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Technical description

6.4 LED display

A 3-character LED display indicates the status of the amplifier after switching on the 24V
supply (ð p.97). When the keys on the front panel are used, the parameter and function
numbers are shown, as well as the numbers for any errors that may occur (ð p.98).

6.5 Grounding system

AGND — analog inputs, internal analog ground, encoder emulation, RS232, CAN
DGND — digital inputs/outputs and the 24V supply, optically isolated.

6.6 Electrical braking (regen circuit)

During electrical braking with the aid of the motor, energy is fed back into the servo ampli-
fier. This regenerative energy (hence the term “regen” circuit) is dissipated as heat in the
regen resistor. The regen resistor is switched in by the regen circuit.
The setup software can be used to adapt the regen circuit (thresholds) according to the
electrical supply voltage.
Our customer service can help you with the calculation of the regen power that is neces-
sary for your system. A simple method is described in the Online help of the setup soft-
ware.
A description of the interface can be found on page 51.

Functional description:
1.- Individual amplifiers, not coupled through the DC bus link circuit (DC+, DC-)
If the energy fed back from the motor has an average or peak power that exceeds the
preset level for the regen power rating, then the servo amplifier generates the warning
“n02 regen power exceeded” and the regen circuit is switched off.
The next internal check of the DC bus link voltage (after a few milliseconds) detects an
overvoltage and the output stage is switched off, with the error message “Overvoltage
F02” (ð p.98).
The BTB/RTO contact (terminals X3/2,3) will be opened at the same time (ðp.74)

2.- Several servo amplifiers coupled through the DC bus link (DC+, DC-)
Thanks to the built-in regen circuit, several amplifiers (even with different current ratings)
can be operated off a common DC bus link, without requiring any additional measures.
The combined (peak and continuos) power of all amplifiers is always available. The
switch-off on overvoltage takes place as described under 1. (above) for the amplifier that
has the lowest switch-off threshold (resulting from tolerances).

Technical data of the regen circuits dependent on the amplifiers type and the mains volt-
age situation see table on the next page.

SERVOSTAR ® 300 Product Manual 23

Technical description 10/2007 Danaher Motion

Technical Data:

Regen circuit Supply voltage / V

Rated data Dim. 115 230 400 480
Switch-on (upper) threshold of regen circuit V 200 400
Overvoltage F02
(S30361) V 235 455
Regen resistor (internal) Ohm 66 66
303

Continuous power in regen circuit (RBint) W 20 20

—
Pulse power in regen circuit (RBint max. 1s) kW 0.75 3
Regen resistor (external), optional Ohm 66 66
Continuous power in regen circuit (RBext) max. kW 0.3 0.3
Pulse power in regen circuit (RBext max. 1s) kW 0.75 3
Switch-on (upper) threshold of regen circuit V 200 400
(S30661/S31061)

Overvoltage F02 V 235 455

306 / 310

Regen resistor (internal) Ohm 66 66

Continuous power in regen circuit (RBint) W 50 50
—
Pulse power in regen circuit (RBint max. 1s) kW 0.75 3
Regen resistor (external), optional Ohm 66 66
Continuous power in regen circuit (RBext) max. kW 1 1
Pulse power in regen circuit (RBext max. 1s) kW 0.75 3
Switch-on (upper) threshold of regen circuit V 400 720 840
Overvoltage F02 V 455 800 900
(S30101)

Regen resistor (internal) Ohm 91 91 91

341

Continuous power in regen circuit (RBint) W 20 20 20

—
Pulse power in regen circuit (RBint max. 1s) kW 2.1 7 9
Regen resistor (external), optional Ohm 91 91 91
Continuous power in regen circuit (RBext) max. kW 0.3 0.3 0.3
Pulse power in regen circuit (RBext max. 1s) kW 2.1 7 9
Switch-on (upper) threshold of regen circuit V 400 720 840
(S30301/S30601)

Overvoltage F02 V 455 800 900

343 / 346

Regen resistor (internal) Ohm 91 91 91

Continuous power in regen circuit (RBint) W 50 50 50
—
Pulse power in regen circuit (RBint max. 1s) kW 2.1 7 9
Regen resistor (external), optional Ohm 91 91 91
Continuous power in regen circuit (RBext) max. kW 1.0 1.0 1.0
Pulse power in regen circuit (RBext max. 1s) kW 2.1 7 9

Suitable external regen resistors can be found in our accessories manual.

24 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Technical description

6.7 Switch-on and switch-off behavior

This chapter describes the switch-on and switch-off behavior of the SERVOSTAR and the
steps required to achieve operational stopping or emergency stop behavior that complies
with standards.

The servo amplifier’s 24 V supply must remain constant. The ASCII commands
ACTFAULT (error response) and STOPMODE (ENABLE signal response) dictate
how the drive will behave.

ACTFAULT / Behavior (see also ASCII reference in the online help of the setup soft-
STOPMODE ware)
0 Motor coasts to a standstill in an uncontrolled manner
1 (default) Motor is braked in a controlled manner

Behavior during a power failure

The servo amplifiers use an integrated circuit to detect if one or more input phases
(power supply feed) fail. The behavior of the servo amplifier is set using the setup soft-
ware: Under “Response to Loss of Input Phase” (PMODE) on the Basic Setup screen,
select:
l Warning if the higher-level control system is to bring the drive to a standstill: War-
ning n05 is output if an input phase is missing, and the motor current is limited to 4 A.
The servo amplifier is not disabled. The higher-level control system can now selecti-
vely end the current cycle or start bringing the drive to a standstill. Therefore, the er-
ror message “MAINS BTB, F16" is output on a digital output of the servo amplifier
and evaluated by the control system, for instance.
l Error message if the servo amplifier is to bring the drive to a standstill: Error messa-
ge F19 is output if an input phase is missing. The servo amplifier is disabled and the
BTB contact opens. Where the factory setting is unchanged (ACTFAULT=1), the mo-
tor is braked using the set “EMERGENCY STOP RAMP”.

Behavior when undervoltage threshold is reached

If the undervoltage threshold is undershot in the DC bus link (the threshold value
depends on the type of servo amplifier), the error message “UNDERVOLTAGE, F05" is
displayed. The drive response depends on the ACTFAULT/STOPMODE setting.
Behavior with enabled “holding brake” function
Servo amplifiers with an enabled holding brake function have a special procedure for
switching off the output stage ( ð p. 22). Removing the ENABLE signal triggers electrical
braking. As with all electronic circuits, the general rule applies that there is a possibility of
the internal “holding brake” module failing. Bringing a motor to a standstill using a holding
brake in a way that is personnel safe also requires an electromechanical “make” contact
for the holding equipment and a suppressor device for the brake.
Behavior of the restart lock -AS-
With the personnel safe, TÜV-approved restart lock –AS-, the drive can be secured on
standstill using its internal electronics so that even when power is being supplied, the
drive shaft is protected against unintentional restart. The chapter “Personnel safe restart
lock -AS-” describes how to use the restart lock –AS-. See page 77 onwards.

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6.7.1 Behavior in standard operation

The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online
help). The diagram below illustrates the correct functional sequence for switching the
servo amplifier on and off.

DC bus link

Motor speed

Power Stage
enable (internal)

Devices which are equipped with a selected “Brake” function use a special sequence for
switching off the output stage (ð p.22).
The built-in restart lock -AS- can be used to switch off the drive, so that personnel safety
is ensured at the drive shaft (ð p. 77).

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6.7.2 Behavior in the event of an error (with standard setting)

The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online
help). The diagram shows the startup procedure and the procedure that the internal con-
trol system follows in the event of one or more electrical supply phases failing, assuming
that the standard parameter settings apply.

(F16/F19 = error messages Mains BTB /input phase, F05 = error message Undervoltage)

Even if there is no intervention from an external control system (in the example, the
ENABLE signal remains active), the motor is immediately braked using the emergency
stop ramp if an input phase error is detected and assuming that no changes have been
made to the factory setting (ACTFAULT=1).

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6.8 Stop- / Emergency Stop- Function to EN 60204

With the personnel safe, TÜV-approved restart lock –AS- (see page 77 onwards)
the drive can be secured on standstill (torque-free) using its internal electronics so
that even when power is being supplied, the drive shaft is protected against
unintentional restart (Category 3, in accordance with EN954-1).

6.8.1 Stop: Standards

The Stop function is used to shut down the machine in normal operation. The Stop func-
tions are defined by EN 60204 (VDE 0113), paragraphs 9.2.2 and 9.2.5.3.
Category 0: Shut-down by immediate switching-off of the energy supply to the
drive machinery (i.e. an uncontrolled shut-down);
Category 1: A controlled shut-down , whereby the energy supply to the drive
machinery is maintained to perform the shut-down, and the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, whereby the energy supply to the drive
machinery is maintained.

The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to

implement the stop categories. If necessary, change the parameters via the
terminal screen of the setup software and store the data in the EEPROM.

The Stop Category must be determined by a risk evaluation of the machine. In addition,
suitable means must be provided to guarantee a reliable shut-down.
Category 0 and Category 1 Stops must be operable independently of the operating mode,
whereby a Category 0 Stop must have priority. Stop functions must be implemented by
disconnection of the appropriate circuitry, and have priority over assigned start func-
tions.
If necessary, provision must be made for the connection of protective devices and
lock-outs. If applicable, the Stop function must signal its status to the control logic. A reset
of the Stop function must not create a hazardous situation.

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6.8.2 Emergency Stop: Standards

The emergency Stop function is used for the fastest possible shut-down of the machine
in a dangerous situation. The Emergency Stop function can be triggered by the actions of
a single person. It must be fully functional and available at all times. The user must not
have to work out how to operate this mechanism.
The Emergency Stop function is defined by EN 60204 (VDE 0113), paragraph 9.2.5.4.
In addition to the requirements for Stop, the emergency Stop must fulfil the following
requirements:
l emergency stop must have priority over all other functions and controls in all opera-
ting situations;
l the energy supply to any drive machinery that could cause dangerous situations
must be switched off as fast as possible, without causing any further hazards (e.g. by
using mechanical latching devices that do not require an external supply of energy,
by counter-current braking in Stop Category 1);
l the reset must not initiate a restart.
If necessary, provision must be made for the additional connection of emergency stop
devices (see EN 60204, "Requirements for emergency stop devices"). The Emergency
Stop must be effective as a stop of either Category 0 or Category 1.
The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired, electromechanical components may be used for the Category 0 Emer-
gency Stop function. It must not be triggered using switching logic (hardware or software),
by transferring commands via a communication network, or via a data link.
The drive must be shut down using an electromechanical circuit. If the connected servo
motor has an integrated brake, this must always be controlled by an electromechanical
circuit as well.
Category 1
With the Category 1 Emergency Stop function, there must be absolute certainty in terms
of the power supply for the machine drives being switched off (i.e., secured) using elec-
tromechanical components. Additional Emergency Stop equipment may be connected.
Bringing the motor to a standstill by interrupting the mains supply and using controlled
electronic braking. The 24 V supply for the servo amplifier must remain constant. The
issue of which circuit should be used is highly dependent on the requirements of the
application at hand.
Usually a brake in a servo motor only has the function of a holding brake. To ensure an
emergency stop function, the braking torque that is required must be checked. If the hold-
ing brake fulfills the dynamic requirements, it must be taken into acount that this applica-
tion will cause increased wear.

The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to

implement the stop categories. If necessary, change the parameters via the
terminal screen of the setup software and store the data in the EEPROM.

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6.8.3 Implementation of the Stop Category 0

Bringing the motor to a standstill by immediately switching off the amplifier power supply
(STOPMODE & ACTFAULT parameters set to 1). The switching sequence is precisely
determined by this circuit in order to avoid undesirable fault messages and servo ampli-
fier failures.
It is not possible to achieve a Category 0 shut-down with the servo amplifier alone, since
hard-wired electromechanical components are compulsory for this type of disconnection.
A brake that is built into the motor must have an additional electromechanical control cir-
cuit, as well as the control through the SERVOSTAR 300, in order to meet Category 0.
Usually a brake in a servo motor only has the function of a holding brake. To ensure an
emergency stop function, the braking torque that is required must be checked. If the hold-
ing brake fulfills the dynamic requirements, it must be taken into acount that this applica-
tion will cause increased wear.
Circuit suggestion
(with EMERGENCY STOP Category 0, control function with contactor relays)

SERVOSTAR

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6.8.4 Implementation of the Stop Category 1

Bringing the motor to a standstill by interrupting the mains supply and using controlled
electronic braking (STOPMODE & ACTFAULT parameters set to 1). The 24 V supply
for the SERVOSTAR must remain constant.
The drive is braked in a controlled manner during the stopping (disabling) procedure. If
the speed VEL0 (see sequence diagram in chapter 6.3) is undershot, the holding brake is
applied and the output stage is disabled.
As soon as two separate time periods (set at the time relay) have elapsed, the mains sup-
ply and the holding brake are electrically isolated.

Should an internal SERVOSTAR 300 fault occur, the motor is forced to a standstill
once K20 drops out.

Circuit suggestion
(with EMERGENCY STOP Category 1, control function with contactor relays)

SERVOSTAR

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6.8.5 Implementation of the Stop Category 2

The machine receives an operational stop (disable) command and brakes the drive using
the set braking ramp (STOPMODE & ACTFAULT parameters set to 1).
The drive is braked in a controlled manner during the stopping (disabling) procedure. If
the speed VEL0 (see sequence diagram in chapter 6.3) is undershot, the holding brake is
applied and the output stage is disabled. In this case, there is no interruption of the elec-
trical supply.
If the electrical supply is switched off, not only will the controlled braking procedure be
performed, but the mains supply and the holding brake will also be electrically isolated fol-
lowing a time period set at the time relay.
Circuit suggestion
(with EMERGENCY STOP Category 1, control function with contactor relays)

SERVOSTAR

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6.9 Shock-hazard protection

6.9.1 Leakage current

Leakage current via the PE conductor results from the combination of equipment and
cable leakage currents. The leakage current frequency pattern comprises a number of
frequencies, whereby the residual-current circuit breakers definitively evaluate the 50Hz
current. For this reason, the leakage current cannot be measured using a conventional
multimeter.
As a rule of thumb, the following assumption can be made for leakage current on our
low-capacity cables at a mains voltage of 400 V, depending on the clock frequency of the
output stage:
Ileak = n x 20mA + L x 1mA/m at 8kHz clock frequency at the output stage
Ileak = n x 20mA + L x 2mA/m at a 16kHz clock frequency at the output stage
(where Ileak=leakage current, n=number of amplifiers, L=length of motor cable)
At other mains voltage ratings, the leakage current varies in proportion to the voltage.
Example: 2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:
2 x 20mA + 25m x 1mA/m = 65mA leakage current.

Since the leakage current to PE is more than 3.5 mA, in compliance with EN50178
the PE connection must either be doubled or a connecting cable with a
cross-section >10mm² must be used. Use the PE terminals and the PE bolt in order
to fulfil this requirement.

The following measures can be used to minimise leakage currents.

— Reduce the length of the engine cable
— Use low-capacity cables (see p.43)
— Remove external EMC filters (radio-interference suppressors are integrated)

6.9.2 Residual-current circuit breakers (FI)

In conformity with IEC 60364-4-41 – Regulations for installation and EN 60204 – Electri-
cal equipment of machinery, residual-current circuit-breakers (called FI below) can be
used provided the requisite regulations are complied with.
The SERVOSTAR 300 is a 3-phase system with a B6 bridge. Therefore, FIs which are
sensitive to all currents must be used in order to detect any D.C. fault current. Refer to
chapter 6.9.1 for the rule of thumb for determining the leakage current.
Rated residual currents in the FI
Protection against "indirect contact" (personal fire protection) for stationary
10 -30 mA
and mobile equipment, as well as for "direct contact".
Protection against "indirect contact" (personal fire protection) for stationary
50 -300 mA
equipment

Recommendation: In order to protect against direct contact (with motor cables

shorter than 5 m) we recommend that each servo amplifier be protected
individually using a 30mA residual-current circuit-breaker which is sensitive to all
currents.

If you use a selective FI circuit-breaker, the more intelligent evaluation process will pre-
vent spurious tripping of the circuit-breakers.

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6.9.3 Isolating transformers

If protection against indirect contact is absolutely essential despite a higher leakage cur-
rent, or if an alternative form of shock-hazard protection is sought, the SERVOSTAR 300
can also be operated via an isolating transformer (schematic connection see p.48).
A ground-leakage monitor can be used to monitor for short circuits.

We would advise you to keep the length of wiring between the transformer and the
servo amplifier as short as possible.

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Danaher Motion 10/2007 Mechanical Installation

7 Mechanical Installation
7.1 Important notes
l Protect the servo amplifier from impermissible stresses. In particular, do not let any
components become bent or any insulation distances altered during transport and
handling. Avoid contact with electronic components and contacts.
l Ensure that there is an adequate flow of cool, filtered air into the bottom of the control
cabinet, or use a heat exchanger. Please refer to page 21.
l Take care that the servo amplifier and motor are properly grounded.
Do not use painted (i.e. non-conductive) mounting plates.
l Don't mount devices, which produce magnetic fields, directly beside the servo ampli-
fier. Strong magnetic fields could directly affect internal components. Install devices
which produce magnetic field with distance to the servo amplifiers and/or shield the
magnetic fields.

7.2 Guide to mechanical installation

The following notes should help you to carry out the mechanical installation in a sensible
sequence, without overlooking anything important.

In a closed control cabinet. Please refer to page 21.

Site The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p.36.

Check that the ventilation of the servo amplifier is unimpeded, and

Ventilation keep within the permitted ambient temperature ð p.21. Keep the re-
quired space clear above and below the servo amplifier ð p.36.

Assemble the servo amplifier and power supply close together, on the
Assembly
conductive, grounded mounting plate in the cabinet.

For EMC-compliant shielding and grounding ð p.47.

Grounding
Ground the mounting plate, motor housing and CNC-GND of the
Shielding
control system. Notes on connection techniques ð p.42.

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7.3 Assembly
Material: 3 x M5 hexagon socket screws to DIN 912
Tool required : 4 mm Allen key

SERVOSTAR 300

36 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Mechanical Installation

7.4 Dimensions

ly.
s on
e
yp
0At 1
nd
1 xx6
a S3 x01
A x
h6 S3
n wit
Fa

0
.31
03.. 6
3 .34
T AR 41..
OS R3
ERV STA
S O
RV
SE

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Mechanical Installation 10/2007 Danaher Motion

This page has been deliberately left blank.

38 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Electrical installation

8 Electrical installation
8.1 Important notes
l Check the combination of servo amplifier and motor. Compare the rated voltage and
current of the units. Implement the wiring according to the connection diagram on
page 41.
l Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or
+DC, –DC is not exceeded by more than 10% even in the most unfavorable circums-
tances (see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals can
lead to destruction of the regen circuit and the servo amplifier.
l The fusing of the AC supply input and 24V supply must be installed by the
user (ð p.20).
l Route power and control cables separately. We recommend a distance of at least
200mm. This improves the interference immunity required by EMC regulations.
If a motor power cable is used that includes cores for brake control, the brake con-
trol cores must be separately shielded.
Ground the shielding at both ends (ð p.47).
l Ground all shielding with large areas (low impedance), with metalized connector hou-
sings or shield connection clamps wherever possible. Notes on connection techni-
ques can be found on page 42.
l Feedback lines may not be extended, since thereby the shielding would be interrup-
ted and the signal processing could be disturbed.
l Lines between amplifiers and external regen resistor must be shielded.
l Install all power cables with an adequate cross-section, as per EN 60204 (ð p.21)
and use the requested cable material (ð p. 43) to reach max. cable length.
l Wire the BTB/RTO contact in series into the safety circuit of the installation. The sa-
fety circuit must operate the supply contactor. This is the only way to ensure monito-
ring of the servo amplifier.
l It is permissible to use the setup software to alter the settings of the servo amplifier.
Any other alterations will invalidate the warranty.

Never disconnect the electrical connections to the servo amplifier while it is live.
In unfavorable circumstances this could cause destruction of the electronics.
Residual charges in the capacitors can have dangerous levels up to 300 seconds
after switching off the electrical supply. Measure the bus voltage on the DC bus
link (+DC/-DC) and wait until the voltage has fallen below 40V.
Control and power connections can still be live, even if the motor is not rotating.

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8.2 Guide to electrical installation

The following notes should help you to carry out the electrical installation in a sensible
sequence, without overlooking anything important.

Cable selection Select cables in accordance with EN 60204 ð p.21.

For EMC-compliant shielding and grounding ð p.47.

Grounding
Ground the mounting plate, motor housing and CNC-GND of the
Shielding
control system. Notes on connection techniques ð p.42.

Route power leads and control cables separately.

Wiring Wire the BTB/RTO contact in series into the safety circuit of the
system.
— Connect the digital control inputs and outputs.
— Connect up AGND (also if fieldbuses are used).
— Connect the analog input source, if required.
— Connect the feedback device.
— Connect the encoder emulation, if required.
— Connect the expansion card
— (see corresponding notes from page 101).
— Connect the motor cable
— Connect shielding to EMC connectors (shield connection) at both
— ends. Use the motor choke (3YL) if cable > 25 meters.
— Connect motor-holding brake, connect shielding to EMC
— connector/shield connection at both ends.
— If required, connect the external regen resistor (with fusing).
— Connect the auxiliary supply
— (maximum permissible voltage values ð p.21).
— Connect the main electrical supply
— (maximum permissible voltage values ð p.21).
— Connect the PC (ð p.75).

— Final check of the implementation of the wiring against the

Final check
— wiring diagrams that have been used.

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8.3 Wiring
8.3.1 Important Notes

Only professional staff who are qualified in electrical engineering are allowed to
install the servo amplifier.

The installation procedure is described as an example. A different procedure may be

appropriate or necessary, depending on the application of the equipments.
We provide further know-how through training courses (on request).

Warning !
Only install and wire up the equipment when it is not live, i.e. when neither the
electrical supply nor the 24 V auxiliary voltage nor the supply voltages of any other
connected equipment is switched on.
Take care that the cabinet is safely disconnected (with a lock-out, warning signs
etc.). The individual voltages will be switched on for the first time during setup.

The ground symbol X , which you will find in all the wiring diagrams, indicates
that you must take care to provide an electrically conductive connection with the
largest feasible surface area between the unit indicated and the mounting plate in
the control cabinet. This connection is for the effective grounding of HF
interference, and must not be confused with the PE-symbol W
(PE = protective earth, safety measure as per EN 60204).

Use the following connection diagrams :

Overview : page 47
Mains power : page 49
Motor : page 51
Feedback : page 52ff
Electronic Gearing / Master Slave
Master-Slave : page 67
Pulse-Direction : page 68
Encoder Emulation
ROD (A quad B) : page 70
SSI : page 71
Digital and analog inputs and outputs : page 72ff
RS232 / PC : page 75
CAN Interface : page 76
Restart lock -AS- : page 81
Expansion cards
I/O-14/08 : page 104
PROFIBUS : page 105
SERCOS : page 107
DeviceNet : page 108
EtherCat : page 111
SynqNet : page 113
2CAN : page 115

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8.3.2 Shielding connection to the front panel

Remove the outside shroud of the cable

and the shielding braid on the desired core
length. Secure the cores with a cable tie.

Remove the outside shroud of the line on a

length from for instance 30mm without da-
maging the shielding braid.

Pull a cable tie by the slot in the shielding

rail on the front panel of the servo amplifier.

Press the shielding of the cable firmly

against the front panel with the cable tie.

Use the shield clamp that is delivered with

the motor cable for the shield connection of
the motor cable. The clamp must be hoo-
ked in the lower shroud and guarantees op-
timal contact between shield and shroud.

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8.3.3 Technical data for connecting cables

Further information on the chemical, mechanical and electrical characteristics of the

cables can be obtained from our customer service.

Observe the rules in the section "Conductor cross-sections" on page 21. To reach
the max. permitted cable length, you must use cable material that matches the
capacitance requirements listed below.

Insulation material
Sheathing PUR (polyurethane, code 11Y)
Core insulation PETP (polyesteraphthalate, code 12Y)

Capacitance
Motor cable less than 150 pF/m
Resolver/Encoder cable less than 120 pF/m

Technical data
For a detailed description of cable types and how to assemble them, please refer to the
accessories manual.

Motor cables longer than 25m require the use of a motor choke 3YL.

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8.4 Components of a servo system

PC

Controls / PLC

SERVOSTAR 300

24V PSU

Fuses
Regen resistor
(optional)

Drive cut-out

Motor choke
(optional)

Terminals
Motor

Cables drawn bold are shielded. Electrical ground is drawn with dash-dotted lines.
Optional devices are connected with dashed lines to the servo amplifier. The
required accessories are described in our accessories manual.

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8.5 Block diagram

The block diagram below just provides an overview.

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8.6 Connector assignments

The connectors of the expansion

card depend on used expansion
card (see pages 102 ff).

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8.7 Connection diagram (Overview)

Refer to the Safety Instructions (ð p.9)

and Use as Directed (ð p.10) ! SERVOSTAR 300

ð p.54ff

ð p.72

ð p.53

ð p.73

ð p.51
ð p.74

ð p.78
ð p.73
ð p.51

ð p.70
ð p.71
ð p.67
ð p.49 ð p.68

ð p.76

ð p.50
ð p.75

ð p.102
ð p.105
ð p.106
ð p.108
ð p.111
ð p.113

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8.8 Electrical supply

8.8.1 Connection to various mains supply networks

This page illustrates all the possible connection variations for different electrical supply
networks.

An isolating transformer is always required for 400 … 480V networks that are
asymmetrically grounded or not grounded.

110V : SERVOSTAR 303-310* 400V / 480V : SERVOSTAR 341-346*

230V : all types
SERVOSTAR

SERVOSTAR SERVOSTAR

SERVOSTAR SERVOSTAR

SERVOSTAR SERVOSTAR

SERVOSTAR SERVOSTAR

SERVOSTAR SERVOSTAR

* Order code reference see p. 119

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8.8.2 Mains supply connection (X0)

8.8.2.1 Three phase

— Directly to 3-phase supply network, filter is integrated

— Fusing (e.g. fusible cut-outs) to be provided by the user ð p.20

SERVOSTAR 300

8.8.2.2 Two phase without neutral

SERVOSTAR 300

8.8.2.3 Single phase with neutral

SERVOSTAR 300

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8.8.3 24V auxiliary supply (X4)

— External 24V DC power supply, electrically isolated, e.g. via an isolating transformer
— Required current rating ð p.18
— Integrated EMC filter for the 24V auxiliary supply

SERVOSTAR 300

8.8.4 DC bus link (X8)

Terminals X8/1 (-DC) and X8/3 (+RBext). Can be connected in parallel, whereby the
regen power is divided between all the amplifiers that are connected to the same DC bus
link circuit.

SERVOSTAR 300 SERVOSTAR 300

Only SERVOSTAR 300 servo amplifiers with mains supply from the same mains
(identical mains supply voltage) may be connected by the DC bus link.

The sum of the rated currents for all of the servo amplifiers connected in parallel
to an SERVOSTAR 303-310 must not exceed 24 A.
The sum of the rated currents for all of the servo amplifiers connected in parallel
to an SERVOSTAR 341-346 must not exceed 40A.

Use unshielded single cores (2.5mm²) with a max. length of 200 mm. Use shielded
cables for longer lengths.

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8.9 Motor connection with brake (X9)

Cable length £ 25 meters
SERVOSTAR 300

Cable length >25 meters

For cable lengths above 25m up to max. 50m, the motor choke 3YL must be wired
into the motor cable, close to the amplifier.

SERVOSTAR 300

8.10 External regen resistor (X8)

Remove the plug-in link between the terminals X8/5 (-RB) and X8/4 (+Rbint).

SERVOSTAR 300

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8.11 Feedback
Every closed servo system will normally require at least one feedback device for sending
actual values from the motor to the servo drive. Depending on the type of feedback
device used, information will be fed back to the servo amplifier using digital or analog
means. Up to three feedback devices can be used at the same time. SERVOSTAR 300
supports the most common types of feedback device whose functions must be assigned
with the parameters
FBTYPE (screen page FEEDBACK), primary Feedback
EXTPOS (screen page POSITION CONTROLLER), secondary Feedback
GEARMODE (screen page ELECTRONIC GEARING)
in the setup software. Scaling and other settings must always be made here.

ASCII Commu- Speed Position- electr.

Configuration Location
Parameter tation control control gearing
One Feedback motor FBTYPE X X X
Two Feedbacks motor FBTYPE X X
(Position externally) externally EXTPOS X
Two Feedbacks motor FBTYPE X X X
(Gearing externally) externally GEARMODE X
Three Feedbacks motor FBTYPE X X
(Position and Gea- externally EXTPOS X
ring externally) externally GEARMODE X
For a detailed description of the ASCII parameters, please refer to the online help of the
setup software.
The table below provides an overview of the supported feedback types, their correspond-
ing parameters and a reference to the relevant connection diagram in each case. On
each of these, the pin assignment shown on the encoder side relates to the Danaher
Motion motors.

primary secondary
Connec- Wiring EXTPOS,
Feedback type FBTYPE
tor diagram GEARMODE
Resolver X2 ð p.53 0 -
20, 22*,
SinCos Encoder BISS X1 ð p.54 -
23*, 24*
SinCos Encoder ENDAT X1 ð p.55 4, 21* 8
SinCos Encoder HIPERFACE X1 ð p.56 2 9
SinCos Encoder w/o daten channel X1 ð p.57 1, 3, 7, 8 6, 7
SinCos Encoder + Hall X1 ð p.58 5, 6 -
ROD** (AquadB) 5V X1 ð p.59 17 -
ROD (AquadB) 5V + Hall X1 ð p.60 15 -
ROD (AquadB) 5V X5 ð p.61 13, 19 3
ROD (AquadB) 5V + Hall X5/X1 ð p.62 18 -
ROD (AquadB) 24V X3 ð p.63 16 2
ROD (AquadB) 24V + Hall X3/X1 ð p.64 14 -
SSI X5 ð p.65 9* 5
Hall X1 ð p.66 11* -
Sensorless (w/o Feedback) - - 10* -
Step/Direction 5V X5 ð p.68 - 4
Step/Direction 24V X3 ð p.69 - 1
* Can only be set on the terminal screen of the setup software
** ROD is an abbreviation for “incremental encoder”.

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8.11.1 Resolver (X2)

Connection of a Resolver (2 to 36-poles) as a feedback system (primary, ð p.52). The

thermostat contact in the motor is connected via the resolver cable to X2 and evaluated
there.
If cable lengths of more than 100 meters are planned, please contact our customer ser-
vice.
FBTYPE: 0

SERVOSTAR 300 SubD 9 round 12-pin

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8.11.2 Sine Encoder with BISS (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feed-

back system (primary, ð p.52).
The thermostat contact in the motor is connected via the encoder cable to X1 and
evaluated there.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 350 kHz

Type FBTYPE Up Remarks

5V digital 20 5V +/-5% adjust on screen page FEEDBACK
12V digital 22 7,5...11V
5V analog 23 5V +/-5% adjust on sreen page TERMINAL
12V analog 24 7,5...11V

SubD 15 round, 17-pin

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8.11.3 Sine Encoder with EnDat 2.1

Wiring of a single-turn or multi-turn sine-cosine encoder with EnDat interface as a feed-

back system (primary and secondary, ð p.52). Preferred types are the ECN1313 and
EQN1325 encoders.
The thermostat contact in the motor is connected via the encoder cable to X1 and evalu-
ated there. All signals are connected using our pre-assembled encoder connection
cable.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 350 kHz

Type FBTYPE Remarks

ENDAT 4 adjust on screen page FEEDBACK
ENDAT + Wake&Shake 21 adjust on screen page TERMINAL

SERVOSTAR 300 SubD 15 round, 17-pin

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8.11.4 Sine Encoder with HIPERFACE (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with HIPERFACE interface as a

feedback system (primary and secondary, ð p.52).
The thermostat contact in the motor is connected via the encoder cable to X1 and evalu-
ated there. All signals are connected using our pre-assembled encoder connection
cable.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 350 kHz, FBTYPE: 2

SERVOSTAR 300 SubD 15 round, 17-pin

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8.11.5 Sine Encoder without data channel (X1)

Wiring of a sine-cosine encoder without data channel as a feedback (primary and sec-
ondary, ð p.52). Every time the 24V auxiliary voltage is switched on, the amplifier needs
start-up information for the position controller (parameter value MPHASE). Depending on
the feedback type either wake&shake is executed or the value for MPHASE is read out of
the amplifier's EEPROM.
The thermostat contact in the motor is connected via the encoder cable to X1 and evalu-
ated there.
If lead lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 350 kHz

Type FBTYPE Up Remarks

SinCos 5V 1 5V +/-5% MPHASE from EEPROM
SinCos 12V 3 7,5...11V MPHASE from EEPROM
SinCos 5V 7 5V +/-5% MPHASE with wake & shake
SinCos 12V 8 7,5...11V MPHASE with wake & shake

Don't use this feedback type with vertical load (hanging load).

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8.11.6 Sine Encoder with Hall (X1)

Feedback devices (incremental or sine-cosine), which don't deliver an absolute informa-

tion for commutation, can be used as complete feedback system combined with an addi-
tional Hall encoder (primary, ð p.52).
All signals are connected to X1 and evaluated there. If cable lengths of more than 25m
are planned, please consult our customer service.
Frequency limit (sin, cos): 350 kHz

Type FBTYPE Up Remarks

SinCos 5V with Hall 5 5V +/-5%
SinCos 12V with Hall 6 7,5...11V

SERVOSTAR 300 SubD15

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8.11.7 ROD (AquadB) 5V (X1)

Wiring of a 5V incremental encoder (ROD, AquadB) as a feedback (primary, ð p.52). The

thermostat contact in the motor is connected to X1 and evaluated there.
Every time the 24V auxiliary voltage is switched on, the amplifier need start-up informa-
tion for the position controller (parameter value MPHASE). With this feedback type the
amplifier executes a wake&shake every time the 24V auxiliary voltage is switched on.
If lead lengths of more than 50m are planned, please consult our customer service.
Frequency limit (A, B): 350 kHz, FBTYPE: 17

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8.11.8 ROD (AquadB) 5V with Hall (X1)

Wiring of a ComCoder as a feedback unit (primary, ð p.52). For the commutation hall
sensors are used and for the resolution an incremental encoder. The thermostat contact
in the motor is connected to X1 and evaluated there. With our ComCoder cable all sig-
nals are connected correctly.
With separate feedback devices (Encoder and Hall are two devices) the wiring must be
done similar to chapter 8.11.6, but the amplifier's pinout is identical to the wiring diagram
shown below.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit (A,B): 350 kHz, FBTYPE: 15

SERVOSTAR 300 SubD15 round, 17 pin

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8.11.9 ROD (AquadB) 5V (X5)

A 5V incremental encoder (AquadB) can be used as standard motor feedback (primary

and secondary, ð p.52). The thermostat contact in the motor is connected to X1.
Every time the 24V auxiliary voltage is switched on, the amplifier need start-up informa-
tion for the position controller (parameter value MPHASE). Depending on the feedback
type either wake&shake is executed or the value for MPHASE is read out of the ampli-
fier's EEPROM.
If lead lengths of more than 50m are planned please consult our customer service.
Frequency limit (A, B, N): 1.5 MHz

Type FBTYPE Up Remarks

ROD (AquadB) 5V 13 5V +/-5% MPHASE from EEPROM
ROD (AquadB) 5V 19 5V +/-5% MPHASE from wake & shake

Don't use this feedback type with vertical load (hanging load).

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8.11.10 ROD (AquadB) 5V with Hall (X5/X1)

Wiring of a 5V incremental encoder (ROD, AquadB) with Hall sensors as a feedback unit
(primary, ð p.52). For the commutation hall sensors are used and for the resolution an
incremental encoder. The thermostat contact in the motor is connected to X1 and evalu-
ated there.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit X5: 1.5 MHz, X1: 350 kHz, FBTYPE: 18

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8.11.11 ROD (AquadB) 24V (X3)

Wiring of a 24V incremental encoder (ROD AquadB) as a feedback system (primary or

secondary, ð p.52). The thermostat contact in the motor is connected to X1 or X2.
Every time the 24V auxiliary voltage is switched on, the amplifier need start-up informa-
tion for the position controller (parameter value MPHASE). With this feedback type the
amplifier executes a wake&shake is executed every time the 24V auxiliary voltage is
switched on.
This uses the digital inputs DIGITAL-IN 1 and 2 on connector X3.
If cable lengths of more than 25m are planned, please consult our customer service.

Frequency limit: 100 kHz, transition time tv £ 0,1µs, FBTYPE: 16

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8.11.12 ROD (AquadB) 24V with Hall (X3/X1)

Wiring of a 24V incremental encoder (ROD, AquadB) and Hall sensors as a feedback unit
(primary, ð p.52). For the commutation hall sensors are used and for the resolution an
incremental encoder. The thermostat contact in the motor is connected to X1 and evalu-
ated there.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit X3: 100 kHz, X1: 350 kHz FBTYPE: 14

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8.11.13 SSI Encoder (X5)

Wiring of a synchronous serial absolute-encoder as a feedback system (primary or sec-

ondary, ð p.52). The signal sequence can be read in Gray code or in Binary (standard)
code.
The thermostat contact in the motor is connected to X1 and evaluated there.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit: 1.5 MHz, FBTYPE: 9 (adjustable with Terminal)

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8.11.14 Hall sensors (X1)

Wiring of Hall sensors as a feedback unit (primary or secondary, ð p.52).

The thermostat contact in the motor is connected to X1 and evaluated there.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit: 350 kHz, FBTYPE: 11 (adjustable with Terminal)

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8.12 Electronic Gearing, Master-slave operation

In the case of the “electronic gearing” functionality (see setup software and description of
GEARMODE parameter), the servo amplifier is controlled by a secondary feedback
device as a slave.
It is possible to set up master/slave systems, use an external encoder as a setpoint
encoder or connect the amplifier to a stepper motor control.
The amplifier is parameterized using the setup software (electronic gearing). The resolu-
tion (number of pulses per revolution) can be adjusted.
The following types of external encoder can be used:

Wiring
secondary Feedback type Connector GEARMODE
diagram
SinCos Encoder ENDAT X1 ð p.55 8
SinCos Encoder HIPERFACE X1 ð p.56 9
SinCos Encoder w/o data channel X1 ð p.57 6, 7
ROD* (AquadB) 5V X5 ð p.61 3
ROD (AquadB) 24V X3 ð p.63 2
SSI X5 ð p.65 5
Step/direction 5V X5 ð p.68 4
Step/direction 24V X3 ð p.69 1

* ROD is an abbreviation for incremental encoder

8.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5)

You can link several SERVOSTAR amplifiers together in master-slave operation.

Master: position autput to X5 (screen page "Encoder emulation")
Slave: screen page "Electronic gearing" (GEARMODE)
Up to 16 slave amplifiers can be controlled by the master, via the encoder output. The
SubD connector X5 is used for this purpose.
Frequency limit: 1.5 MHz
Example for Master-Slave operation with two SERVOSTAR amplifiers:
Slave GEARMODE: 3 Master ENCMODE:1

SERVOSTAR 300 SERVOSTAR

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8.12.2 Connection to stepper motor controllers (step and direction)

You can connect the servo amplifier to a third-party stepper-motor controller. Parameter
setting for the slave amplifier is carried out with the aid of the setup software (electronic
gearing). The number of steps can be adjusted, so that the servo amplifier can be
adapted to match the step-direction signals of any stepper controller. Various monitoring
signals can be generated.

Observe the frequency limit!

Using an A quad B encoder provides better EMC noise immunity.

Speed profile and signal diagram

8.12.2.1 Step/Direction with 5 V signal level (X5)

Wiring of the servo amplifier (SubD connector X5) to a stepper-motor controller with a 5 V
signal level.
Frequency limit: 1.5 MHz, GEARMODE: 4

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8.12.2.2 Step/Direction with 24 V signal level (X3)

Wiring of the servo amplifier to a stepper-motor controller with a 24 V signal level. Used
are the digital inputs DIGITAL-IN 1 and 2 on connector X3.
Frequency limit: 100 kHz, GEARMODE: 1

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8.13 Encoder emulation

8.13.1 Incremental encoder output - A quad B (X5)

The incremental-encoder interface is part of the standard package. Select encoder func-
tion ROD (A Quad B) Encoder (“Encoder Emulation” screen page). The servo amplifier
calculates the motor shaft position from the cyclic- absolute signals of the resolver or
encoder, generating incremental-encoder compatible pulses from this information. Pulse
outputs on the SubD connector X5 are 2 signals, A and B, with 90° phase difference (i.e.
in quadrature, hence the alternative term “A quad B” output), with a zero pulse.
The resolution (before multiplication) can be set by the RESOLUTION function:

Enc. function (ENCMODE) Feedback system Resolution (lines) Zero pulse (NI)
once per turn
2 pole Resolver 256...4096
(only at A=B=1)
ROD (1)
256...524288 once per turn
Encoder
(28 ... 219) (only at A=B=1)
22 … 27 (multiplica- encoder signal
ROD interpolation (3) Encoder tion) TTL line x en- passed through
coder resolution from X1 to X5
Use the NI-OFFSET parameter to adjust + save the zero pulse position within one
mechanical turn. The drivers operate off an internal supply voltage.
The maximum permissible cable length is 100 meters.
Connections and signals for the incremental encoder interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the
shaft's end)

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8.13.2 SSI encoder output (X5)

The SSI interface (synchronous serial absolute-encoder emulation) is part of the standard
package. Select encoder function SSI (“Encoder Emulation” screen page). The servo
amplifier calculates the motor shaft position from the cyclic-absolute signals of the
resolver or encoder. From this information a SSI date (Stegmann patent specification DE
3445617C2) is provided. Max 32 bits are transferred. The leading data bit contains the
number of revolutions and are selectable from 12 to 16 bits. The following max. 16 bits
contain the resolution and are not variable.
The following table shows the allocation of the SSI date depending upon selected number
of revolutions:
Revolution Resolution (variable)
SSIREVOL
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit

13 12 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
12 11 10 9 8 7 6 5 4 3 2 1 0
11 10 9 8 7 6 5 4 3 2 1 0

The signal sequence can be output in Gray code or in Binary (standard) code.
The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the
setup software (cycle time 1,3 µs or 10 µs).
The drivers operate off an internal supply voltage.
Connection and signals for the SSI interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the end
of the motor shaft)

SERVOSTAR

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8.14 Digital and analog inputs and outputs

8.14.1 Analog inputs (X3)

The servo amplifier is fitted with two programmable differential inputs for analog
setpoints. AGND (X3/7) must always be joined to the GND of the controls as a ground
reference.
Technical characteristics
— Differential-input voltage max. ± 10 V
— Ground reference AGND, terminal X3/7
— Input resistance 2.4 kW
— Common-mode voltage range for both inputs ± 10 V
— Update rate 62,5 µs

SERVOSTAR 300

Analog-In 1 input (terminals X3/3-4)

Differential input voltage max. ± 10 V, resolution 14-bit, scalable.
Standard setting : speed setpoint
Analog-In 2 input (terminals X3/5-6)
Differential input voltage max. ± 10 V, resolution 12-bit, scalable.
Standard setting : torque setpoint
Application examples for setpoint input Analog-In 2:
— adjustable external current limit
— reduced-sensitivity input for setting-up/jog operation
— pre-control / override
Defining the direction of rotation
Standard setting : clockwise rotation of the motor shaft (looking at the shaft end)
— Positive voltage between terminal X3/3 (+ ) and terminal X3/4 ( - ) or
— Positive voltage between terminal X3/5 (+ ) and terminal X3/6 ( - )
To reverse the direction of rotation, swap the connections to terminals X3/3-4 or X3/5-6
respectively, or change the ROTATION DIRECTION parameter in the “Speed controller”
screen page.

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8.14.2 Digital inputs (X3/X4)

All digital inputs are electrically isolated via optocouplers.

Technical characteristics
— Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4)
— The inputs at X3 are PLC-compatible (IEC 61131-2 Type 1)
High: 11...30 V / 2...11 mA , Low: -3...5 V / <1 mA
— Update rate Software:250 µs / Hardware: 2 µs

SERVOSTAR 300

ENABLE input
The output stage of the servo amplifier is enabled by applying the ENABLE signal
(terminal X3/12, 24 V input, active high). Enable is possible only if input AS-Enable has a
24 V signal (see page 77ff).
In the disabled state (low signal) the connected motor has no torque.
AS-ENABLE input
An additional digital input (AS-Enable) releases the power output stage of the amplifier as
long as a 24 V signal is applied to this input. If the AS-Enable input goes open-circuit,
then power will no longer be supplied to the motor, the drive will lose all torque and
coast down to a stop. A fail-safe brake function for the drive, if one is required, must be
ensured through a mechanical brake since electrical braking with the aid of the drive is no
longer possible.
You can thus achieve a restart lock-out for personnel safety by using the AS-enable input
in conjunction with an external safety circuit.
You can find further information and connection examples on page 77.

This input is not compatible with IEC 61131-2.

Programmable digital inputs

You can use the DIGITAL-IN1 to DIGITAL-IN4 digital inputs to initiate pre-programmed
functions that are stored in the servo amplifier. A list of these pre-programmed functions
can be found on the “Digital I/O” screen page of our setup software.
If an input was freshly assigned to a pre-programmed function, then the data set must be
saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the
amplifier setup software for example).

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8.14.3 Digital outputs (X3)

Technical characteristics
— Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4)
— All digital outputs are floating
— DIGITAL-OUT1 and 2 : Open Emitter, max. 30 V DC, 10 mA
BTB/RTO : Relay output, max. 30 V DC or 42 V AC, 0.5 A
— Update rate 250 µs

SERVOSTAR 300

Ready-to-operate contact BTB/RTO

Operational readiness (terminals X3/1 and X3/2 ) is signaled by a floating relay contact.
The contact is closed when the servo amplifier is ready for operation, and the signal is
not influenced by the enable signal, the I²t-limit, or the regen threshold.

All faults cause the BTB/RTO contact to open and the output stage to be switched
off (if the BTB/RTO contact is open, the output stage is inhibited -> no power
output). A list of the error messages can be found on page 98.

Programmable digital outputs DIGITAL-OUT 1 / 2:

You can use the digital outputs DIGITAL-OUT1 (terminal X3/13) and DIGITAL-OUT2 (ter-
minal X3/14) to output messages from pre-programmed functions that are stored in the
servo amplifier.
A list of these pre-programmed functions can be found on the “I/O digital” screen page of
our setup software.
If an output is to be freshly assigned to a pre-programmed function, then the parameter
set must be saved in the EEPROM of the servo amplifier and a reset has to be carried out
(with the amplifier setup software for example).

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8.15 RS232 interface, PC connection (X6)

Operating, position control, and motion-block parameters can be set up by using the
setup software on an ordinary commercial PC.
Connect the PC interface (X6) of the servo amplifier to a serial interface on the PC via a
null-modem cable, while the supply to the equipment is switched off.

Do not use a null-modem power link cable!

This interface has the same electrical potential as the CANopen interface.
The interface is selected and set up in the setup software. Further notes on page 84.
With the optional -2CAN- expansion card, the two interfaces for RS232 and CAN, which
would otherwise use the same connector X6, are separated out onto three connectors
(ð p.114).

SERVOSTAR 300

Interface cable between the PC and servo amplifiers of the SERVOSTAR 300 series:
(View : looking at the solder side of the SubD sockets on the cable)

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8.16 CANopen interface (X6)

The interface for connection to the CAN-bus (default : 500 kBaud). The integrated profile
is based on the CANopen DS301 communication profile and the DS402 drive profile.
The following functions are available in connection with the position controller:
Jogging with variable speed, homing run (zeroing to reference), start motion task, start
direct task, digital setpoint provision, data transmission functions and many others.
Detailed information can be found in the CANopen manual. The interface is at the same
electrical potential as the RS232 interface. The analog setpoint inputs can still be used.
With the optional -2CAN- expansion card, the two interfaces for RS232 and CAN, which
otherwise use the same connector X6, are separated out onto three connectors (with ter-
mination, ð p.114).

SERVOSTAR 300

CAN-bus cable

To meet ISO 11898, a bus cable with a characteristic impedance of 120 W should be
used. The maximum usable cable length for reliable communication decreases with
increasing transmission speed. As a guide, you can use the following values which we
have measured, but they are not to be taken as assured limits:
Cable data: Characteristic impedance 100-120 W
Cable capacitance max. 60 nF/km
Lead loop resistance 159.8 W/km
Cable length, depending on the transmission rate

Transmission rate (kBaud) max. cable length (m)

1000 10
500 70
250 115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance
(loop resistance, 115 W/km) make it possible to achieve greater distances.
(Characteristic impedance 150 ± 5 W Þ terminating resistor 150 ± 5 W).
For EMC reasons, the SubD connector housing must fulfill the following requirements:
— metal or metalized housing
— provision for cable shielding connection on the housing, large-area connection

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8.17 Personnel safe restart lock -AS-

A frequently required application task is the protection of personnel against the restarting
of drives. This can be achieved by an electronic inhibit or with mechanical elements (posi-
tively driven relay contacts).
When positively driven relay contacts where used, either the net contactor in the mains
supply circuit switched off or the motor was disconnected from the servo amplifier by an
additional contactor.
The disadvantages of this method are :
— the DC bus link has to be charged up again at restart
— wear on the contacts of the contactors, caused by switching under load
— extensive wiring required, with additional switching components
The restart lock -AS- avoids these disadvantages.
The conceptual examination of the function "safe stop" (called restart lock AS in the fol-
lowing) was accomplished by the BG-Institute for Occupational Safety and Health and the
classification in category 3 according to EN 954-1 was confirmed.
Advantages of the restart lock -AS- :
— the DC bus link remains charged up, since the mains supply line remains active
— only low voltages are switched, so there is no contact wear
— very little wiring is required
— the functionality and the personnel safety when using the circuit recommendations
in this documentation have been approved by the Trade Liability Association.

8.17.1 Safety instructions

l Observe the chapter "use as directed" for the restart lock -AS- (ð p. 78)
l If the restart lock -AS- is automatically activated by a control system, then
make sure that the output of the control is monitored for possible malfunction.
This can be used to prevent a faulty output from activating the restart lock -AS-
unintendedly.
l Since the restart lock is a single-channel system, erroneous engaging will not
be recognized.
l Keep to the following functional sequence when the restart lock -AS- is used :
1. Brake the drive in a controlled manner (speed setpoint = 0V)
2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)
3. If there is a suspended load, block the drive mechanically
4. Activate the restart lock -AS-

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8.17.2 Use as directed

The restart lock -AS- is exclusively intended to provide safety for personnel, by prevent-
ing the restart of a system. To achieve this personnel safety, the wiring of the safety cir-
cuits must meet the safety requirements of EN60204, EN12100 and EN 954-1 category 3.
The -AS- restart lock must only be activated when the motor is no longer rotating
(setpoint = 0V, speed = 0rpm, enable = 0V).

Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).

The -AS- restart lock must not be used if the drive is to be made inactive for the following
reasons :
1. - cleaning, maintenance and repair operations
- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the
personnel, and secured (main switch).
2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off (by the
emergency-stop button).

8.17.3 Technical data and pinning

Input voltage 20 V..30 V

Input current 40 mA – 75 mA (Ieff)
Peak current 220 mA (Is)

8.17.4 Enlosure

Since the servo amplifier meets enclosure IP20, you must select the environment ensur-
ing a safe operation of the servo amplifier. The enclosure must meet IP54 at least.

8.17.5 Wiring

If the wiring leads outside the demanded enclosure (IP54), the cables must be laid dura-
bly (firmly), protected from outside damage (e.g. laying in a cable duct), in different
sheathed cables or protected individually by grounding connection.
If wiring remains within the demanded enclosure, then it has to meet the requirements of
the standard EN 60204-1, section 14-3.

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8.17.6 Functional description

If the restart lock -AS- is not needed, then the input AS-ENABLE must be connected
directly with +24VDC. The restart lock is then passed by and cannot not be used.
In case of use of the restart lock the input AS Enable must be connected to the exit of
a security control or a safety relay, which meets at least to the requirements of the
category 3 after EN 954-1 (see the connection diagram on page 81).
Possible states of the servo amplifier in connection with restart lock -AS-:

AS-ENABLE ENABLE Display Motor has torque Safety cat. 3

0V 0V -S- no yes
0V +24 V F27 no yes
+24 V 0V normal status e.g. 06 no no
+24 V +24 V normal status e.g. E06 yes no
If the restart lock is engaged during operation by separating input AS ENABLE from 24
VDC, the motor runs down out of control and the servo amplifier displays the error F27.

There is no possibility of braking the drive controlled. If a controlled braking before

the use of the restart lock is necessary, the drive must be braked and the input
AS-ENABLE has to be separated from +24 VDC time-delayed.

The restart lock -AS- does not provide an electrical separation from the power
output. If access to the motor power terminals is necessary, the servo amplifier
must be disconnected from mains supply considering the discharging time of the
intermediate circuit.

Since the restart lock is a single-channel system, erroneous engaging will not be recog-
nized. When wiring the input AS-ENABLE within one enclosure it must be paid attention
to the fact that the used cables and the enclosure meet the requirements of EN 60204-1.
If the wiring leads outside the demanded enclosure, the cables must be laid durably
(firmly), and protected from outside damage.

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8.17.6.1 Signal diagram (sequence)

The diagram shows how to use restart lock -AS- to ensure a safe stop of the drive and
error free operation of the servo amplifier.
1. Brake the drive in a controlled manner (speed setpoint = 0 V)
2. When speed = 0 rpm, disable the servo amplifier (Enable = 0 V)
3. Activate the restart lock -AS- (AS-Enable = 0 V)

Suspended loads can set themselves to motion on motors without brake, because
the motor loses all torque when restart lock -AS- is engaged (AS Enable open
and/or 0 V).

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8.17.6.2 Control circuit

The example shows a circuit diagram with two separated work areas connected to one
emergency stop circuit. For each work area individually "safe stop" of the drives is
switched by a protective screen.
The safety switchgears used in the example are manufactured by Pilz and fulfill at least
the safety category 3 according to EN 954-1. Further information to the safety
switchgears is available from Pilz. The use of safety switchgears of other manufacturers
is possible, if these also fulfill the safety category 3 according to EN 954-1.

Emergency-stop circuit acc.

to EN 954-1 category 4

Safe stop acc. to EN954-1 category 3 for 3 drives

Safe stop acc. to EN 954-1 category 3 for 2 drives

Consider the wiring instructions on page 78.

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8.17.6.3 Functional test

With initial starting and after each interference into the wiring of the drive or after
exchange of one or several components of the drive the function of the restart lock
must be tested.

1. Method:
1. Stop drive, with setpoint 0V, keep servo amplifier enabled.
Do not enter hazardous area!
2. Activate the restart lock -AS- e.g. by opening protective screen. (voltage at X4/5 0 V)
Now the BTB/RTO contact opens, the net contactor releases and the servoamplifier dis-
plays error F27.
2. Method:
1. Stop all drives, with setpoint 0V, disable servo amplifier.
2. Activate the restart lock -AS- e.g. by opening protective screen. (voltage at X4/5 0 V)
Now the servo amplifier displays -S-.

8.17.6.4 Mains supply circuit

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9 Setup
9.1 Important notes
Only professional personnel with extensive knowledge in the fields of electrical
engineering and drive technology are allowed to setup the servo amplifier.

The procedure for setup is described as an example. Depending on the application, a dif-
ferent procedure may be appropriate or necessary. In multi-axis systems, set up each
servo amplifier individually.

Before setting up, the manufacturer of the machine must generate a hazard
analysis for the machine, and take appropriate measures to ensure that unforeseen
movements cannot cause injury or damage to any person or property.

Check that all connection components that are live in operation are safely
protected against bodily contact. The equipment produces potentially lethal
voltages up to 900 V.
Never undo the electrical connections to the servo amplifier while it is live.
Capacitors can still have dangerous residual charges up to 300 seconds after
switching off the supply voltage.
The heat sink and front panel of the amplifier can reach temperatures up to 80°C in
operation. Check the heat sink temperature. Wait until the heat sink has cooled
down to 40°C before touching it.

If the servo amplifier has been stored for more than 1 year, it will be necessary to
re-form the capacitors in the DC bus link circuit. To do this, disconnect all
electrical connections and apply single-phase 230 V AC to terminals L1 / L2 of the
servo amplifier for about 30 minutes. This will re-form the capacitors.

Additional information on setting up the equipment:

The adaptation of parameters and the effects on the control loop behavior are
described in the online help of the setup software.
The setting up of any expansion card that may be fitted is described in the
corresponding manual on the CD-ROM.
We can provide further know-how through training courses (on request).

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9.2 Setup software

9.2.1 General

This chapter describes the installation of the setup software DRIVEGUI.EXE for the
SERVOSTAR 300 digital servo amplifiers.
We offer training and familiarization courses on request.

9.2.1.1 Use as directed

The setup software is intended to be used for altering and saving the operating
parameters for the SERVOSTAR 300 series of servo amplifiers. The attached servo
amplifier can be set up with the help of this software, and during this procedure the drive
can be controlled directly by the service functions.

Only professional personnel who have the relevant expertise described on page 7
are permitted to carry out online parameter setting for a drive that is running.
Sets of data that have been stored on data media are not safe against unintended
alteration by other persons.
After loading a set of data you must therefore always check all parameters before
enabling the servo amplifier.

9.2.1.2 Software description

The servo amplifiers must be adapted to the requirements of your machine.

Usually you will not have to carry out this parameter setting yourself on the amplifier, but
on a PC, with the assistance of the setup software. The PC is connected to the servo
amplifier by a null-modem cable (serial, see p.75). The setup software provides the com-
munication between the PC and SERVOSTAR 300.
You can find the setup software on the accompanying CD-ROM and in the download
area of our website.
With very little effort you can alter parameters and instantly observe the effect on the
drive, since there is a continuous (online) connection to the amplifier. At the same time,
important actual values are read out from the amplifier and displayed on the monitor of
the PC (oscilloscope functions).
Any interface modules (expansion cards) which may be built into the amplifier are auto-
matically recognized, and the additional parameters which are required for position con-
trol or motion-block definition are made available.
You can save sets of data on data media (archiving) and load them again. You can also
print out the data sets.
We supply you with motor-specific default sets of data for the most common combinations
of servo amplifier and motor. In most applications you will be able to use these default
values to get your drive running without any problems.
An extensive online help with integrated description of all variables and functions sup-
ports you in each situation.

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9.2.1.3 Hardware requirements

The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of
the PC by a null-modem cable (not a null-modem link cable!) (ð p.75).

Connect / disconnect the interface cable only when the electrical supply is
switched off for both the PC and the servo amplifier.

The interface in the servo amplifier has the same potential level as the CANopen inter-
face.
Minimum requirements for the PC:
Processor : at least Pentium® II or comparable
Operating system : WINDOWS 2000 / XP
Graphics adapter : Windows compatible, color
Drives : hard disk with at least 10 MB free space
CD-ROM drive
Interface : one free serial interface (COM1 ... COM10)

9.2.1.4 Operating systems

WINDOWS 2000 / XP
DRIVEGUI.EXE will run under WINDOWS 2000 and WINDOWS XP.
Emergency operation is feasible through an ASCII terminal emulation (without graphical
user interface).
Interface settings : 38400 bps, databit 8, no parity, stopbit 1, no flow control
Unix, Linux
The functioning of the software has not been tested for WINDOWS running within Unix or
Linux.

9.2.2 Installation under WINDOWS 2000 / XP

The CD-ROM includes an installation program for the setup software.

Installation
Autostart function activated:
Insert the CD-ROM into a free drive. A window with the start screen opens. There you
find a link to the setup software DRIVEGUI.EXE. Click it and follow the instructions.
Autostart function deactivated:
Insert the CD-ROM into a free drive. Click on START (task bar), then on Run. Enter the
program call: x:\index.htm (x = correct CD drive letter).
Click OK and proceed as described above.

Connection to the serial interface of the PC:

Connect the interface cable to a serial interface on your PC (COM1 to COM10) and to the
serial interface of the servo amplifier SERVOSTAR 300 (ð p.75).

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9.3 Quickstart
9.3.1 Preparation

9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier

1. Unpack servo amplifier and accessories

2. Observe safety instructions in the manuals
3. Mount the servo amplifier as described in chapter 7
4. Wire the servo amplifier as described in chapter 8 or apply the minimum wiring for drive
testing as described in chapter 9.3.1.3
5. Install the software as described in chapter 9.2

9.3.1.2 Documents

You need access to these documents (located on the product CD-ROM, you can down-
load the latest editions from our website):
l Product Manual (this manual)
l Accessories Manual
l CANopen communication profile Manual

Depending on the installed expansion card you need one of these documents:
l PROFIBUS DP communication profile Manual
l DeviceNet communication profile Manual
l SERCOS communication profile Manual
l EtherCat communication profile (in process) Manual

You need Acrobat Reader to read the PDFs, an installation link is on every screen of the
product CD-ROM.

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9.3.1.3 Minimum Wiring for Drive Test

This wiring does not fulfill any requirements to safety or functionality of your
application, it just shows the required wiring for drive testing without load.

Motor-Feedback

ENC
RES
PC
CAN
X3 1
Power ON 2
Enable
24V ON
12
+ X4 1
24V DC 3 2
- 5

X8 4

Motor-Power
Motor

Power

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9.3.2 Connect

l Connect the interface cable to a serial interface on your PC and to the serial interface
X6 of the servo amplifier. USB to serial converter can be used optionally.
l Switch on the 24 V power supply for the servo amplifier.
l Wait about 30 seconds, until the front display of the servo amplifier displays the cur-
rent class (e.g. for 3 A). If the power supply voltage is switched on, too, a lea-
ding P is displayed (e.g. for Power, 3 A).

If a fault code ( ) or a warning ( ) or a status message (./_ / E/S)

appears in the display, you will find the description on page 98 / 99. If there is fault,
fix the problem.

Double-Click the DRIVEGUI.EXE icon on your Windows desktop to

start the software.

You can work offline or online with

DRIVEGUI.EXE. Work ONLINE now.

If the communication is start-

ed for the first time, you have
to setup the communication
parameters.
Choose the communication
system and the interface,
where the servo amplifier is
connected to.
Click OK.

The software tries to communicate with these parameters. If it's not successful, you
receive this error message:

Frequent causes:
- wrong interface chosen
- wrong connector chosen at the servo amplifier
- interface is used by another software
- 24 V auxiliary voltage for the servo amplifier not wor-
king
- interface cable broken or wrong wiring

Quit the error message. The software starts in the offline mode now, that requires the
manual selection of the amplifier's type. Quit this selection by closing the window.
Fix the communication problem. Restart the software in Online mode.

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If communication works, you see the start screen. Select "Setup Wizard" in the navigation
frame.

Make sure, that the amplifier is disabled (Input Enable connector X3 pin 12 must
be 0 V or open)!

9.3.3 Important Screen Elements

Help Function
The Online-Help gives detailed information to all parameters the servo amplifier can work
with.

Key F1 Starts Online Help for the actual screen page.

Menu bar ? Starts Online Help with the first page.
Context Help. Click the help symbol first. Then click the function for which
you need help.

Tool Bar

Save to EEPROM, required if you changed parameters.

Reset, required if you changed configuration parameters.

Operation Mode, use "0: Digital Velocity" mode for dri-

ve testing.
Status Bar

The status bar shows a green Online symbol, indicating that the communication works.

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9.3.4 Setup Wizard

The Setup Wizard leads you through the necessary steps for configuring your servo
amplifier. Depending on the selected application, only the active screen pages are
necessary.

For a quick setup / drive

test, select the setup
type "Quick Motor/Drive
Setup".

Start the Wizard.

9.3.4.1 Basic Setup

Basic parameters are

setup here.

Response to Loss of Input Phase: Select Single-Phase or Three-Phase operation.

With three-phase operation you can select either warning "n05" or error "F19" in case of
phase loss. The reaction "F19" disables the output stage, "n05" is just a message.
Name: You can enter a name for the servo amplifier (up to 8 characters). This simplifies
the drive identification in the system.
Set Software Enable on Bootup: Don't select this option for the quick test.

Click NEXT.

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9.3.4.2 Units/Mechanical

The user units for all in-

put fields in the setup
software can be prese-
lected here.

Position, Velocity, Acceleration

Select usable units for your application referring to the moved load.
Mechanical Conversion
The relationship between motor shaft revolution (pole pait pitch with linear motors) and
motion distance of the load is specified here. Gear ratio can be calculated here as well.
Detailed information can be found in the online help.
Use the tool based on sample applications for calculating the resolution value:

Calculate PGEARI/PGEARO for..." button

If your application does not corre-

spond to any of the listed examples,
enter the required parameters direct-
ly in the fields on the “Units” screen.

First, select the application that corresponds to your own. Next, set the position unit.
Select the position unit that provides you with the required accuracy for your application.
Set the mechanical data for you application now. If a gearhead is flange-mounted on the
motor, you must also enter the gearhead data (either the number of teeth or the ratio of
the revolutions).
Then click the “Calculate conversion factors and return” button.

Click NEXT.

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9.3.4.3 Motor (rotary) / Feedback

Simplified setting of the

motor related parameters.

Feedback: Select the feedback system used in the motor.

Attention: Resolver is fixed to 2 pole in the Quick Motor/Drive Setup.
Change "pole n°" on feedback screen in Complete Setup later, if required.
Motor type: Click the button "Select from Database...".
Open the database file (mdb_ _ _.csv) and select the used motor out of the list. Special
motors must be defined in the "Complete Setup".
Brake: If the amplifier shall control a brake, change the Brake parameter to "With"
Calculated quick tuning: If you know the Load-to-motor inertia ratio (0 is for no load),
enter the number here and select the desired servo performance. If you don't know the
inertia ratio, select "Do not tune". Click FINISH.

9.3.4.4 Motor (linear) / Feedback (Encoder)

Simplified setting of the

motor related parameters.

Feedback: Select the feedback system used.

Motor type: Click the button "Select from Database..".
Open the database file (mdb_ _ _.csv) and select the used motor. Special motors must
be defined in the "Complete Setup".
Encoder Lines (appears with Feedback Type Sine Encoder):
Click "Calculate" and fill in the Encoder signal period.
Brake: If the amplifier shall control a brake, change the Brake parameter to "With"
Calculated quick tuning: If you know the Load-to-motor inertia ratio, enter the number
here and select the desired servo performance. Otherwise select "Do not tune".

Click FINISH.

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9.3.4.5 Save Parameters and Restart

You are going to finish the Setup Wizard and you have changed several basic parame-
ters. Depending on the parameters you changed, two possible reactions will occure now:
Configuration parameters changed
A warning appears, that you have to restart the amplifier, this is called "coldstart".
Click "YES".
The parameters are
saved to the ampli-
fier's EEPROM auto-
matically and a reset
command restarts
the amplifier (takes some seconds).
Other parameters changed
No warning appears. Save the parameters to the EEPROM of the servo amplifier manu-
ally by clicking the symbol in the tool bar. A coldstart of the amplifier is not neces-
sary.
Select the screen "Motion Service" in the navigation frame.

9.3.5 Motion Service (Jog Mode)

Be aware that the actual position of the load permits the subsequent moving ope-
rations. The axis could move to the hardware limit-switch or the mechanical stop.
Make sure that a jerk or a fast acceleration of the load cannot cause any damage.
l Switch on the power supply for the drive.
l AS-Enable: Apply +24 V to the input AS-Enable [X4/5]
l Hardware-Enable: Apply +24 V to the input Enable [X3/12]. If AS-Enable is missed
or the sequence was wrong, the front display shows .

l Software-Enable: Click the symbol EN in the tool bar. Now the front display
shows an E and the current class (e.g. for Enable, 3 A). Click the symbol
DIS to switch off the output stage (disable).
Jog
(Digital Velocity Mode):
You can move the drive with
constant speed. Enter the
desired speed.
Observe the "safe reduced
speed" requirements for
your application!
The drive moves with the
preset speed when the + or
– button is pressed. It stops
when the button is released.

Actual errors and warnings are listed on the screen "Status". A description of
errors/warnings can be found in the online help or on p.98ff.
Now you have setup and tested the basic functions of the drive successfully.

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9.3.6 More Setup Screens

Observe the safety instructions in the manuals and in the online help before you
change parameters in the additional setup screens.

For all setup functions detailed information can be found in the Online Help system and
the integrated command reference.
Select "Complete Setup" in the Setup-Wizard. Now you have access to:
l Feedback: Adjust the used feedback unit
l Motor: Adjust the used motor
l Control Loops: Current-, Velocity- and Position-Loops can be optimized
l Position Data: Adjust the position control for the requirements of your application.
l Position Registers: up to 16 position values in the motion way can be monitored.
l Electronic Gearing: If the servo amplifier will follow a setpoint as a slave with a gear
ratio, you can select the gearing source here and define the gear ratio.
l Encoder Emulation: select the encoder emulation (position output)
l Analog I/O: setup the analog inputs
l Digital I/O: setup the digital inputs and outputs
l Status (Errors/Warnings): displays amplifiers data with history, actual
faults/warnings
l Monitor: displays the drive data (actual values)
l Homing: definition and start of homing
l Motion task: definition and start of motion task
l Oscilloscope: 4 channel oscilloscope with multiple functionality
l Bode Plot: tool for optimizing the drive
l Terminal: setup the servo amplifier with ASCII commands
l Expansion Card: depending on the built-in expansion card a menu appears

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9.4 Multi-axis systems

9.4.1 Station address for CAN-bus

You can use the keypad on the front panel to preset the station addresses for the individ-
ual amplifiers and the baud rate for communication (ð p.97). Usually the setup software
is used to set all parameters.

9.4.2 Baud rate for CAN-bus

After changing the station address and baud rate you must turn the 24V auxiliary
supply for the servo amplifier off and on again.
Coding of the Baud rate in the LED display :
Coding Baud rate in kbit/s Coding Baud rate in kbit/s
1 10 25 250
2 20 33 333
5 50 50 500
10 100 66 666
12 125 80 800
100 1000

9.5 Keypad operation / LED display

This section illustrates the two possible operating menus and the use of the keys on the
front panel. Normally, the SERVOSTAR 300 only presents the standard menu for your
use. If you want to operate the amplifier via the detailed menu, you must keep the right
key pressed while switching on the 24V supply.

9.5.1 Keypad operation

The two keys can be used to perform the following functions:

Key symbol Functions

press once : move up one menu item, increase number by one
press twice in rapid succession : increase number by ten
press once : decrease number by one
press twice in rapid succession : decrease number by ten
hold right key pressed, and then press left key as well :
to enter a number, “Return” function

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9.5.2 Status display

ð p.95

9.5.3 Standard menu

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9.5.4 Advanced menu

To operate the amplifier via the detailed menu, you must keep the right key pressed while
switching on the 24 V supply.

ð p.95

ð p.95

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9.6 Error messages

Any errors that occur are shown in coded form by an error number in the LED display on
the front panel. All error messages result in the BTB/RTO contact being opened, the out-
put stage being switched off (motor loses all torque), and the holding brake is activated.
Number Explanation
E/P Status Messages Status messages, no error, see p. 96
... Status Message Amplifier is updating the startup configuration
- Status Message Status message, no error, programming mode
-S- AS-Enable AS-Enable input is 0V (with disabled drive only)
F01* Heat Sink Temperature Heat sink temperature too high (default: 80°C)
Overvoltage in DC bus link. Limit depends on the
F02* Overvoltage
electrical supply voltage
F03* Following Error Message from the position controller
F04 Feedback Cable break, short-circuit, short to ground
F05* Undervoltage Undervoltage in DC bus link (default: 100 V)
F06* Motor Temperature Motor temperature too high or temp. sensor defect
F07 Internal Voltages Internal supply voltages not ok
F08* Overspeed Motor runs away, speed is too high
F09 EEPROM Checksum error
F10 Signal Failure X5 Signal failure X5 (cable break or similar)
F11 Brake Cable break, short-circuit, short to ground
F12 Motor Phase Motor phase missing (cable break or similar)
F13* Ambient Temperature Ambient temperature too high
F14 Output Stage Fault in the power output stage
F15 I²t max. I²t maximum value exceeded
F16* Mains BTB/RTO 2 or 3 phases missing in the mains supply feed
Error in the analog-digital conversion, normally
F17 A/D Converter
caused by extreme electromagnetic interference
F18 Regen Circuit Regen circuit faulty or incorrect setting
F19* DC Bus Link DC bus link breakdown
Slot error, depends on the type of expansion card
F20 Slot Error
(see ASCII object reference)
F21 Handling Error Handling error on the expansion card
F22 Reserved Reserved
F23 CAN-Bus Off Severe CAN bus communication error
F24 Warning Warning is displayed as fault
F25 Commutation Error Commutation error
F26 Limit Switch Hardware limit switch error on homing move
Operational error with -AS- , input for AS-Enable
F27 AS
and ENABLE have been set at the same time
F28 Fieldbus Error Fieldbus error (see ASCII command reference)
F29 Fieldbus Error Fieldbus error (see ASCII command reference)
F30 Emergency Timeout Timeout emergency stop
F31 Reserve Reserve
F32 System Error System software not responding correctly
* = these error messages can be cleared without a reset, by using the terminal screen
and sending the ASCII command CLRFAULT (or button CLR FLT ). If only one of these errors

is present and the RESET button or the I/O RESET function is used, only the
CLRFAULT command will be executed.

More information to the messages can be found in the ASCII Object Reference
(Online Help), see parameter ERRCODE. Hints for removal can be found in the
Online help chapter "Trouble-Shooting".

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9.7 Warning messages

Faults which occur, but which do not cause a switch-off of the amplifier output stage
(BTB/RTO contact remains closed), are indicated in the LED display on the front panel by
a coded warning number.
Number Designation Explanation
E/P Status Messages Status messages, no error, see p. 96
... Status Message Amplifier is updating the startup configuration
-S- AS-Enable AS-Enable input is 0V (with disabled drive only)
- Status Message Status message, no error, programming mode
n01 I²t I²t threshold exceeded
n02 Regen power Reached preset regen power limit
n03* S_fault Exceeded preset following error limit
n04* Response monitoring Response monitoring (fieldbus) has been activated
n05 Supply phase Mains supply phase missing
n06* SW limit switch 1 Software limit switch 1 underrun
n07* SW limit switch 2 Software limit switch 2 overrun
n08 Motion task error A faulty motion task was started
No reference point (Home) set at start of motion
n09 No reference point
task
n10* PSTOP PSTOP limit-switch activated
n11* NSTOP NSTOP limit-switch activated
Only for ENDAT or HIPERFACE® :
Motor default values discrepancy between motor number saved in the
n12
loaded encoder and the amplifier, motor default values loa-
ded
n13* Expansion card 24V DC supply for I/O expansion card not ok
SinCos commutation (wake & shake) not comple-
n14 SinCos feedback ted, will be canceled when amplifier is enabled and
wake & shake carried out
n15 Reserve Reserve
n16 Summarized warning Summarized warning for n17 to n31
n17 Fieldbus-sync CAN sync is not logged in
n18 Multiturn overflow Max. number of motor turns exceeded
Motion task ramps are
n19 Range overflow on motion task data
limited
n20 Invalid motion task Invalid motion task
n21 PLC program error For details see PLC code
Max. motortemperatur The user can shut down the process before the tem-
n22
reached perature eror will interrupt the process immediately
n23 Sin Cos feedback Warning level reached
n24 Digital I/O Configuration is not logical
n25-n31 Reserve Reserve
n32 Firmware beta version Firmware is an unreleased beta version
* = these warning messages result in a controlled shut-down of the drive (braking by
emergency stop ramp)

More information to the messages can be found in the ASCII Object Reference
(Online Help), see parameter STATCODE. Hints for removal can be found in the
Online help chapter "Trouble-Shooting".

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9.8 Trouble Shooting

There may be a wide variety of reasons for the fault, depending on the conditions in your
installation. In multi-axis systems there may be further hidden causes of a fault.

Detailled hints for removal of faults can be found in the Online help chapter
"Trouble-Shooting".

Our customer service can give you further assistance with problems.
Fault Possible causes Measures
— wrong cable used — use null-modem cable
HMI message: — cable plugged into wrong position — plug cable into the correct
Communicati- on servo amplifier or PC sockets on the servo amplifier
on fault and PC
— wrong PC interface selected — select correct interface
— servo amplifier not enabled — apply ENABLE signal
— software enable not set — set software enable
— break in setpoint cable — check setpoint cable
Motor does — motor phases swapped — correct motor phase sequence
not rotate — brake not released — check brake control
— drive is mechanically blocked — check mechanism
— motor pole no. set incorrectly — set motor pole no.
— feedback set up incorrectly — set up feedback correctly
— gain is too high (speed controller) — reduce Kp (speed controller)
Motor oscilla-
— feedback cable shielding broken — replace feedback cable
tes
— AGND not wired up — join AGND to CNC-GND
Drive reports — Irms or Ipeak set too low — increase Irms or Ipeak
following er- (keep within motor ratings!)
ror — accel/decel ramp is too long — shorten ramp +/-
Motor over-
— Irms/Ipeak is set too high — reduce Irms/Ipeak
heating
— Kp (speed controller) too low — increase Kp (speed controller)
— Tn (speed controller) too high — use motor default value for
Drive too soft Tn (speed controller)
— ARLPF / ARHPF too high — reduce ARLPF / ARHPF
— ARLP2 too high — reduce ARLP2
— Kp (speed controller) too high — reduce Kp (speed controller)
— Tn (speed controller) too low — use motor default value for
Drive runs
Tn (speed controller)
roughly
— ARLPF / ARHPF too low — increase ARLPF / ARHPF
— ARLP2 too low — increase ARLP2
— offset not correctly adjusted for — adjust offset (analog I/O)
Axis drifts at analog setpoint provision
setpoint = 0V — AGND not joined to the — join AGND and controller-GND
controller-GND of the controls

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10 Expansions Cards
You can find information about availability and order numbers on page 119.

10.1 Guide to installation of expansion cards

l Use a suitable screwdriver to lever off the cover of the option slot.

l Take care that no small items (such as screws) fall into the open option slot.
l Lever off the small metall sheet and push it back to the small slot. Dispose the
big metall sheet.

l Push the expansion card carefully into the provided guide rails of the main
slot, without twisting it.
l Press the expansion card firmly into the slot.

l Screw the screws on the front cover into the threads in the fixing lugs. This en-
sures that the connectors make good contact.

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10.2 Expansion card -I/O-14/08-

This section describes the additional features that the expansion card -I/O-14/08- pro-
vides for the SERVOSTAR 300. If you ordered the expansion card together with the servo
amplifier, then it will be delivered already inserted into the expansion slot of the servo
amplifier and screwed in place.
The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The
functions of the inputs and outputs are adjustable with the setup software.
The I/Os are used to initiate the motion tasks that are stored in the servo amplifier and to
evaluate signals from the integrated position control in the higher-level control system.
The functions of the inputs and signal outputs correspond to the functions that can be
assigned to the digital I/Os on connector X3. All inputs and outputs are electrically iso-
lated from the servo amplifier by optocouplers.

10.2.1 Front view

10.2.2 Technical data

Control inputs 24V / 7mA , PLC-compatible, IEC 1131

Signal output 24V / max. 500mA , PLC-compatible, IEC 1131
24V (18 … 36V) / 100mA plus total current of the
outputs (depends on the input wiring of the controls)
Supply inputs, to IEC 1131 The 24V DC voltage must be supplied by an
electrically isolated power supply (e.g. with
isolating transformer).
Fusing (external) 4 AT
Connectors MiniCombicon, 12-pin, coded on PIN1 and 12
Data – up to 50m long : 22 x 0.5 mm², unshielded,
Cables
Supply– 2 x 1mm², check voltage drop
Waiting time between 2 motion
depends on the response time of the control system
tasks
Addressing time (minimum) 4ms
Starting delay (maximum) 2ms
Response time of digital outputs max. 10ms

10.2.3 LEDs

Two LEDs are mounted next to the terminals on the expansion card. The green LED sig-
nals that the 24V auxiliary supply is available for the expansion card. The red LED signals
faults in the outputs from the expansion card (overload of switching components,
short-circuit).

10.2.4 Entering a motion block number (example)

Motion block number A7 A6 A5 A4 A3 A2 A1 A0

binary 1010 1110 1 0 1 0 1 1 1 0
decimal 174 128 - 32 - 8 4 2 -

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10.2.5 Connector assignments

The functions are adjustable with the setup software. In the table below the default values
are described.
Connector X11A
Default
Pin Dir Description
function
1 In A0 Motion block number, LSB
2 In A1 Motion block number, 21
3 In A2 Motion block number, 22
4 In A3 Motion block number, 23
5 In A4 Motion block number, 24
6 In A5 Motion block number, 25
7 In A6 Motion block number, 26
8 In A7 Motion block number, MSB
Polls the home switch. If a digital input on the base unit is
9 In Reference used as a home input, then the input on the expansion card
will not be evaluated.
Clears the warning of a following error (n03) or the response
10 In F_error_clear
monitoring (n04)
The following task, that is defined in the motion task by “Start
with I/O” is started. The target position of the present motion
11 In Start_MT_Next task must be reached before the following task can be started.
The next motion block can also be started by an appropriately
configured digital input on the base unit.
Starts the "Jog Mode" with a defined speed. “x” is the speed
12 In Start_Jog v= x saved in the servo amplifier for the function "Jog Mode". A ri-
sing edge starts the motion, a falling edge cancels the motion.

Connector X11B
1 In MT_Restart Continues the motion task that was previously interrupted.
Starts the motion task that is addressed by A0-A7 (connector
2 In Start_MT I/O
X11A/1...8).
When the target position for a motion task has been reached
3 Out InPos (the InPosition window), this is signaled by the output of a
HIGH signal. A cable break will not be detected.
The start of each motion task in an automatically executed
sequence of motion tasks is signaled by an inversion of the
Next-InPos output signal. The output produces a LOW signal at the start
4 Out
of the first motion task of the sequence. The form of the mes-
sage can be varied by using ASCII commands.
PosReg 0 Can only be adjusted by ASCII commands/setup software.
A LOW signal indicates that the position has gone outside the
5 Out F_error
acceptable following error window.
6 Out PosReg1 default: SW limit 1, indicated by a HIGH signal
7 Out PosReg2 default: SW limit 2, indicated by a HIGH signal
8 Out PosReg3 Can only be adjusted by ASCII commands/setup software.
9 Out PosReg4 Can only be adjusted by ASCII commands/setup software.
10 Out PosReg5 Can only be adjusted by ASCII commands/setup software.
11 - 24V DC Supply voltage for output signals.
12 - I/O-GND Digital GND for the control system.

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10.2.6 Connection diagram (default)

SERVOSTAR 300

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10.3 Expansion card -PROFIBUS-

This section describes the PROFIBUS expansion card for the SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in our man-
ual “Communication Profile PROFIBUS DP”..
The PROFIBUS expansion card has two 9-pin SubD sockets wired in parallel.
The supply voltage for the expansion card is provided by the servo amplifier.

10.3.1 Front view

10.3.2 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmis-
sion times are all described in the “Installation Guidelines for PROFIBUS-DP/FMS” from
PNO, the PROFIBUS User Organization.

10.3.3 Connection diagram

SERVOSTAR 300

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10.4 Expansion card -SERCOS-

This section describes the SERCOS expansion card for SERVOSTAR 300. Information
on the range of functions and the software protocol can be found in our manual “IDN Ref-
erence Guide SERCOS”.

10.4.1 Front view

10.4.2 LEDs

Indicates whether SERCOS telegrams are being correctly received. In the final
RT Communication Phase 4 this LED should flicker, since cyclical telegrams are being
received.
Indicates that SERCOS telegrams are being transmitted. In the final Communicati-
on Phase 4 this LED should flicker, since cyclical telegrams are being transmitted.
TT Check the station addresses for the controls and the servo amplifier if:
- the LED never lights up in SERCOS Phase 1 or
- the axis cannot be operated, although the RT LED is lighting up cyclically.
Indicates that SERCOS communication is faulty or suffering from interference.

If this LED is very bright, then communication is suffering strong interference, or is

non-existent. Check the SERCOS transmission speed for the controls and the ser-
vo amplifier (BAUD RATE) and the fiber-optic connection.

ERR
If this LED fades or flickers, this indicates a low level of interference for SERCOS
communication, or the optical transmitting power is not correctly matched to the
length of cable. Check the transmitting power of the (physically) previous SER-
COS station. The transmitting power of the servo amplifier can be adjusted in the
setup software DRIVEGUI.EXE on the SERCOS screen page, by altering the
length parameter for the cable length.

10.4.3 Connection technology

For the fiber optic cable connection, only use SERCOS components to the SERCOS
Standard IEC 61491.
Receive data
The fiber optic cable carrying receive data for the drive in the ring structure is connected
to X13 with an F-SMA connector.
Transmit data
Connect the fiber optic cable for the data output to X14 by F-SMA connector.

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10.4.4 Connection diagram

Layout of the SERCOS bus system in ring topology, with optical fiber cables (schematic).

10.4.5 Modifying the station address

The drive address can be set to a value between 0 and 63. With address 0, the drive is
assigned as an amplifier in the SERCOS ring. Set the station address with the:
Keys on the front of the servo amplifier
The SERCOS address can be modified using the keys on the front of the amplifier (p. 96).
Setup software
The address can also be modified in the setup software, “CAN/Fieldbus” screen (please
refer to the setup software online help). Alternatively, enter the command ADDR # in the
“Terminal” screen, where # is the new address of the drive.

10.4.6 Modifying the baud rate and optical power

If the baud rate is not set correctly, communication is not possible.

The SBAUD # parameter can be used to set the baud rate, where # is the baud rate. If
the optical power is not set correctly, errors occur in telegram transmission and the red
LED on the drive lights up. During normal communication, the green send and receive
LEDs flash, giving the impression that the relevant LED is on.
The SLEN # parameter can be used to specify the optical range for a standard 1 mm²
glass fibre cable, where # is the length of the cable in metres.

SBAUD SLEN
2 2 Mbaud 0 Very short connection
4 4 Mbaud 1…< 15 Length of the connection with a 1 mm² plastic cable
8 8 Mbaud 15…< 30 Length of the connection with a 1 mm² plastic cable
16 16 Mbaud ³ 30 Length of the connection with a 1 mm² plastic cable
Setup software
The parameters can be modified in the setup software, “SERCOS” screen (please refer to
the setup software the online help). Alternatively, the commands SBAUD # and SLEN #
can be entered in the “Terminal” screen.

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10.5 Expansion card -DEVICENET-

This section describes the DeviceNet expansion card for SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in our man-
ual “DeviceNet Communication Profile”.

10.5.1 Front view

10.5.2 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmis-
sion times are all described in the “DeviceNet Specification, Volume I, II”, published by
ODVA.

10.5.3 Connection diagram

SERVOSTAR 300

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10.5.4 Combined module/network status-LED

LED Meaning
The device is not online.
off - The device has not yet finished the Dup_MAC_ID test.
- The device is possibly not yet switched on.
The device is operating as normal, is online, and the connections have been
green
established. The device has been assigned to a master.
The device is operating as normal, is online, but the connections have not
been established.
blinking - The device has passed the Dup_MAC_ID test and is online, but the
green connection to other nodes have not been established.
- This device has not been assigned to a master.
- Missing, incomplete or wrong configuration.
blinking An error that can be cleared and/or at least one I/O connection are in a waiting
red state.
- An error has occurred that cannot can be cleared; it may be necessary to
replace the device.
red - Communication device failure. The device has detected a fault that
prevents communication with the network (for instance, a MAC ID appears
twice or BUSOFF).

10.5.5 Setting the station address (device address)

The station address for the servo amplifier can be set in three different ways:
l Set the rotary switches at the front of the expansion card to a value between 0 and
63. Each switch represents a decimal figure. For example, to set the address for the
drive to 10, set MSD to 1 and LSD to 0.
l Set the rotary switches at the front of the expansion card to a value higher than 63.
Now you can set up the station address by using the ASCII commands DNMACID x,
SAVE, COLDSTART, whereby “x” stands for the station address.
l Set the rotary switches at the front of the expansion card to a value higher than 63.
Now you can set up the station address by using the DeviceNet Object (Class 0x03,
Attribute 1). This is normally carried out with the help of a DeviceNet software setup
tool. You must save the parameters in non-volatile memory (Class 0x25, Attribute
0x65) and then restart the drive after setting/altering the address.

10.5.6 Setting the transmission speed

The DeviceNet transmission speed can be set in three different ways:

l Set the rotary switch for Baud rate (at the front of the option card) to a value between
0 and 2. 0 = 125 kbit/s, 1 = 250 kbit/s, 2 = 500 kbit/s.
l Set the rotary switch for Baud rate (at the front of the option card) to a value higher
than 2. Now you can set the Baud rate by using the terminal commands DNBAUD x,
SAVE, COLDSTART, whereby “x” stands for 125, 250 or 500 .
l Set the rotary switch for Baud rate (at the front of the option card) to a value higher
than 2. Now you can set the Baud rate by using the DeviceNet Object (Class 0x03,
Attribute 2) to a value between 0 and 2. This is normally carried out with the help of a
DeviceNet software setup tool. You must save the parameters in non-volatile memo-
ry (Class 0x25, Attribute 0x65) and then restart the drive after altering the baud rate.

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10.5.7 Bus cable

To meet ISO 898, a bus cable with a characteristic impedance of 120 W should be used.
The maximum usable cable length for reliable communication decreases with increasing
transmission speed. As a guide, you can use the following values which we have mea-
sured, but they are not to be taken as assured limits.

General characteristic Specification

Bit rates 125 kbit, 250 kbit, 500 kbit
500 meters at 125 kBaud
Distance with larger
250 meters at 250 kBaud
bus connections
100 meters at 500 kBaud
Number of nodes 64
Signal environment CAN
Modulation Basic bandwidth
Coupling medium DC-coupled differential transmit/receive operation
Isolation 500 V (option: optocoupler on the transceiver's node side)
Typical differential input im- Shunt C = 5pF
pedance (recessive state) Shunt R = 25KW (power on)
Shunt C = 24pF + 36 pF/m of the permanently
Min. differential input impe-
attached stub cable
dance (recessive state)
Shunt R = 20KW
-25 V to +18 V (CAN_H, CAN_L)
The voltages for CAN_H and CAN_L refer to the ground pin
Absolute max.
of the transceiver. The voltage is higher than that on the
voltage range
V-terminal by the amount of the forward voltage drop of the
Schottky diode. This voltage drop must be < 0.6V.

Grounding:
The DeviceNet network must only be grounded at one point, to avoid ground loops. The
circuitry for the physical layer in all devices are referenced to the V-bus signal. The
ground connection is made via the power supply for the bus system. The current flowing
between V- and ground must not flow through any device other than the power supply.
Bus topology:
The DeviceNet medium utilizes a linear bus topology. Termination resistors are required
at each end of the connecting cable. Stub cables are permitted up to a length of 6 meters,
so that at least one node can be connected.
Termination resistors:
DeviceNet requires a termination at each end of the connecting cable.
These resistors must meet the following requirements: 120W, 1% metal-film, 1/4 W

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10.6 Expansion card -ETHERCAT-

This section describes the EtherCat expansion card for SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in the
EtherCat documentation. This expansion cards enables the servo amplifier to be con-
nected to the EtherCat network via RJ-45 connectors (IN and OUT ports).

10.6.1 Front view

10.6.2 LEDs

LED Function
flickering = Booting Error
blinking = Invalid Configuration
ERROR single flash = Unsolicited State Change
double flash = Watchdog Timeout
off = No Error
on = Device is in state OPERATIONAL
blinking = Device is in state PRE-OPERATIONAL
RUN
single flash = Device is in state SAFE-OPERATIONAL
off = Device is in state INIT
on = linked, but not active at X20A (in)
ACT IN flickering = linked and active at X20A (in)
off = not linked at X20A (in)
on = linked, but not active at X20B (out)
ACT OUT flickering = linked and active at X20B (out)
off = not linked at X20B (out)

10.6.3 Connection diagram

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10.7 Expansion card -SYNQNET-

This section describes the SynqNet expansion card for SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in the
SynqNet documentation.

10.7.1 Front view

LED2 LED1 LED4 LED3

10.7.2 NODE ID Switch

With these hexadecimal switches you can set the main and low significant bytes of the
Node ID seperately. SynqNet does not require an address for correct operation in the net-
work, however in some machines this can be a convenient way of identifying build options
to the application program.

10.7.3 Node LED table

LED# Name Function

ON = receive valid (IN port)
LED1, green LINK_IN
OFF= not valid, power off, or reset.
ON = network cyclic
LED2, yellow CYCLIC BLINK = network not cyclic
OFF = power off, or reset
ON = receive valid (OUT port)
LED3, green LINK_OUT
OFF = not valid, power off, or reset
ON = repeater on, network cyclic
LED4, yellow REPEATER BLINK = repeater on, network not cyclic
OFF = repeater off, power off, or reset

10.7.4 SynqNet Connection, Connector X21B/C (RJ-45)

Connection to the SynqNet network via RJ-45 connectors (IN and OUT ports) with inte-
grated LEDs.

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10.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket)

Inputs (In): 24V (20...28V), opto-isolated, one high-speed input (Pin 4)

Outputs (Out): 24V, opto-isolated, Darlington driver

Pinout connector X21A (SubD 15 pin)

Pin Type Description Pin Type Description
1 In +24V power supply 9 In GND power supply
NODE- indicates a problem
2 Out 10 Out OUT_00 digital output
ALARM with the node
3 Out OUT_01 digital output 11 Out OUT_02 digital output
4 In IN_00 capture input (fast) 12 In IN_02 digital input
5 In IN_04 digital input 13 In IN_03 digital input
limit switch, negati-
6 In IN_01 digital input 14 In NEGLIM
ve direction
NODE-
7 In HOME reference switch 15 In disables Node
DISABLE
limit switch, positive
8 In POSLIM
direction

10.7.6 Connection diagram digital inputs/outputs, connector X21A

SERVOSTAR 3xx

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10.8 Expansion module -2CAN-

Connector X6 of the SERVOSTAR is assigned to the signals for the RS232 interface and
the CAN interface. It is therefore not the standard pin assignment for these interfaces,
and a special cable is required to be able to use both interfaces simultaneously.
The -2CAN- expansion module provides the interfaces on separate Sub-D connectors.

The two CAN connectors are wired in parallel. A termination resistor (120 W) for the CAN
bus can be switched into circuit if the SERVOSTAR is at the end of the bus.

10.8.1 Installation

The modul must be placed onto the option slot after levering off the cover of the option
slot and replacing the small cover (see p. 101):
l Screw the distance pieces into the fixing lugs of the option slot.
l Place the expansion module onto the option slot.
l Screw the screws into the threads of the distance pieces.
l Plug the Sub-D9 socket into connector X6 on the SERVOSTAR

10.8.2 Front view

10.8.3 Connection technology

Standard shielded cables can be used for the RS232 and CAN interfaces.

If the servo amplifier is the last device on the CAN bus, then the switch for the bus
termination must be set to ON.
Otherwise, the switch must be set to OFF (condition as delivered).

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10.8.4 Connector assignments

RS232 CAN1=CAN2
X6A Pin Signal X6B=X6C Pin Signal
1 Vcc 1
2 RxD 2 CAN-Low
3 TxD 3 CAN-GND
4 4
5 GND 5
6 6
7 7 CAN-High
8 8
9 9

10.8.5 Connection diagram

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This page has been deliberately left blank.

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11 Appendix
11.1 Glossary
C Clock Clock signal
Common-mode voltage The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
CONNECT modules Modules built into the servo amplifier, with integra-
ted position control, that provide special versions
of the interface for the connection to the higher-
level control.
Counts Internal count pulses, 1 pulse = 1/220 turn-1
Continuous power of regen circuit Mean power that can be dissipated in the regen
circuit
Current controller Regulates the difference between the current
setpoint and the actual value to 0
Output : power output voltage
D DC bus link Rectified and smoothed power voltage
Disable Removal of the ENABLE signal
E Earth short electrical connection between a phase and
the protective earth (PE)
Enable Enable signal for the servo amplifier,
Hardware-Enable with 24V signal to X3,
Software-Enable command by setup Software,
fieldbus or permanently set.
Both are required for enabling the amplifier.
ENABLE Enable signal for the servo amplifier (+24 V)
F Fieldbus interface CANopen, PROFIBUS, SERCOS etc.
Final speed (limit speed) Maximum value for the speed normalization at
±10 V
G GRAY-code Special format for representing binary numbers
H Holding brake Brake in the motor, that can only be used when the
motor is at standstill
I I²t threshold Monitoring of the r.m.s. current that is actually
required
Input drift Temperature and age-dependent alteration of an
analog input
Incremental encoder interface Position signaling by 2 signals with 90° phase
difference (i.e. in quadrature), is not an absolute
position output
Ipeak, peak current The effective value of the peak current
Irms, effective current The r.m.s. value of the continuous current
K Kp, P-gain Proportional gain of a control loop
L Limit speed (final speed) Maximum value for speed normalization at ±10 V
Limit switch Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact

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M Machine The complete assembly of all connected parts or

devices, of which at least one is movable
Motion block Data packet with all the position control
parameters which are required for a motion task
Multi-axis system Machine with several independently driven axes
N Natural convection Free movement of air for cooling
O Optocoupler Optical connection between two electrically
independent systems
P P-controller Control loop with purely proportional behavior
Phase shift Compensation for the lag between the electro-
magnetic and magnetic fields in the motor
PI-controller Control loop with proportional and
differential behavior
Position controller Regulates the difference between the position
setpoint and the actual position to 0
Output: speed setpoint
Potential isolation electrically decoupled, electrical isolation
Power contactor System protection device with phase monitoring
Pulse power of the regen circuit Maximum power which can be dissipated in the
regen circuit
R regen circuit Converts superfluous energy fed back by the
motor during braking (regenerated energy) into
heat.
Reset New start of the microprocessor
Resolver/digital converter Conversion of the analog resolver signals into
digital information
Reversing mode Operation with a periodic change of direction
Ring core Ferrite rings for interference suppression
ROD-interface Incremental position output
S Servo amplifier Control device for regulating the speed, torque
and position of a servomotor
Setpoint ramps Limits for the rate of change of the speed setpoint
Short-circuit here: electrically conductive connection between
two phases
Speed controller Regulates the difference between the speed
setpoint and the actual value to 0
Output : current setpoint
SSI-interface Cyclically absolute, serial position output
Supply filter Device to divert interference on the power supply
cables to PET
Tachometer voltage Voltage proportional to the actual speed
Thermostat (contact) Temperature-sensitive switch built into the
motor winding
Tn, I-integration time Integral component of a control loop
Z Zero pulse Output once per turn from incremental encoders,
used to zero the machine

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11.2 Order codes

The order numbers of accessories such as cables, regen resistors, mains supplies, etc.,
can be found in the accessories manual.

11.2.1 Servo amplifiers

Article Order code

SERVOSTAR 303 S30361-NA*
SERVOSTAR 306 S30661-NA*
SERVOSTAR 310 S31061-NA*
SERVOSTAR 341 S30101-NA*
SERVOSTAR 343 S30301-NA*
SERVOSTAR 346 S30601-NA*
* NA means without built-in expansion card

11.2.2 Expansion cards

Article EU order code US order code

Expansion card DeviceNet DE-103571 OPT-DN
Expansion card PROFIBUS DP DE-106712 OPT-PB3
Expansion card SERCOS DE-90879 OPT-SE
Expansion card I/0-14/08 DE-90057 OPT-EI
Expansion card EtherCat DE-108350 OPT-EC
Expansion card SynqNet DE-200073 OPT-SN
Expansion module 2CAN DE-101174 not available

11.2.3 Mating connectors

Article EU order code US order code

Mating connector X3 DE-107554 CON-S3X3
Mating connector X4 DE-107555 CON-S3X4
Mating connector X0 (115/230V) DE-105856 CON-S3X0L
Mating connector X8 (115/230V) DE-107556 CON-S3X8L
Mating connector X9 (115/230V) DE-107631 CON-S3X9L
Mating connector X0 (230/400/480V) DE-107557 CON-S3X0H
Mating connector X8 (230/400/480V) DE-107558 CON-S3X8H
Mating connector X9 (230/400/480V) DE-107467 CON-S3X9H

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11.3 Index
! 24V aux. supply, interface . . . . . . . 50 K Keypad operation . . . . . . . . . . . . 95
A Ambient temperature . . . . . . . . . . 21 L Leakage current . . . . . . . . . . . . . 33
AS ENABLE . . . . . . . . . . . . . . . 73 LED display . . . . . . . . . . . . . . . 95
Assembly . . . . . . . . . . . . . . . . 36 M Maintenance . . . . . . . . . . . . . . 13
B Baud rate . . . . . . . . . . . . . . . . 95 Master-slave . . . . . . . . . . . . . . 67
BISS encoder interface . . . . . . . . . 54 Motor interface . . . . . . . . . . . . . 51
Block diagram (overview) . . . . . . . . 45 Mounting position . . . . . . . . . . . . 21
Brake, see also motor-holding brake . . 22 N Nameplate. . . . . . . . . . . . . . . . 14
BTB/RTO . . . . . . . . . . . . . . . . 74 Noise emission . . . . . . . . . . . . . 21
C CAN-bus cable . . . . . . . . . . . . . 76 O Operating systems . . . . . . . . . . . 85
CANopen interface . . . . . . . . . . . 76 Optical power, SERCOS. . . . . . . . 107
CE conformance . . . . . . . . . . . . 11 Order codes . . . . . . . . . . . . . . 119
ComCoder. . . . . . . . . . . . . . . . 60 Outputs
Conductor cross-sections . . . . . . . . 21 BTB/RTO . . . . . . . . . . . . . . 74
Connection diagram. . . . . . . . . . . 47 DIGI-OUT 1/2 . . . . . . . . . . . . 74
Connection technology . . . . . . . . . 42 P Package supplied . . . . . . . . . . . . 14
Connector assignments . . . . . . . . . 46
Packaging . . . . . . . . . . . . . . . . 13
D DC bus link, interface . . . . . . . . . . 50 Part number scheme . . . . . . . . . . 15
Disposal . . . . . . . . . . . . . . . . . 13 PC cable . . . . . . . . . . . . . . . . 75
E EMC . . . . . . . . . . . . . . . . . . . 39 PC connection. . . . . . . . . . . . . . 75
ENABLE . . . . . . . . . . . . . . . . . 73 Pollution level . . . . . . . . . . . . . . 21
Enclosure protection . . . . . . . . . . 21 Q Quickstart . . . . . . . . . . . . . . . . 86
Encoder emulation . . . . . . . . . . . 70 R Regen circuit . . . . . . . . . . . . . . 23
EnDat encoder interface . . . . . . . . 55
Regen resistor
Error messages . . . . . . . . . . . . . 98
Interface, ext. . . . . . . . . . . . . 51
Expansion card
Technical data . . . . . . . . . . . . 23
-2CAN- . . . . . . . . . . . . . . . 114
Resolver, interface . . . . . . . . . . . 53
-DeviceNet- . . . . . . . . . . . . . 108
Restart lock -AS- . . . . . . . . . . . . 77
-EtherCat- . . . . . . . . . . . . . 111
ROD, interface . . . . . . . . . . . . . 70
Guide to installation . . . . . . . . 101
RS232/PC, interface . . . . . . . . . . 75
-I/O-14/08- . . . . . . . . . . . . . 102
-PROFIBUS- . . . . . . . . . . . . 105 S Safety instructions . . . . . . . . . . . . 9
-SERCOS- . . . . . . . . . . . . . 106 Setup . . . . . . . . . . . . . . . . . . 83
-SynqNet-. . . . . . . . . . . . . . 112 Shielding
External fusing . . . . . . . . . . . . . 20 Connection diagram,. . . . . . . . . 47
F Feedback . . . . . . . . . . . . . . . . 52 Installation . . . . . . . . . . . . . . 40
Shock-hazard protection . . . . . . . . 33
Forming . . . . . . . . . . . . . . . . . 83
Site . . . . . . . . . . . . . . . . . . . 35
G Glossary . . . . . . . . . . . . . . . . 117 Site altitude . . . . . . . . . . . . . . . 21
Ground symbol . . . . . . . . . . . . . 41 SSI, interface . . . . . . . . . . . . . . 71
Grounding Stacking height . . . . . . . . . . . . . 13
Connection diagram . . . . . . . . . 47 Standards . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . 40 Station address, CAN-bus . . . . . . . 95
H Hardware requirements . . . . . . . . . 85 Storage . . . . . . . . . . . . . . . . . 13
Hiperface encoder interface. . . . . . . 56 Supply connection, interface . . . . . . 49
Humidity Supply networks. . . . . . . . . . . . . 48
in operation . . . . . . . . . . . . . 21 Supply voltage . . . . . . . . . . . . . 21
Storage . . . . . . . . . . . . . . . 13 Switch-on/switch-off behavior . . . . . . 25
System components, overview . . . . . 44
I Inputs
Analog . . . . . . . . . . . . . . . . 72 T Target group . . . . . . . . . . . . . . . 7
Digital . . . . . . . . . . . . . . . . 73 Technical data. . . . . . . . . . . . . . 18
Installation Tightening torques, connectors . . . . . 20
Electrical . . . . . . . . . . . . . . . 39 Transport . . . . . . . . . . . . . . . . 13
Expansion cards . . . . . . . . . . 101 U Use as directed
Mechanical. . . . . . . . . . . . . . 35 Restart lock AS . . . . . . . . . . . 78
Software . . . . . . . . . . . . . . . 85 Servo amplifiers . . . . . . . . . . . 10
Setup software. . . . . . . . . . . . 84

120 SERVOSTAR ® 300 Product Manual

Danaher Motion 10/2007 Appendix

V Ventilation
Installation . . . . . . . . . . . . . . 35
Technical data . . . . . . . . . . . . 21
Vibrations . . . . . . . . . . . . . . . . 21
W Warning messages . . . . . . . . . . . 99
Wiring . . . . . . . . . . . . . . . . . . 40

SERVOSTAR ® 300 Product Manual 121

Sales and Service

We are committed to quality customer service. In order to serve in the most effective way,
please contact your local sales representative for assistance.
If you are unaware of your local sales representative, please contact us.

Europe
Danaher Motion Customer Support Europe
E-Mail support_dus.germany@danahermotion.com
Internet www.DanaherMotion.net
Tel.: +49(0)203 - 99 79 - 0
Fax: +49(0)203 - 99 79 - 216

North America
Danaher Motion Customer Support North America
Internet www.DanaherMotion.com
E-Mail DMAC@danahermotion.com
Phone: +1 - 540 - 633 - 3400
Fax: +1 - 540 - 639 - 4162