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ServoOne junior

Operation Manual

Servocontroller
BG2 to BG5
2.0 A – 16 A
ID no.:  1300.20B.5-00 Date: 09/2015 ServoOne junior Operation Manual 2

ServoOne junior high-performance drives


The modularity of the ServoOne junior guarantees you optimum integration into the ma-
chine process. Whether in high-speed field bus communication with the central multi-ax-
is machine controller or with distributed programmable Motion Control intelligence in the
drive controller, the ServoOne junior is a master of both.

Sizes BG2 BG3 BG4 BG5

We reserve the right to make technical changes.


This Operation manual has been prepared based on DIN EN 82079-1. The content
was compiled with the greatest care and attention, and based on the latest information
ServoOne junior Operation Manual available to us.
ID no.: 1300.20B.5-00 We should nevertheless point out that this document cannot always be updated in line
with ongoing technical developments in our products.
ID no.: 09/2015
Information and specifications may be subject to change at any time. For information on
Applicable as from firmware version:  V1.25-01
the latest version please visit www.lti-motion.com.
The German version is the original of this Operation Manual.
Table of contents 3 Mechanical installation................................................................. 13
3.1 Notes for operation.................................................................................................. 13
3.2 Wall mounting.......................................................................................................... 13

1 General.......................................................................................... 5 3.2.1 Dimensions of the devices........................................................................ 14

1.1 Target group.............................................................................................................. 5 3.2.2 Mounting clearances................................................................................. 15

1.2 Prerequisites.............................................................................................................. 5
4 Electrical installation..................................................................... 17
1.3 Reference documents............................................................................................... 5
4.1 Notes for installation................................................................................................ 17
1.4 Order code................................................................................................................ 6
4.2 Layout..................................................................................................................... 18
1.5 Production data......................................................................................................... 7
4.3 Connection diagram BG2 to BG4............................................................................ 20
1.6 Scope of supply........................................................................................................ 7
4.4 Connection diagram BG5........................................................................................ 21
1.7 Pictograms................................................................................................................ 7
4.5 Effective EMC installation........................................................................................ 22
1.8 Disclaimer.................................................................................................................. 7
4.5.1 Interference immunity of drive controllers..................................................22
1.9 Disposal .................................................................................................................... 7
4.5.2 Specimen setup........................................................................................22
1.10 Helpline/Support & Service Center............................................................................ 8
4.6 Protective earth conductor connection................................................................... 25

2 Safety............................................................................................ 9 4.7 Electrical isolation concept...................................................................................... 26

2.1 Overview................................................................................................................... 9 4.8 Connection of the supply voltages.......................................................................... 27

2.2 For your safety........................................................................................................... 9 4.8.1 Connection of control supply (+24 V DC)................................................... 27

2.3 General safety instructions and warnings................................................................ 10 4.8.2 Connection of mains supply ..................................................................... 28

2.4 Intended use............................................................................................................ 10 4.8.3 Connected load and mains fuse................................................................29

2.4.1 Repair........................................................................................................ 11 4.9 Control connections................................................................................................ 31

2.5 Usage contrary to intended use.............................................................................. 11 4.9.1 Specification of control connections......................................................... 31

2.6 Responsibility.......................................................................................................... 11 4.9.2 Connection of motor brake X13.................................................................32

2.7 Relevant laws, standards and directives applied..................................................... 11 4.10 Specification, Ethernet interface.............................................................................. 33

2.8 Declaration of conformity......................................................................................... 12 4.11 Option 1................................................................................................................... 33


4.12 Option 2................................................................................................................... 33

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4.13 Encoder connection................................................................................................ 34 6 Diagnostics.................................................................................. 53


4.13.1 Ready made encoder cables....................................................................35 6.1 Device states........................................................................................................... 53
4.13.2 Resolver connection X6............................................................................35 6.2 Error indication........................................................................................................ 53
4.13.3 Connection for high-resolution encoder....................................................36 6.3 Error codes.............................................................................................................. 53
4.14 Motor connection.................................................................................................... 37 6.4 Helpline/Support & Service..................................................................................... 54
4.14.1 Motor temperature sensor......................................................................... 37
4.14.2 Connection of the LSH/LST motors.......................................................... 37 7 Safe Torque Off (STO).................................................................. 55
4.14.3 Switching in the motor cable.....................................................................38
8 Appendix..................................................................................... 57
4.15 Brake chopper connection...................................................................................... 39
8.1 Servocontroller current loads.................................................................................. 57
4.15.1 Protection in case of brake chopper fault..................................................39
8.2 Technical data ServoOne junior...............................................................................60
4.15.2 Design with integrated braking resistor (BG3+4+5)...................................39
8.3 Ambient conditions.................................................................................................. 62
4.15.3 Connection of an external braking resistor................................................ 41
8.4 UL certification........................................................................................................ 63

5 Commissioning............................................................................ 43
A Glossary...................................................................................... 65
5.1 Notes for operation.................................................................................................. 43
5.2 Initial commissioning............................................................................................... 43
5.2.1 Switching on control supply......................................................................44
5.2.2 Establishing connection between PC and drive controller........................44
5.2.3 Setting parameters....................................................................................44
5.2.4 Controlling drive using DriveManager 5.....................................................44
5.3 Serial commissioning............................................................................................... 46
5.4 Integrated control unit.............................................................................................. 46
5.4.1 Function of buttons T1 and T2..................................................................48
5.4.2 Display......................................................................................................48
5.4.3 Parameter menu (PA)................................................................................49
5.4.4 Error numbers...........................................................................................49
5.4.5 Ethernet IP address menu (IP)...................................................................49
5.4.6 Field bus address menu (Fb)..................................................................... 51
1 General 1.3 Reference documents
ID no.
Document Contents
The product DVD from LTI Motion contains the complete documentation for the related Format
product series. The documentation for a product series includes the Operation manual ServoOne junior - Safety, device installation, installation, commissioning, diagnostics, 1300.20B.x
(hardware description), device help (software description) as well as further user manu- Operation Manual specifications, certification and applicable standards, technical data PDF
als (e.g. field bus description) and specifications. They are available in the formats PDF,
ServoOne single-axis
HTML or chm. Safety, device installation, installation, commissioning, diagnostics, 1100.20B.x
system -
specifications, certification and applicable standards, technical data PDF
Operation Manual
Safety, device installation, installation, commissioning, diagnostics,
1.1 Target group ServoOne multi-axis system - STO, operation with servocontroller as supply, planning, application 1101.20B.x
Operation Manual example, specifications, certification and PDF
applicable standards, technical data
Dear user, ServoOne multi-axis system Safety, device installation, installation, commissioning, diagnostics,
1101.21B.x
Supply unit - specification, certification and applicable standards,
the documentation forms part of the device and contains important information on PDF
Operation Manual technical data
operation and service. It is aimed at all persons who undertake mounting, installation, Safety, commissioning, communication phases, parameter interface,
ServoOne Sercos II - 1100.29B.x
commissioning and servicing work on the product. error, warning and status messages, operation modes, weighting,
User Manual PDF
referencing, touchprobe, parameter lists
Safety, installation and connection, commissioning and configuration,
1.2 Prerequisites ServoOne Sercos III -
User Manual
parameterisation, data transmission, scaling and weighting, function-
ality, error message and diagnostics, parameter lists
1108.26B.x
PDF

Prerequisites for the usage of devices from LTI MOTION GmbH: ServoOne field bus options
Safety, commissioning, data transmission, operation modes, refer-
CANopen/EtherCAT - 1108.28B.x
yy The documentation on the devices is to be stored so it legible, accessible at all times and for the encing, parameters, technical data
User Manual
entire life of the product. Information, notes on ordering, specifications and
technical data on:
yy Read and ensure you understand the documentation on your device. ServoOne System - 1100.24B.x
ServoOne junior, ServoOne single-axis system, ServoOne multi-axis
System catalogue PDF
yy Qualification: to prevent injury or damage, personnel may only work on the device if they have system, safety technology, communication, technology, function
packages, accessories and motors
electrical engineering qualifications.
Description of the software functionality ServoOne,
yy Knowledge required: firmware versions: 0842.26B.x
ServoOne - Device help - SO junior from V1.30-xx PDF and
− National health and safety regulations (e.g. VBG 4 in Germany) - SO single-axis system from V3.25-xx HTML
− Mounting, installation, commissioning and operation of the device - SO multi-axis system from V3.25-xx
Context-sensitive help for DriveManager version 5.x graphic PC
Work in other areas, for example transport, storage and disposal is only allowed to be Program help DriveManager 5 0842.25B.x
user software for initial commissioning and serial commissioning,
PC user software HTML, chm
undertaken by trained personnel. operation, diagnostics and project management

NOTE
This Operation manual applies to the servocontroller ServoOne junior (referred
to in the following as the servocontroller or SOJ for short). This manual does
not replace the Operation manuals for the ServoOne single and multi-axis
system.

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1.4 Order code Article


SO2 4 . 006 . 0 0 2 1 . 0 0 0 0 . X
designation
The ServoOne junior (SOJ) has the article designation SO2x.xxx.xxxx.xxxx.x . The
provides information on the related variant of the SOJ supplied. The significance of the ServoOne junior (SOJ)

individual characters of the article designation is given in the following order code. You
will find the complete order code with all values in the ServoOne system catalogue. System voltage: 3 x 400 V
1/3 x 230 V
4
2

2.0 A 002
Rated current BG2
3.0 A 003
3.5 A 004
BG3
5.9 A 006
6.5 A 007
BG4
8 A 008
12 A, 012
BG5
16 A 016

Mains supply AC 0

Safety systems STO 0

Option 1 Communi- Not included 0


cation Sercos II 1
PROFIBUS 2
EtherCAT 3
CANopen 4
PROFINET 7
Sercos III 8

Option 2 Technology Not included 0


Second SinCos encoder 1
TTL encoder simulation/TTL master encoder 2
TTL encoder with commutation signals 5
Analogue/digital input/output expansion (MIO) 6
Digital input/output expansion (DIO) 8
Single-cable interface D

Housing/cooling Air-cooled (standard) 0


method Air-cooled with internal braking resistor (not BG2) 1

Function package Basic (without additional function package) 0


iPlc 1

Special design None 0

Protection Standard 0
PCBs with protective varnish 1

Hardware version (may be multi-digit) X


1.5 Production data 1.7 Pictograms
On rating plates for the ServoOne junior drive controllers you will find the serial number, The pictograms used in this Operation manual signify the following for the user:
from which you can identify the date of manufacture based on the following key. For the
location of the rating plate on the SOJ refer to "Figure 4.1 Layout ServoOne junior BG2 NOTE
to BG4" and "Figure 4.2 Layout ServoOne junior BG5". Useful information or reference to other documents.

1. ACTION TO BE TAKEN
(digit) Processing step undertaken by the user or the system.
Year of production You will find the pictogram used in this Operation manual for "Safety instructions and
warnings" in chapter 2 Safety.
Week of production

1.8 Disclaimer
SN.: JJWWxxxxx Following the documentation on the devices from LTI MOTION GmbH is a
Figure 1.1    ServoOne junior hardware rating plate prerequisite:
yy For safe operation.
yy To achieve stated performance features and product characteristics.
1.6 Scope of supply LTI MOTION GmbH does not accept any liability for injuries, damage or financial losses
that result from the failure to follow the documentation.
The scope of supply includes:
yy ServoOne junior drive controller
1.9 Disposal
yy Terminal kit for control and power terminals
(depending on device power and variant) Follow the applicable national regulations! If necessary, dispose of individual parts, de-
yy Set with shield connecting plates and fixing material pending on their characteristics and existing national regulations, e.g. as:
yy Product DVD with booklet yy Electrical waste
yy Plastic
yy Metal
Or engage a certified disposal organisation with scrapping

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1.10 Helpline/Support & Service Center


Our Helpline will help you with fast, specific assistance if you have any technical queries
relating to project planning or commissioning your device.
Address: LTI MOTION GmbH
Gewerbestraße 5-9
35633 Lahnau
The Helpline is available by e-mail or telephone:
Service hours: Mo.-Fr.: 8 a.m. - 5 p.m. (CET)
E-mail: helpline@lti-motion.com
Phone: +49 6441 966-180
If you need further assistance, our specialists at the Global Sales Support (GSS) will be
happy to help.
Internet: www.lti-motion.com → Support & Service → Trouble Ticket
Service hours: Mo.-Fr.: 8 a.m. - 5 p.m. (CET)
E-mail: salessupport@lti-motion.com
Phone: +49 6441 966-0

NOTE:
You will find detailed information on our services on our web site www.lti-mo-
tion.com in "Support & Service".
2 Safety 3. Protection against magnetic and/or electromagnetic fields during installa-
tion and operation.
Persons fitted with heart pacemakers, metallic implants and hearing aids etc. must not be allowed
access to the following areas:

2.1 Overview • Areas in the immediate vicinity of electrical equipment!


• Areas in which electronics components and drive controllers are installed,
repaired and operated!
Our devices are state-of-the-art and comply with recognised safety regulations, never- • Areas where motors are installed, repaired and operated!
theless hazards can arise. In this chapter: Motors with permanent magnets pose particular hazards.

yy We provide information on residual risks and hazards that can emanate from
our devices on usage as intended. 4. During installation observe the following:
• Comply with connection conditions and technical data as per the documentation and the rating
yy We warn about the foreseeable misuse of our devices. plate!
yy We refer to the necessary care and measures to be taken to prevent risks. • Comply with standards and directives on electrical installation, such as cable cross-section,
shielding, etc.!
• Do not touch electronic components and contacts!
2.2 For your safety Electrostatic discharge can harm people and destroy components!
• Take protection measures and use protective devices as per the applicable regulations (e.g. EN
60204 or EN 61800-5-1)!
NOTE • Take "device earthing" protection measure!
Only install and place in operation your device taking into account the docu-
mentation for the related device family! 5. Ambient conditions
Our devices are quick and safe to operate. For your own safety and for the safe function- • Follow the instructions on the transport, storage and correct operation of the devices stated in
the operation manual in "A Appendix".
ing of your device, please be sure to observe the following points:

1. Follow safety instructions for the devices:


Follow all safety instructions and warnings in the entire documentation related to the device series.

2. Electric drives are dangerous:


• Due to electrical voltages up to 480 V AC and up to 800 V DC
• Dangerously high voltages of ≥50 V may still be present 10 min. after the power is cut (capac-
itor charge). So check that electrical power is not present! See also the warning label on the
front panel on the device.
• Rotating parts
• Automatically starting drives.
• Hot components and surfaces

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2.3 General safety instructions and warnings Pay attention to special safety instructions and warnings that are given here in the document before a
specific action and that warn the user about a specific hazard!

Hazards may emanate from our devices. For this reason it is imperative you follow the
safety instructions and warnings in this document. NOTE:
The pictograms may also be used on their own with the signal word, e.g.
DANGER! Risk of injury due to electrical power!
in the connection diagrams, however they have the same function as in the
• Carelessness will result in serious injuries or death. complete warning.
Follow safety instructions and warnings in this document and on the device.
DANGER WARNING CAUTION

WARNING! Risk of injury due to electrical power!


• Carelessness may result in serious injuries or death.
Follow safety instructions and warnings in this document and on the device.

2.4 Intended use


CAUTION! Risk of injury or damage to the device due to incorrect operation!
• Carelessness may result in minor injuries or Our devices are components intended for stationary electrical systems and machines in
damage. the industrial and commercial sector.
Follow safety instructions and warnings in this document and on the device.
The devices in the product range ServoOne junior conform to the
Machinery Directive 2006/42/EC (applicable until 20.04.2016)
WARNING! Risk of injury due to hot surfaces and components!
• Carelessness may result in serious burns.
Tested and certified in accordance with applicable standards (see declaration of conformity in
Electronic components may become hot during operation! chap. 2.8).
Follow safety instructions and warnings in this document and on the device!
When installed in machines it is prohibited to start-up intended operation until it has been
ascertained that the completed machine fully complies with the provisions of the Machin-
Caution! Damage due to electrostatic discharge! ery Directive (2006/42/EC); compliance with EN 60204 is mandatory.
• Electrostatic discharge can destroy components.
Starting up intended operation is only permitted on compliance with the EMC Directive
Do not touch electronic components and contacts!
2004/108/EC (applicable until 20.04.2016).
Follow safety instructions and warnings in this document and on the device!
The devices fulfil the demands of the harmonised product standard EN 61800-5-1.
DANGER! Risk of injury due to rotating parts on the motor! You will find information on the installation of your device in chapter "3 Mechanical instal-
• Carelessness will result in serious injuries or death. lation".
Follow safety instructions and warnings in this document.
2.4.1 Repair Pay attention to the topic of “Electrical equipment of machines” in EN 60204-1:2006
“Safety of machinery”. The safety requirements on electrical machines defined there are
Only have repairs undertaken by authorised repair shops. Unauthorised opening and in- intended to protect personnel and machinery or systems.
correct intervention could lead to death, physical injury or material damage. The warranty
The emergency stop function (as per EN 60204) shuts down the supply of power to a
provided by LTI Motion would thereby be rendered void.
machine, which results in the drives coasting down in an uncontrolled manner. To avert
hazards, check whether it is appropriate:

2.5 Usage contrary to intended use − To keep individual drives in operation


− To initiate specific safety procedures
Our devices are: − To incorporate a Safe Torque Off function (Safe Torque Off: movement stop
yy Not intended for installation in vehicles. Deployment of the device in non-sta- by "switching off the electrical supply" - STO)
tionary equipment is classed as non-standard ambient conditions, and is
permissible only by special agreement.
yy Not intended for installation in environments with harmful oils, acids, gases,
2.7 Relevant laws, standards and directives
vapours, dusts, radiation etc. applied
yy Not approved for usage in special applications (e.g. in potentially explosive
atmospheres or areas in which there is a risk of fire). For information on the laws, standards and directives applied by LTI MOTION, refer to
yy Not approved for usage outside a cabinet the declaration of conformity.
yy Not approved for the generation of high-frequency onboard NOTE:
networks for which the device is not designed
Depending on the specific application for the devices, other laws, standards
and directives with provisions on "Safety" may apply. If necessary, contact the
2.6 Responsibility machine or system manufacturer.

Electronic devices are fundamentally not fail-safe. The installer and/or operator of a com-
plete machine or system is responsible for ensuring:
yy That the drive is rendered safe if the device fails
yy The safety of personnel and machinery
yy The complete machine is in correct working order
yy For the risk assessment on the complete machine or system according to
EN ISO 12100:2011 (formerly EN ISO 14121:2007) and EN ISO 13849-1
(formerly DIN EN 954-1)

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2.8 Declaration of conformity


3 Mechanical installation 3.2 Wall mounting
Step Action Comment

3.1 Notes for operation Mark out the position of the tapped holes on the backing
Dimensional drawings/hole spacing see
Figure 3.1, Figure 3.2
1. plate.
The thread surface area will provide you
Cut a thread for each fixing screw in the backing plate.
CAUTION Damage to the device due to incorrect installation conditions! with good, full-area contact.

The device may be destroyed.


For this reason Mount the servocontroller vertically on the backing Observe the mounting clearances! The
• Moisture must not be allowed to enter the device 2. plate. contact area must be bare metal.
• There must not be any aggressive or conductive substances in the ambient air
• Foreign bodies such as drilling chips, screws, washers etc. must not be allowed to enter the
device Mount the other components, such as the mains filter, The cable between mains filter and servo-
• The ventilation openings must not covered 3. mains choke etc., on the backing plate. controller may be max. 30 cm long.

Note the following points:


yy Cooling air must be able to flow through the device without restriction. 4. Continue with the electrical installation in chapter 3.
yy For mounting in switch cabinets with convection (= heat loss is discharged to the outside via the
cabinet walls), always fit an internal air circulation fan.
Table 3.1  Mechanical installation
yy The backing plate must be well-earthed.
yy The device is designed only for vertical installation in switch cabinets. The switch cabinet must as
a minimum provide IP4x protection.
yy To attain the best result for EMC-compatible installation you should use a chromated or galva-
nized backing plate. If backing plates are varnished, remove the coating from the contact area! NOTE
The devices themselves have an aluminium back panel. Forced cooling by external air flow is necessary
yy Maximum pollution degree 2 for all sizes of the ServoOne junior. The air must
be able to flow unhindered through the device. If
NOTE a temperature cut-out occurs, the cooling condi-
According to EN ISO 13849-2 the switch cabinet must have IP54 protection tions must be improved.
or higher on using the STO (Safe Torque OFF) safety function. Air flow: minimum 1.2 m/s
Further information on environmental conditions can be found in the appendix.

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3.2.1 Dimensions of the devices A1

Size BG2 BG3 BG4 BG5


T
SO22.003 SO22.006 SO22.008 SO24.012
ServoOne junior
SO24.002 SO24.004 SO24.007 SO24.016
Weight [kg] 1.0 1.5 2.8 5.9
B (width) 55 90
H (height) 1)
210 290 291
C H1
T (depth)1) 142 189 235.5
A 27.5 20 C
BG2 + BG3 H
A1 - - 40 50
H1
C 225 305 313 BG4
BG2+BG3+BG4
C1 5 6
D Ø 4.8 C1 D
A
H1 235 315 324 B
Screws 2 x M4 4 x M4
All dimensions in mm C1 D
1) without terminals/connections A
B
Table 3.2  ServoOne junior dimensions - see Figure 3.1 and Figure 3.2
Figure 3.1  Dimensional drawing BG2, BG3, BG4

.
NOTE
A A1
T If ServoOne junior devices are attached to other product ranges, correspond-
D
ing measures must be taken to prevent the devices affecting each other
thermally.

Size BG2 BG3 BG4 BG5

SO22.003 SO22.006 SO22.008 SO24.012


ServoOne junior
SO24.002 SO24.004 SO24.007 SO24.016
E Direct butt mounting
F 1) ≥100 ≥150
G 1)
≥235 ≥280

C H G
H1 F

Drawing: E
Dimensions in mm

C1 H2
B

Figure 3.2  Dimensional drawing BG5


F

3.2.2 Mounting clearances 1) The bend radius of the connecting cables must be taken into account

The minimum distances specified in the table apply for devices of the same power. Table 3.3  ServoOne junior Mounting clearances
When butt mounting devices with different drive power you should arrange the devices
according to their power (e.g., viewed from the left, BG5-BG4-BG3-BG2). This arrange-
ment will minimise the thermal interaction.

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4 Electrical installation mounted to the drive controller and the shielding of the motor cable should not be stripped
back too far.
− If possible signal lines should only enter from one side into the switch cabinet.
− Lines of the same electric circuit must be twisted.

4.1 Notes for installation − Avoid unnecessary cable lengths and loops.
yy Earthing measures
DANGER Risk of injury due to electrical power! − Earthing measures of relevance for the drive controller are described in section “4.6
Protective earth conductor connection”.
• Carelessness will result in serious injuries or death.
Never wire or disconnect electrical connections while these are live! Always disconnect the power yy Shielding measures
before working on the device. Dangerously high voltages of ≥50 V may still be present 10 min.
after the power is cut (capacitor charge). So check that electrical power is not present!
− Do not strip the cable shields back too far, and lay them with large area connections both on
the component and on the backing plate or on the PE rail (main earth) for the backing plate.
Work on the device must only be carried out after the DC link voltage has dropped below a yy External components
residual voltage of 50 V (indicated by monitoring LED H1 and to be measured on terminals X1/L-
and L+). − Place larger loads near the supply.

A dangerous voltage may be present at the device, even if the device does not emit any visual − Contactors, relays, solenoid valves (switched inductances) must be wired with suppressors.
or audible signals/indications (e.g. with mains voltage applied to terminal X3 and missing control The wiring must be directly connected to the respective coil.
supply +24 V on X2)! − Any switched inductance should be at least 0.2 m away from the process controlled
assemblies.
The following general guidelines apply for the installation of drive controllers:
yy Additional information can be found in the corresponding connection description.
yy Compliance with the EMC product standard If you require further detailed information on installation you should consult the LTi Helpline (see
− Commissioning (i.e. starting intended operation) is only permitted on compliance with the “Commissioning” on page 43).
EMC product standard EN 61800-3. The installer/operator of a machine and/or system must
provide proof of compliance with the protection targets stipulated in the standard.
yy Cable type
− Use only shielded mains, motor and signal lines with double copper braiding with 60 to 70 %
coverage.
yy Cable laying
− Route mains, motor and signal cables separated from one another. If possible, keep a
distance of at least 0.2 m, otherwise use separators. They should not run in parallel. If
crossovers are unavoidable, they should wherever possible be configured perpendicular (at a
90° angle).
− Always route the motor cable without interruptions and the shortest way out of the control
cabinet. When using a motor contactor for example, the component should be directly

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4.2 Layout Number Designation


D1, D2 7-segment display
The following shows the layout with the corresponding positions of plugs and terminals.
H1 DC link voltage indicator LED (only size BG2 to BG4)
For better orientation we have identified the designations of plugs and terminals with an
abbreviation. OP1 Installation space for option 1 (Communication)

T1, T2 Button
H1
X1 Power connections (only size BG2 to BG4)
X1
X2 Connection for control supply UV
X8
X3 AC power connection
X7
PE (bottom) Device protective earth conductor connection
X6
X4 Control terminals
D1, D2
X5 Motor temperature monitoring

X6 Resolver connection
T1, T2
X7 Connection for high-resolution encoder

X8 Option 2 (Technology)
X9
X9 Ethernet interface
X2
X5 X13 Connection for motor brake

X13 Table 4.1  Key to layout ServoOne junior BG2 to BG4


X3
X4
TS-Software

PE
TS-Hardware
OP1

Figure 4.1  Layout ServoOne junior BG2 to BG4


Number Designation
D1, D2 7-segment display
PE
X1.c OP1 Installation space for option 1 (Communication)
X1.b
X1.a T1, T2 Button

S PE (top) Motor PE connection

X8 X1.a Motor connection (only size BG5)

X7 X1.b Measurement of DC link voltage (only size BG5)

X6
X1.c Connection for braking resistor (only size BG5)

X2 Connection for control supply UV


D1, D2
X3 AC power connection
T1, T2
PE (bottom) Device protective earth conductor connection

X4 Control terminals
X9
X2 X5 Motor temperature monitoring
X5
X13 X6 Resolver connection
X3
X7 Connection for high-resolution encoder
X4
X8 Option 2 (Technology)
T. Software X9 Ethernet interface

X13 Connection for motor brake


T. Hardware
S Receptacle for shield plate (see “Detail 1: Motor cable BG5” on page 23)
PE
T. Software Software rating plate
OP1
T. Hardware Hardware rating plate

Table 4.2  Key to layout ServoOne junior BG5

Figure 4.2  Layout ServoOne junior BG5

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4.3 Connection diagram BG2 to BG4 Number Designation Details

D1, D2 7-segment display Page 48


Top view
1) T1, T2 Button Page 48
X1 U
Motor
V 3~ Connection for motor, braking resistor
W
X1 Page 37
and measurement of DC link voltage
D1, D2 L- DC-link
T1, T2 L+
Danger!
RB X2 Connection for control supply Page 27
Braking
resistor
Service Ethernet X9 X3 Connection for AC power supply Page 29
interface
n
X8 Option 2 X4 Control terminals Page 31
(+) (-)
Control X4
n X5 Connection for motor temperature monitoring1) Page 37
11

3
1

X7
12

ISA00+
2

1+ 10
13
3

Analogue set point 1


8

4 Encoder
14
4

ISA00- 1- 9
15
5

10

5
ISA01+
Analogue set point 2 6
ISA01- X6 Connection for resolver 1) Page 35
+24 V DC against
E/A-GND 15 ISD00
6
1

X6
6
2

16 ISD01
X7 Connection for high-resolution encoder 1) Page 36
7

1+ 5
3

Resolver
8
4

17 ISD02 1- 9
9

18 ISD03
19 ISD04
20 ISD05 Option 1 Communication Page 33
21 ISD06 +/1
X5
-/2
10 ENPO (STO)
Front PE PE connection Page 25
22 ISDSH (STO) V+ 4 +24 V DC supply for
12
Diagnosis
RSH
X13 GND 3 brake
STO 11
OSD03 2 Brake (+)
23 Brake (-) X8 (Option 2) Technology Page 33
Relay GND 1
Relay 24 OSD04

Digital0 7 OSD00
X9 Ethernet interface Page 33
Digital1 8 OSD01 X3 PE Mains 3-phase
Digital2 9 OSD02 L3 L3
Danger! FN L2
E/A-GND 1 DGND L2
L1 L1
X13 Connection for motor brake Page 32
K1
2,14 +24 V (UH)
PE
13 DGND

+ + +24 V DC supply for 1) Screen connections via separate shield plates Page 23
Communication X2 – - control electronic (UV)
field buses Option 1
Connection for housing PE conductor Page 25
1)
Bottom view 1) NOTE: The temperature sensor for the motor winding can be connected either via the encoder cables (X6 or X7) or to terminal X5.
Figure 4.3  Connection diagram BG2 to BG4
Table 4.3  Key to connection diagram BG2 to BG4
4.4 Connection diagram BG5 Number Designation Details

D1, D2 7-segment display Page 48


Top view
T1, T2 Button Page 48
U Motor
V 3 ~ X1.a Motor connection Page 37
X1.a W

D1, D2
Danger 1)
L- DC-link
X1.b Measurement of DC link voltage -
T1, T2 X1.b L+

L+ X1.c Connection for braking resistor Page 37


Service Ethernet X9 X1.c RB
Braking
interface 1) resistor X2 Connection for control supply Page 27
n
X8 Option 2 X3 Connection for AC power supply Page 29
1) (+) (-)
Control X4 X4 Control terminals Page 31
3 11
n
1

X7
12

ISA00+
2

1+ 10
13
3

Analogue set point 1


8

4 Encoder
14

X5 Connection for motor temperature monitoring1) Page 37


4

ISA00- 1- 9
15
5

10

5
ISA01+
Analogue set point 2 6
ISA01-
+24 V DC against X6 Connection for resolver 1) Page 35
E/A-GND 15 ISD00
6
1

X6
6
2

16 ISD01
7

1+ 5
X7 Connection for high-resolution encoder 1)
Page 36
3

Resolver
8
4

17 ISD02 1- 9
9

18 ISD03
19 ISD04
1) Option 1 Communication Page 33
20 ISD05
21 ISD06 +/1
X5 PE Connection for PE conductor Page 25
-/2
10 ENPO (STO)
22 ISDSH (STO) Front X8 (Option 2) Technology Page 33
V+ 4 +24 V DC supply for
12 GND 3
Diagnosis RSH
X13 brake
STO 11
OSD03 2 Brake (+)
X9 Ethernet interface Page 33
23
GND 1
Brake (-)
Relay Relay
24 OSD04
X13 Connection for motor brake Page 32
Digital0 7 OSD00
8 OSD01 X3
Digital1
9 OSD02 Danger
Mains 3-phase
1) Screen connections via separate shield plates Page 23
Digital2 L3 L3
L2 FN L2
E/A-GND 1 DGND
L1 L1 1) NOTE: The temperature sensor for the motor winding can be connected either via the encoder cables (X6 or X7) or to terminal X5.
K1
2,14 +24 V (UH)
13 DGND
Table 4.4  Key to connection diagram
+ + +24 V DC supply for
Communication X2 – - control electronic (UV)
field buses Option 1

Bottom view

Figure 4.4  Connection diagram ServoOne junior BG5

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4.5 Effective EMC installation

4.5.1 Interference immunity of drive controllers A Detail 1

NOTE
This is a restricted availability product in accordance with IEC 61800-3. This
product may cause radio interference in domestic environments; in such
Detail 2
cases the operator may need to take appropriate countermeasures.
External radio frequency interference suppression filters (EMCxxx) are available for the
drive controllers. With the measurement method specified and the external mains filter,
these drive controllers conform to the EMC product standard IEC 61800-3 for "First
B
environment" (residential C2) and "Second environment" (industrial C3). Detail 3

4.5.2 Specimen setup


Detail 4
The specimen setup presented on the following pages is intended to illustrate the key
measures necessary to ensure an effective EMC installation.

NOTE
The specimen setup merely presents a recommendation, and does not C
automatically guarantee compliance with applicable EMC directives.
The installer/operator of a machine and/or system must provide proof of
compliance with the protection targets stipulated in the standard.

Overview
. Figure 4.5 presents an overview of the minimum components required:
D
A. Backing plate with cable ducts
B. ServoOne junior
C. Mains filter
D. Mains choke
E. Distributor rail for AC power supply and control supply (+24 V DC) E
The layout and cabling are based on the requirements in section 4.1 The numbered red
arrows refer to four very important detailed notes presented on the following pages.
Figure 4.5  Specimen setup - Overview
Detail 1: Motor cable
Make sure that on devices BG2 to BG4 the motor connection is connected to terminal
(X1) and on devices BG5 to terminal (X1a, X1b, X1c):
yy Fasten the shield connection plate supplied (shield plate for BG2 to BG4 see Figure 4.6, shield
plate for BG5 see Figure 4.7) to the top of the device. Ensure the plate is in contact over a
large area with the heat sink on the ServoOne junior and with the backing plate. Use a serrated X1a
washer. X1b
X1c

X1

Figure 4.8  Detail 1: Motor cable BG2 to BG4 Figure 4.9  Detail 1: Motor cable BG5
Figure 4.6  Shield plate BG2 to BG4 Figure 4.7  Shield plate BG5

yy Strip the shielding of the motor cable back only as short as absolutely necessary.
yy Connect the motor cable shield over a large area to the shield connection plate using the clamp
supplied.

NOTE
Ready made motor cables are available for LTI Motion servomotors. For
details refer to the ServoOne system catalogue (ID. no.: 1100.04B.x) or to the
Servomotors order catalogue (ID no.: 0814.05B.x).

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Detail 2: Control supply (+24 V DC) Detail 3: Mains filter and mains connection
At the connection for the control voltage (X2) pay attention to: At the output of the mains filter and the AC mains connection (X3):
yy Secure the second of the two shield connection plates supplied to the mount on the bottom of yy Connect the litz wire on the output of the mains filter directly to the AC mains connection (X3) on
the unit using the screw. Ensure the plate is in contact over a large area with the heat sink on the the ServoOne junior. The litz wires must not be extended, so the mains filter should be installed
ServoOne junior and with the backing plate. Use a serrated washer. correspondingly close to the ServoOne junior. But be sure to maintain the necessary minimum
yy Pull a shielding sleeve over the control supply cable and strip it back only as short as necessary clearance (see “Table 3.3 ServoOne junior Mounting clearances”).
before the control supply connection (X2). yy Fix the litz wire to the shield connection plate using a cable tie as necessary.
yy Connect the shielding sleeve on the control supply cable with a large area connection to the yy The leakage current of the ServoOne junior is >3.5 mA. So:
shield connection plate using the clamp supplied. − Connect the protective earth conductor from the output of the mains filter to connection (X3)
on the ServoOne junior BG2 to B4 or to the housing of the ServoOne junior BG5 and
− One of the PE connections on the heat sink on the ServoOne junior using a cable of at least
the same cross-section to the main earth for the distributor rail.
X2

X3

Figure 4.11  Specimen setup - Detail 3: Mains filter and mains connection

Figure 4.10  Specimen setup - Detail 2: Control supply


Detail 4: Control cables 4.6 Protective earth conductor connection
At the control terminals (X4) of the ServoOne junior:
yy Strip the shielding of the control cables back only as short as absolutely necessary. PE mains connection
Step Action
yy Connect the shield on the control cables with a large area connection to the shield connection according to DIN EN 61800-5-1
tab on the mains filter using the clamp supplied. If this is not possible, connect the control cable Earth each of the drive controllers!
shield directly to the backing plate with a large area connection directly adjacent to the ServoOne
junior.
1. Connect the terminal in a star configuration For the PE connection the following
and with a large area connection to the PE applies (as leakage current >3.5 mA):
bar (main earth) in the control cabinet. Use protective earth conductors with the
same cross-section as the mains power
Also connect the PE conductor terminals on all other cables, though at least 10 mm².
components, such as mains choke, filter, etc. in a Also comply with local and national
2. star configuration and with a large area regulations and conditions.
X4 connection to the PE bar (main earth) in the control
cabinet.

U 1 U 2 V 1 V 2 W 1W 2 U 1 U 2 V 1 V 2 W 1W 2 U 1 U 2 V 1 V 2 W 1W 2

PE
Figure 4.12  Specimen setup - Detail 4: Control cables Figure 4.13  Star configuration layout for the PE conductor

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4.7 Electrical isolation concept Ethernet


X9

The control electronics, with their logic (µP), the encoder terminals and the inputs and
outputs, are electrically isolated from the power section (power supply/DC link). All ISD00
X4/15 I LIM
PE
V µP Resolver
X6
control terminals are designed as safety extra-low voltage/protective extra-low voltage ISD01
ISD02
ISD03 V µP Geber
(SELV/PELV) circuits and must only be operated with such SELV/PELV voltages, as per ISD04
ISD05 DGND
GNDµP
X7

the relevant specification. This provides reliable protection against electric shock on the X4/21 I LIM
V µP
ISD06
control side. GNDµP

A separate control supply, compliant with the requirements of a SELV/PELV, is therefore DGND GNDµP
X5/ϑ +
PTC des Motors
needed. ENPO
X4/10 I LIM
X5/ϑ −

X4/3
ISA00+
The overview opposite shows the potential references for the individual connections in A/D X4/4
ISA00-
detail. DGND

X4/22 I LIM GNDµP


ISDSH X4/5
This concept also delivers higher operational safety and reliability of the drive controller. ISA01+
A/D X4/6
ISA01-

X4/14 DGND X2/+


F1 GNDµP
SELV = Safety Extra Low Voltage UH X4/2
ϑ
F2
PELV = Protective Extra Low Voltage
ϑ V µP

X4/13 Steuer-
UV
DGND X4/1 µP versorgung
24 V DC

DGND GNDµP X2/-

X4/7 X13/2
OSD00 OSD03
X13/1 Motorbremse
GND

DGND X13/3
GND 24 V DC
X4/8 X13/4 Versorgung
OSD01
UV Bremse

X4/12

RSH
DGND X4/11
X4/9 GNDµP X4/23
OSD02

F3 OSD04
X4/24
ϑ
DGND komplexe RC-Glied Polyswitch
PE GNDµP GNDµP
nicht lineare
DGND
Impedanz

Figure 4.14  Electrical isolation concept ServoOne junior


4.8 Connection of the supply voltages NOTE
Suitable measures must generally be applied to provide adequate cable
protection.
The supply of power to the ServoOne junior is separate for the control and power
sections. The control supply should always be connected first, so that the device
parameters can be set with DriveManager 5 and, above all, the device set to the correct DANGER Risk of injury due to electrical power!
supply for the power section.
• Carelessness will result in serious injuries or death.
CAUTION! Damage to the device due to incorrect operation! When the mains voltage is switched on at terminal X3 and there is no control supply (+24 V DC at
X2), a dangerous voltage is present on the device with no visual signal on the display or acoustic
• Carelessness can cause damage to the device. indication by fan noise. If visible in the installed state, LED H1 (see Figure 4.1) indicates whether
Only when the mains voltage has been pre-set in the device firmware and the device has been voltage is present on the device. Even if H1 is completely off, X1 must be checked to ensure no
restarted (if the mains voltage or switching frequency has been changed) may the mains power electrical power is present.
supply for the supply for the power section be activated.

NOTE
4.8.1 Connection of control supply (+24 V DC) The start-up current for the supply voltage for the BG2 to BG5 may be two to
three times the operating current.
Device 1 (e.g. BG2) Device 2 (e.g. BG2)
X2 max. 10 A gG X2
+ + 24 V DC ±10 % +
external power
supply
X3 X3
L1 L1

next servocontroller

Figure 4.15  Connection of control supply ServoOne junior

Control supply (Specification)


• UV = +24 V DC ±10%, stabilised and filtered.
• IV = 2 A (BG2 to BG5)
Control X2/+
supply X2/- • Internal polarity reversal protection
• The power supply unit used must have a safe and reliable isolation against
the mains system acc. to EN 50178 or EN 61800-5-1

Table 4.5  Specification of control supply ServoOne junior

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4.8.2 Connection of mains supply Note the following points:


Switching the mains power:
Procedure: yy In the event of excessively frequent switching the device protects itself by means of high-
resistance decoupling from the mains. After a rest phase of a few minutes the device is ready to
Step Action Comment
start once again.
Specify the cable cross-section depending on the maxi- Cable cross-section according to local
1. TN and TT system: Operation is permitted if:
mum current and ambient temperature. regulations and conditions.
yy In the case of single-phase devices for 1 x 230 V AC the supply system conforms to the
Wire the drive controller with the mains filter*), max. cable
2. length 0.3 m (with non-shielded cable)!
maximum overvoltage category III as per EN 61800-5-1.
yy In the case of three-phase devices with phase conductor voltages 3 x 230 V AC, 3 x 400 V AC,
Wire the mains choke*) Reduces the distortion (THD) in the system
3. (if installed) and prolongs the life of the drive controller. 3 x 460 V AC and 3 x 480 V AC
yy The star point of the supply system is earthed and
Install a mains isolating device K1
4. (power circuit breaker, contactor, etc.).
Do not switch on the power!
yy The supply system conforms to the maximum overvoltage category III as per EN 61800-5-1 at a
Use mains fuses system voltage (phase conductor → neutral point) of maximum 277 V.
For compliance with equipment safety
5. (duty class gG) to isolate all poles of the drive controller
requirements laid down in EN 61800-5-1 IT system: Operation is not permitted!
from the mains supply.
*)
optional
yy In case of an earth fault the voltage is approx. twice as high. Clearances and creepages to
EN 61800-5-1 are no longer maintained.
DANGER! Risk of injury due to electrical power!
Connection of the drive controllers via a mains choke is imperative:
• Carelessness will result in serious injuries or death.
yy Where the drive controller is used in applications with disturbance variables corresponding to
Never wire or disconnect electrical connections while these are live! Always disconnect the power
before working on the device. Dangerously high voltages of ≥50 V may still be present 10 min. environment class 3, as per EN 61000-2-4 and above (harsh industrial environment)
after the power is cut (capacitor charge). So check that electrical power is not present! yy In the case of single-phase mains supply
CAUTION! Risk or injury or damage to the device due to incorrect yy For compliance with EN 61800-3 or IEC 61800-3
earth leakage circuit breaker! For further information on permissible current loads, technical data and ambient
• Carelessness may result in injuries or damage. conditions please refer to the appendix.
If local regulations require the installation of an earth leakage circuit breaker, the following applies:
In case of a fault the drive controller is able to generate DC leakage currents without zero cross- NOTE
ing. Drive controllers therefore must only be operated with (RCDs) 1) type B for AC fault currents,
pulsating or smooth DC fault currents, which are suitable for servo controller operation, see Please be aware that the ServoOne junior is not rated for environment class 3.
IEC 60755. RCMs 2) can also be used for monitoring purposes. Further measures are essential to achieve this environment class! For further
1) residual current protective device information please consult your project engineer.
2) residual current monitor
4.8.3 Connected load and mains fuse Mains supply for BG2 and BG3 devices
NOTE
Max. cable cross-section 2) of
Device rated power 1) [kVA] Specified mains Before commissioning, the value of the connected mains voltage must be set
Drive the terminal [mm²]
fuse, duty class on the drive controller (factory setting = 3 x 230 V AC / 3 x 400 V AC).
controller
With mains Without Ferr. with Ferr. w/o gG [A]
choke (4% uK) mains choke insul 3) insul 3) BG2 and BG3
1 x 16 max. (1-phase) X2
SO22.003 1.3 1.6
2.5 2.5 3 x 16 max. (3-phase) +
SO24.002 1.5 1.9 3 x. 6 max Mains Mains Mains
3-phase choke filter
F1 K1
SO22.006 2.6 3.2
1 x 16 max. (1-phase) X3
3 x 16 max. (3-phase) L1 L1
2.5 2.5
L2 L2
SO24.004 2.7 3.3 3 x 10 max. L3 L3
1 x 20 max. (1 phase)
SO22.008 3.5 4.3
4 4 3 x 20 max. (3 phase)
SO24.007 5.0 6.1 3 x 16 max.
SO24.012 8.1 10.5 3 x 32 max. Figure 4.16  Connection BG2 and BG3 mains supply 3 x 230 V (SO22.xxx) or 3 x 400 V
4 6 (SO24.xxx) depending on device design
SO24.016 10.2 13.2 3 x 40 max.
1) At 3 x 230 V AC or 3 x 400 V AC mains voltage and FT ≥ 8 kHz
BG2 and BG3
2) The minimum cross-section of the mains power cable depends on the local regulations and conditions, as well as on the rated current of the drive
controller.
X2
3) Ferr. with insul. = Ferrule with plastic insulation, Ferr. w/o insul. = Ferrule without plastic insulation +
Table 4.6  Connected load and mains fuse Mains Mains Mains
1-phase choke filter
F1 K1
X3
L1 L1
N L2
L3

Figure 4.17  Connection BG2 and BG3 mains supply 1 x 230 V) (SO22.XXX)

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Mains supply for BG4 devices Mains supply for BG5 devices
NOTE NOTE:
Before commissioning, the value of the connected mains voltage must be set Before commissioning, the value of the connected mains voltage must be set
on the drive controller (factory setting = 3 x 230 V AC / 3 x 400 V AC). on the drive controller (factory setting = 3 x 400 V AC).

BG4 Mains Mains Mains


X2 3-phase F1 K1 choke filter
+ X2 +
Mains L3
3-phase
L2 L3
L1 L2
L3 L1
L2 X3
L3
L1 L2
F1 K1 Mains Mains L1
choke filter X3

Figure 4.18  Connection of BG4 to mains supply 3 x 230 V (SO22.xxx) or 3 x 400 V (SO24.xxx)
depending on device design

BG4
X2
Mains + Figure 4.20  Connection of BG5 to mains supply 3 x 400 V (SO24.xxx) depending on device
1-phase
design

N L3
L1 L2
F1 K1 Mains Mains L1
choke filter X3

Figure 4.19  Connection of BG4 to mains supply 1 x 230 V (SO22.XXX)


4.9 Control connections 4.9.1 Specification of control connections
Des. Term. Specification Electrical isolation
Step Action Comment
Analogue inputs
Check whether complete device settings are already
1. available, i.e. whether the drive has already been • UIN = ±10 V DC
configured. ISA0+ X4/3 • Resolution 12 bits; RIN approx. 101 kΩ
ISA0- X4/4
• Terminal scan cycle in "IP mode" = 125 µs, otherwise no
If this is the case, a special control terminal assign- ISA1+ X4/5
ISA1- X4/6 = 1 ms
ment applies.
2. Please contact your project engineer to obtain the • Tolerance: U ±1% of the measuring range end value
terminal assignment! Digital inputs
• Frequency range <500 Hz
3. Choose a terminal assignment. Initial commissioning ISD00 X4/15
ISD01 X4/16 • Terminal scan cycle in = 1 ms
ISD02 X4/17 • Switching level Low/High: ≤4.8 V / ≥18 V yes X4
Earth the cable shields over a large area at ISD03 X4/18 • UIN max = +24 V DC +20%
both ends. ISD04 X4/19 REL 24 12 RSH
• IIN at +24 V DC = typ. 3 mA
Wire the control terminals with shielded cables. Rigid conductor sizes: 0.2 to 1.5 mm² REL 23 11 RSH
The following is imperative: STO request X4/22, Flexible conductor sizes: • Frequency range ≤500 kHz
4. ENPO X4/10 and a start signal (with control via - Ferrule without plastic sleeve:
ISDSH 22 10 ENPO
• Switching level Low/High: ≤4.8 V / ≥18 V ISD06 21 9 OSD02
terminal). 0.2 to 1.5 mm²
- Ferrule with plastic sleeve: ISD05 X4/20 • UIN max = +24 V DC +20% ISD05 20 8 OSD01
yes
0.2 to 0.75 mm² ISD06 X4/21 • IIN max max at +24 V DC = 10 mA, RIN approx. 3 kΩ ISD04 19 7 OSD00
ISD03 18 6 ISA1-
• Internal signal delay < 2 μs suitable as trigger input for
ISD02 17 5 ISA1+
quickly saving actual position
5. Keep all contacts open (inputs inactive). ISD01 16 4 ISA0-
• Disable restart inhibit (STO) and enable power stage = ISD00 15 3 ISA0+
High level +24V 14 2 +24V
• OSSD support DGND 13 1 DGND
6. Check all connections again! Continue with chapter “5 Commissioning”
• 10 ms
ENPO X4/10 yes
• Switching level Low/High: ≤4.8 V / ≥18 V
• UIN max = +24 V DC +20%
Note the following points: • IIN at +24 V DC = typ. 3 mA
yy Always wire the control terminals with shielded cables. Digital outputs
yy Lay the control cables separately from the mains power and motor cables. • No destruction in case of short-circuit (+24 V DC ->
yy A cable type with double copper braiding, with 60 - 70% coverage, must be used for all shielded OSD00 X4/7 DGND), but device may briefly shut down.
connections. OSD01 X4/8 • Imax = 50 mA, PLC-compatible yes
OSD02 X4/9 • Terminal scan cycle in = 1 ms
• High-side driver
Table 4.7  Specification of control connections X4

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Des. Term. Specification Electrical isolation 4.9.2 Connection of motor brake X13
STO "Safe Torque Off"
Connector X13 is intended for connection of a motor brake.
• "Request STO" input = Low level
• OSSD support Des. Term. Connection Specification
ISDSH OSD03 X13/2 • Short-circuit proof
X4/22 • Switching level Low/High: ≤4.8 V / ≥18 V yes
(STO) IBR < 2.0 A Motor
• UIN max = +24 V DC +20% GND X13/1 3~ • External control supply +24 V DC
• IIN at +24 V DC = typ. 3 mA Front
(IIN = 2.1 A) required via X13/3 (GND) and X13/4
(V+)
Diagnostics STO, both cut-off channels GND X13/3 X13
V+ 4 24 V DC ext.
• UBR = UV-∆U` (∆U` typically approx. 1.4 V)
active, one NO contact with automatically V+ X13/4 GND 3
supply

RSH X4/11 X4/12 X4 • To actuate a motor holding brake up to IBR =


resetting circuit-breaker (polyswitch) yes OSD03
2

RSH X4/12 X4/11 1


Brake (+) 2.0 A max.
• 25 V / 200 mA AC, cos ϕ = 1 GND
Brake (-)
REL 24 12 RSH • Overcurrent causes cyclic shutdown
• 30 V / 200 mA DC, cos ϕ = 1
REL 23 11 RSH • Also usable as configurable digital output
Relay outputs ISDSH 22 10 ENPO • Cable break monitor:
IBR > 2.0 A Motor
ISD06 21 9 OSD02 3~ With the brake driver switched on, cable break
Relay, 1 NO contact Front
ISD05 20 8 OSD01 is detected at output currents < 200 mA.
• 25 V / 1.0 A AC, cos ϕ = 1 (AC1) ISD04 19 7 OSD00 X13 The cable break monitoring can be disabled.
X4/23
X4/23 4 24 V DC ext.
REL • 30 V / 1.0 A DC, cos ϕ = 1 (DC1) X4/24 ISD03 18 6 ISA1-
V+
supply
X4/24 GND 3

• Switching delay approx. 10 ms ISD02 17 5 ISA1+ OSD03


2
24 V DC
• Cycle time 1 ms ISD01 16 4 ISA0- GND
1

ISD00 15 3 ISA0+ Brake (-)


Auxiliary voltage +24V 14 2 +24V
Brake (+)

• Auxiliary voltage output (UH) for feeding the digital DGND 13 1 DGND

control inputs
• UH = UV-∆U (∆U typically approx. 1.2 V), no destruction
X4/2
+24 V in case of short circuit (+24 V DC -> DGND), but yes
X4/14
device may briefly shut down. Table 4.8  Specification of the terminal connections X13
• Imax = 80 mA (per pin) with self-resetting circuit
breaker (polyswitch)
NOTE:
Digital ground
For brakes with higher current requirements (> 2.0 A), a relay must be
X4/1 provided. The cable break monitoring on X13 is then no longer usable and
DGND Reference ground for +24 V DC yes
X4/13 must be provided externally.
Table 4.7  Specification of control connections X4
4.10 Specification, Ethernet interface 4.12 Option 2
The service and diagnostic interface X9 is designed as a TCP/IP Ethernet interface. It Option 2 can be factory-configured with various technology options. Additional or special
is suitable for connection of a PC for commissioning, service and diagnostics and for encoders can be evaluated here for example.
programming of the drive controller.
You will find all available options in the ServoOne system catalogue. The user manuals
The following software can communicate with the drive controller via the Ethernet for the respective options provide detailed information on commissioning.
interface:
yy LTI Motion DriveManager 5 for commissioning, service and diagnostics on the ServoOne junior
yy CoDeSys 3.x programming system for programming the ServoOne junior in the languages of
IEC 61131-3. For this purpose a drive controller licence is required.
Specification of interface:
yy Transfer rate 10/100 Mbits/s BASE
yy Line protocol IEEE802.3 compliant
yy Connection via standard commercially available crosslink cable, CAT 5 (e.g. LTI-Motion accessory
CC-ECL03, see also ServoOne system catalogue)

4.11 Option 1
Depending on the ServoOne junior variant, Option 1 is factory-configured with various
options. Field bus options such as EtherCAT or Sercos are available.
You will find all available options in the ServoOne system catalogue. The user manuals
for the respective options provide detailed information on commissioning.

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4.13 Encoder connection NOTE:


Do not split the encoder cable, for example to route the signals via terminals in
the switch cabinet. The knurled screws on the D-Sub connector housing must
All encoder connections are located on the top of the unit.
be tightly locked!
Encoder connection for LSH/T motors Drive controller
Motor (with installed encoder) Encoder cable
connection
Please use the ready made motor and encoder cables from LTI Motion GmbH to
connect the LSH/T synchronous motors (see Servomotors order catalogue). With resolver
Variant A e.g. LSH/LST H074-2-30-320/T1 KRY2-KSxxx X6
without further options
Assignment of drive controller motor - encoder connection
G13: = SinCos multiturn encoder
Compare the rating plates of the components. Make absolutely sure you are using the with SSI/EnDat interface KGS2-KSxxx X7
e.g. LSH/LST H074-2-30-320/T1,G13
correct components according to variant A, B or C! Variant B
G12: = SinCos singleturn encoder
with SSI/EnDat interface KGS2-KSxxx X7
KGH3-KS xxx e.g. LSH/LST H074-2-30-320T1,G12
Variant C
X7 G6: = SinCos singleturn encoder
X1
KGS2-KS xxx
Variant B with HIPERFACE® interface KGH3-KSxxx X7
X6 high-resolution encoder e.g. LSH/LST H074-2-30-320/T1,G6
KRY2-KS xxx Variant C
Variant A G6M: = SinCos multiturn encoder
HIPERFACE®-Multiturn: LSH074-2-30-320/T1, G6M with HIPERFACE® interface KGH3-KSxxx X7
e.g. HIPERFACE®-Singleturn: LSH074-2-30-320/T1, G6 e.g. LSH/LST H074-2-30-320/T1,G6M

Table 4.9  Variants of motors, encoder type and encoder cable

hochauflösender Geber

SinCos-Multiturn: LSH074-2-30-320/T1, G13


e.g. SinCos-Singleturn: LSH074-2-30-320/T1, G12
KM5-KS-xxx

Resolver

e.g. LSH074-2-30-320/T1 without further option

Figure 4.21  Motor/encoder cable assignment


4.13.1 Ready made encoder cables KRY2-KSxxx KGS2-KSxxx KGH4-KSxxx

The specifications can only be assured on the usage of LTi system cables. Temperature range -40 ... +85 °C -35 ... +80 °C -30 ... +80 °C
Cable diameter approx. 8.8 mm
Outer sheath material PUR
K xxx - KS xxx
Ready made cable Resistance Oil, hydrolysis and microbe resistant (VDE0472)
Resolver cable RY2 UL style 20233, 80 °C - 300 V,
Encoder Approvals
system
Encoder cable SSI, EnDat GS2 CSA-C22.2N.210-M90, 75 °C - 300 V FT1
Encoder cable HIPERFACE® GH4
Table 4.10  Technical data encoder cable
Suitable for energy chains KS

Cable length (m)

4.13.2 Resolver connection X6


Encoder cable KRY2-KS-xxx Order code
A resolver is connected to slot X6 (9-pin D-Sub socket).

Technical data Figure X6/Pin Function

KRY2-KSxxx KGS2-KSxxx KGH4-KSxxx 1 Sin+ / (S2) analogue differential input track A


G6, G6.x 2 Refsin / (S4) analogue differential input track A
G3, G5, G12.x
Encoder system Resolver (Singleturn / multiturn
(Singleturn / multiturn
with HIPERFACE®
X6 3 Cos+ / (S1) analogue differential input track B
with SSI/EnDat interface)
interface)
4 Supply voltage 5 ... 12 V, internally connected to X7/3
1 = S2 1 = A- 1 = REFCOS

Resolver
2 = S4 2 = A+ 2 = +COS 5 ϑ+ (PTC, KTY, Klixon) internally connected toX7/10 1)

6
3 = S1 3 = VCC (+5 V) 3 = Us 7 – 12 V

7
6 Ref+ analogue excitation

3
4 = n.c. 4 = DATA+ 4 = Data+ RS485

8
4
5 = PTC+ 5 = DATA- 5 = Data- RS485

9
5
6 = R1 6 = B- 6 = REFSIN Ref- analogue excitation (ground reference point for pin 6 and
Controller-end assign- 7
7 = R2 8 = GND 7 = Bridge to PIN 12 pin 4)
ment (sub-D connector)
8 = S3 11 = B+ 8 = GND 8 Refcos / (S3) analogue differential input track B
9 = PTC- 12 = VCC (Sense) 11 = +SIN
13 = GND (Sense) 12 = Bridge to PIN 7 9 ϑ- (PTC, KTY, Klixon) internally connected to X7/9 1)
14 = CLK+ 9, 10, 13, 14, 15 = n.c.
15 = CLK- 1) Be sure to pay attention to the note headed "ATTENTION" in Table 4.14!
7, 9, 10 = n.c.
Table 4.11  Pin assignment X6 resolver connection
Suitable for energy
yes
chains
Minimum bending radius 90 mm 100 mm 90 mm
Table 4.10  Technical data encoder cable

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4.13.3 Connection for high-resolution encoder SinCos


Absolute value Absolute value
SinCos absolute value
The interface X7 enables evaluation of the following encoder types. X7 Pin encoder EnDat encoder HIPER-
and TTL encoder
(digital) FACE®
SSI/EnDat
Figure Function
1 A- A- - REFCOS
SinCos encoder with zero pulse
X7 e.g. Heidenhain ERN1381, ROD486 2 A+ A+ - +COS

Heidenhain SinCos encoder with EnDat interface 7 to 12 V


+5 V DC ±5%, IOUT max = 250 mA (150 mA for hardware The sum of the cur-
e.g. 13 bit singleturn encoder (ECN1313.EnDat01) and 25 bit multiturn encoder 3 (typ. 11 V)
versions 0..1), monitoring via sensor cable rents tapped at X7/3
(EQN1325-EnDat01) max. 100 mA
Encoder/ SSI

and X6/4 must not


Heidenhain encoder with digital EnDat interface 4 R+ Data + Data + Data + exceed the specified
Single or multiturn encoder value!
5 R- Data - Data - Data -
SinCos encoder with SSI interface
e.g. 13 bit singleturn and 25 bit multiturn encoder (ECN413-SSI, EQN425-SSI) 6 B- B- - REFSIN
Sick-Stegmann SinCos encoder with HIPERFACE® interface 7 - - - US switch
Single and multiturn encoder, e.g. SRS50, SRM50
8 GND GND GND GND
Table 4.12  Suitable encoder types on X7
9 ϑ- (PTC, KTY, Klixon) internally connected to X6/9 1)
NOTE: 10 ϑ+ (PTC, KTY, Klixon) internally connected to X6/5 1)
yy The usage of encoders not included in the range supplied by LTi requires
special approval by LTI Motion. 11 B+ B+ - +SIN

yy The maximum signal input frequency is 500 kHz. 12 Sense + Sense + Sense + US switch

yy Encoders with a power supply of 5 V ±5% must have a separate sensor 13 Sense - Sense - Sense - -
After connecting
cable connection. The encoder cable detects the actual supply voltage pin 7 to pin 12, a
14 - CLK+ CLK+ -
at the encoder, thereby compensating for the voltage drop on the cable. voltage of 11.8 V is
15 - CLK - CLK - - set on X7, pin 3!
Only use of the sensor cable ensures that the encoder is supplied with the
correct voltage. The sensor cable must always be connected. 1) Be sure to pay attention to the note headed "ATTENTION" in Table 4.14!

Select the cable type specified by the motor or encoder manufacturer. During this Table 4.13  Pin assignment of the X7 terminal connection
process bear in mind the following:
yy Always used shielded cables. The shield is to be connected at both ends. NOTE:
yy Connect the differential track signals A/B, R or CLK, DATA to each other using twisted pairs. The encoder supply on X7/3 is short-circuit proof on both 5 V and 11 V
yy Do not split the encoder cable, for example to route the signals via terminals in the switch operation. The controller remains in operation enabling the generation of a
cabinet. corresponding error message on evaluating the encoder signals.
4.14 Motor connection 4.14.2 Connection of the LSH/LST motors
For connection of the servomotor product range LSH xxx and LST xxx please use the
Step Action Comment ready made motor cable KM3-KS-xxx (4 x 1.5 mm² + 2 x 2 x 0.75 mm²) or KM4-KS-xxx
(4 x 1.5 mm²).

1. Specify the cable cross-section depending on the


maximum current and ambient temperature.
Cable cross-section according to local
and country-specific regulations and
conditions
Top view

X1 U
Top view

Motor U Motor
V 3 ~ V
W
3~
W X1.a

2.
Danger 1)
Connect the shield at both ends to L- DC-link L- DC-link
Connect the shielded motor cable to terminals X1/ L+ X1.b L+
reduce Danger!
U, V, W and connect the motor to earth at . RB
interference emissions. Braking
resistor
X1.c
L+
RB
Braking
1) resistor

3.
n
n X8 Option 2
Wire the motor temperature sensor and activate X8 Option 2
Connect the shield at both ends to (+) (-)

temperature evaluation using DriveManager. See (+) (-)

reduce interference emissions.


n

11
1

6
X7

12
2

7
1+ 10
also related note. n

13
3

8
Encoder

14
4
X7

9
1- 9

15
5
1+ 10

10
Encoder
1- 9

1
X6

6
2

7
1+ 5

3
Resolver

8
6

4
X6 1- 9

9
1+ 5 Resolver
1- 9

4.14.1 Motor temperature sensor 1)


+/1
X5
+ -/2
X5
Front
Connection SOJ Type of sensor Insulation Front
-
X13
V+ 4
GND 3
+24 V DC supply for
brake
V+ 4 24 V DC supply for OSD03 2 Brake (+)
X13 GND 3 brake
GND 1
Brake (-)
X5 Temperature switch (Klixon), PTC Sensor with basic insulation OSD03 2
Brake (+)

GND 1 Brake (-)

X6 Temperature switch (Klixon), PTC, KTY Sensor with reinforced insulation

X7 Temperature switch (Klixon), PTC, KTY Sensor with reinforced insulation Figure 4.22  Connection of motor BG2 to BG4 Figure 4.23  Connection of motor BG5
Table 4.14  Motor temperature sensor terminal configuration
DC link: Connection BG2 to BG4 X1/L+, L- Connection BG5 X1.b/ L+, L-
CAUTION Damage to the device due to incorrect insulation of the motor winding!
CAUTION! Damage to the device due to DC link coupling!
• Carelessness can cause damage to the motor/device
The motor temperature sensor must, in relation to the motor winding, on connection to X5 be • Carelessness can cause damage to the device
provided with basic insulation, on connection to X6 or X7 with reinforced insulation Coupling together the DC links on several device devices is not allowed.
as per EN 61800-5-1.

NOTE:
In the event of a short-circuit or earth fault in the motor cable, the power stage
is disabled and an error message is issued.

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Ready made motor cable NOTE:


Cores 5 and 6 (PTC) are required only for motors in which the motor PTC
cannot be connected via the encoder cable. In the case of LSH/LSTxxx
KM x - KS xxx motors with resolver, the PTC is connected via the resolver cable.
Ready made motor cable

Version 4.14.3 Switching in the motor cable


Suitable for energy chains
CAUTION! Damage to the device due to switching in the motor cable!
Cable length (m)
• Carelessness can cause damage to the device
Switching in the motor cable must take place with the power cut and the power stage disabled,
Motor cable KMx-KSxxx Order code as otherwise problems such as burned contactor contacts or power stage damage may occur.

Technical data
To ensure unpowered switch-on, you must make sure that the contacts of the motor
KM4-KSxxx KM5-KSxxx contactor are closed before the drive controller power stage is enabled. At the moment
For motors with plug-in the contactor is switched off it is necessary for the contact to remain closed until the
to IN = 16 A
power connection drive controller power stage is shut down and the motor current is 0. This is done by
in fixed installation 90 mm inserting appropriate safety times for the switching of the motor contactor in the control
Minimum
bend radius sequence of your machine.
in flexible use 120 mm
Temperature range -30 ... +80 °C NOTE:
Cable diameter approx. 12 mm Despite these measures, the possibility cannot be ruled out that the drive
(3+T) x 1.5 mm² + controller may malfunction during switching in the motor cable.
Cable cross-section (3+T) x 1.5 mm²
2 x 2 x 0.75 mm²
Outer sheath material PUR
Oil, hydrolysis and microbe resistant (VDE0472),
Resistance
UL 1581, flame-resistant (DIN EN 50265-2-1)
U=1 U=1
V=2 V=2
W=3 W=3
Earth = ye/gn Earth = ye/gn
Allocation of the cores
PTC = 5
PTC = 6
Brake + = 7
Brake - = 8
UL AWM 80°C - 600V/1000V
Approvals
CSA AWM 80°C - 600V/1000V FT1
Table 4.15  Technical data motor cable
4.15 Brake chopper connection Device Technology
Rated resist- Peak braking Pulse
K1
ance RBR power PPBr energy WIBr
In regenerative operation, e.g. when braking the drive, the motor feeds energy back to SO22.006 100 Ω 1500 W 1) 150 Ws 120
the drive controller. This increases the voltage in the DC link. If the voltage exceeds a
threshold value, the internal braking transistor is activated and the regenerated power is 1000 W 2)
SO24.004 420 Ω 1300 W 3) 140 Ws 50
converted into heat by means of a braking resistor. 1400 W 4)

SO22.008 1690 W 1) 6000 Ws 170


4.15.1 Protection in case of brake chopper fault
90 Ω 4700 W 2)
WARNING! Risk of injury due to hot surfaces caused by a faulty brake chopper! SO24.007 Wire resistance 6170 W 3) 6000 Ws 120
6500 W 4)
• Carelessness may result in serious burns or damage.
If the brake chopper is overloaded the internal brake chopper transistor may be switched on con- 4700 W 2)
tinuously, which will result in the overheating of the device and the braking resistor. Temperatures SO24.012 90 Ω 6170 W 3) 6000 Ws 120
of up to 250 °C may be reached. To prevent more serious damage we recommend the activation 6500 W 4)
of the following software function:
4700 W 2)
You can activate this function by assigning BC_FAIL(56) to any digital output (DriveManager 5 SO24.016 90 Ω 6170 W 3) 6000 Ws 120
►Subject area "I/O configuration" ►Digital outputs ►OSD00 to OSD02). In the event of a fault 6500 W 4)
the selected output then switches from 24 V to 0 V. 1) Data referred to 1 x 230 V AC mains voltage (BR switch-on threshold 390 V DC)
This signal ensures that the drive controller is safely disconnected from the mains supply. 2) Data referred to 3 x 400 V AC mains voltage (BR switch-on threshold 650 V DC)
3) Data referred to 3 x 460 V AC mains voltage (BR switch-on threshold 745 V DC)

For detailed information on setting parameters refer to the "ServoOne device help". 4) Data referred to 3 x 480 V AC mains voltage (BR switch-on threshold 765 V DC)
K1 = Factor for the calculation of the permissible continuous braking power, see next page
Table 4.16  Data of the integrated braking resistor (design SO2x.xxx.xxxx.1xxx)
4.15.2 Design with integrated braking resistor (BG3+4+5)
If the drive is not permanently operated at its power limit, the reduced power dissipation
For drive controllers with an integrated braking resistor (model SO2x.xxx.xxxx.1xxx)
of the drive can be used as braking power.
only the peak braking power is stated in the appendix. The permissible continuous
braking power must be calculated. It depends on the effective utilisation of the controller NOTE:
in the corresponding application.
The rest of the calculation assumes that the drive controller is used at
The drive controller is thermally designed in such a way that no energy input by the maximum permissible ambient temperature. This means that any additional
internal braking resistor is permitted during continuous operation at rated current and at energy input for the internal braking resistor due to a lower ambient
maximum ambient temperature. temperature will be neglected.
Consequently, a controller design featuring an integrated braking resistor only makes
sense when the effective drive controller utilisation is ≤80 % or the braking resistor
is designed for one-off emergency stop. In the event of an emergency stop, only the
thermal capacity of the braking resistor can be used for a one-off braking action. The
permissible energy WIBr can be taken from the following table.

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Method to calculate the continuous braking power: CAUTION! Damage to the device with integrated braking resistor due to connection
of an ext. braking resistor!
T
1 2 • Carelessness can cause damage to the device
∫ i dt
T
I eff = 1 T
T1 ∫ i 22 dt
yy Calculation of effective drive controller utilisation No additional external braking resistor may be connected to drive controllers SO22.006 to
II eff =
in a cycle T: eff = T
T T0
∫0 i dt SO24.016 with integrated braking resistor.

0
1 2
I eff = T∫ i dt
 T1 I eff 
yy Determination of permissible continuous braking P I DBr = 1 − I∫0effi 2dt
eff = 
× K1
power based on unused drive power: P = 1T− IIeffN  × K1
PDBr = 1 − I0  × K1
DBr
 I NN 
 I eff 
Marginal conditions PDBr = 1 − T  × K1
 1 IIeffTN 
PPDBr ≥
= 11−× T∫ PPBr × Kdt1 Br
1≥×PI PxPBr
P DBr
≥ T ∫N0 PPBrTBrdt
T T∫00
yy A single braking action must not exceed the PDBr ≥ IBrT × PBr
DBr W dt Br
Br
maximum pulse energy of the braking resistor.
1
T1 T∫0 T
PDBr ≥ × PPBr dt Br
yy The continuous braking power calculated for the
PDBrT ≥= P × ∫ P×PBr T dt
∫0 Br
device must be greater than the effective braking
T dt Br
PBr
TPP
PDBr
T = × ∫∫ dt Br
PBr0 × dt Br
power of a device cycle. PBr
T= P
PDBr
DBr
0
0
This results in the minimum permissible PPBr T
cycle time T with calculated continuous T= × ∫ dt Br
P
PDBr T
0
braking power:
T = PBr × ∫ dt Br
PPDBr 0
TBrSum = PPBr ×T
The maximum total on-time of the braking TBrSum = PDBr
P PBr × T
PBr
resistor over a specified cycle time T with T BrSum = P ×T
calculated continuous braking power is:
PDBr
DBr
P
TBrSum = PBr × T
P
PDBr
TBrSum = PBr × T
PDBr
4.15.3 Connection of an external braking resistor WARNING! Risk of injury due to hot surfaces on the ext. braking resistor!
• Carelessness may result in serious burns.
NOTE
The braking resistor heats up very significantly during operation and can reach temperatures of
yy Be sure to follow the installation instructions for the external braking up to 250 °C. On touching there is a risk of serious burns to the skin.
resistor.
yy The temperature sensor (bimetallic switch) on the braking resistor must be
Damage to the ext. braking resistor due to lack of temperature monitor-
wired in such a way that the power stage is deactivated and the connected CAUTION
ing!
drive controller is disconnected from the mains supply if the braking resistor
• Carelessness can result in overheating of the ext. braking resistor!
overheats.
The external braking resistor must be monitored by the control. The temperature of the braking
yy The minimum permissible connection resistance of the drive controller must resistor is monitored by a temperature watchdog (Klixon). In the event of overheating the drive
not be infringed, for technical data see appendix. controller must be disconnected from the mains supply.

yy The braking resistor must be connected using a shielded cable.

Size BG2 to BG4 Size BG5


Top view
Top view
U Motor
X1 U
Motor
V
W
3 ~
X1.a
V 3~
W Danger 1)
L- DC-link
L- DC-link
X1.b L+
L+
Danger!
RB
Braking L+
resistor X1.c RB
Braking
1) resistor
n
X8 Option 2
Figure 4.24  Connection of braking resistor (+) (-)

n
11
1

DANGER! Risk of injury due to electrical power! X7


12
2

1+ 10
13
3

Encoder
14
4

1- 9
15
5

10

• Carelessness will result in serious injuries or death.


Never wire or disconnect electrical connections while these are live! Always disconnect the power
before working on the device. Dangerously high voltages of ≥50 V may still be present6 10 min.
1

X6
6
2

after the power is cut (capacitor charge). So check that electrical 1+


power
5 is not present!
7
3

Resolver
8
4

9
9

1-

1)
+/1
X5
-/2
Front
V+ 4 +24 V DC supply for
X13 GND 3 brake
OSD03 2 Brake (+)

GND 1
Brake (-)

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Available braking resistors (excerpt)

Continuous
Article Resis- Peak braking
braking Protection Figure
designation tance1) power 2)
power

BR-090.01.540-UR 35 W 6250 W IP54

BR-090.02.540-UR 150 W 6250 W IP54


90 Ω
BR-090.03.540-UR 300 W 6250 W IP54

BR-090.10.650-UR 1000 W 6250 W IP65 Example:


BR-090.01.540-UR

1) Tolerance ±10%
2) Is the maximum possible braking power depending on the ON-time and cycle time

Table 4.17  Technical data - braking resistors

NOTE:
The available braking resistors with the exact specifications, in particular with
regard to surface temperature, maximum system voltage and high-voltage
strength, are set out in the Installation Manual Braking resistor and ServoOne
system catalogue. See “1.3 Reference documents”.
5 Commissioning 5.2 Initial commissioning
Once the ServoOne junior has been installed as described in chapter "3 Mechanical
installation" and wired with all required power supplies and external components as
5.1 Notes for operation described in chapter "4 Electrical installation", initial commissioning can performed in the
following sequence:

CAUTION Damage to the device due to damaging ambient conditions! Step Action Comment
The device may be irreparably damaged due to harmful ambient
conditions during operation. see Installation Manual DriveMan-
For this reason 1. Install and start PC software
ager 5
• Moisture must not be allowed to enter the device
• There must not be any aggressive or conductive substances in the ambient air
• Foreign bodies such as drilling chips, screws, washers etc. must not be allowed to fall the
device 2. Switching on control supply see section 5.2.1
• The ventilation openings must not covered

WARNING Risk of injury due to hot surfaces on the device! Establishing connection between PC and drive
3. controller
see section 5.2.2
• Carelessness may result in burns.
The device heats up during the operation and the temperature on the heat sink may reach
100 °C. On touching there is a risk of burns to the skin.
4. Setting parameters see section 5.2.3

5. Controlling drive using DriveManager 5 see section 5.2.4

Table 5.1  Initial commissioning step table

NOTE:
Details on STO (Safe Torque Off) have not been taken into account for initial
commissioning, see chapter "7 Safe Torque Off (STO)".

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5.2.1 Switching on control supply 5.2.3 Setting parameters

To initialise and set parameters initially only switch on the +24 V DC control The commissioning wizard in DriveManager 5 is provided for making the
2. 4.
supply. Do not yet switch on the AC mains supply. settings for the drive system. Start the wizard.

Display indication after switching on the control supply NOTES:


yy DriveManager Help
D1 D2 Action Explanation A detailed description of DriveManager 5 as well as the commissioning
wizard can be found in the DriveManager 5 help.
Switching on the external +24 V DC control supply Initialisation in progress
yy Motor dataset
When using LTI servomotors the latest version of the required motor
Initialisation completed Not ready for starting dataset can be downloaded from www.lti-motion.com, category
"Downloads".
Table 5.2  Switch-on status of the ServoOne junior (with +24 V DC control supply)

NOTE:
5.2.4 Controlling drive using DriveManager 5
Details on the control supply can be found in chapter "4.8.1 Connection of
Switch on the AC mains supply. Then enable the power stage and activate
control supply (+24 V DC)". 5.
the control. The drive should be tested without the coupled mechanics.

5.2.2 Establishing connection between PC and drive controller DANGER! Risk of injury due to rotating parts on the motor!
• Carelessness will result in serious injuries or death.
The PC can be connected to the drive controller via Ethernet (TCP/IP).
3. Before starting motors with feather keys in the end of the shaft the keys must be reliably secured
Connect PC and drive controller with an Ethernet connecting cable. against throwing out, as far as this is not already prevented by drive elements such as belt
pulleys, couplings or similar.
NOTE:
yy Initialisation
The communication link between PC and drive controller can only be set
up after the drive controller has completed its initialisation.
yy TCP/IP configuration
If the PC does not recognise the drive controller connected, please
check the settings for the Ethernet interface (see Installation Manual
DriveManager 5).
CAUTION! Damage to the motor due to incorrect operation during motor test run! Display indication after switching on the AC mains supply
Carelessness can result in significant damage to the motor or machine. D1 D2 Action Reaction Explanation
• It is imperative the safety instructions and warnings from chapter 2 are followed during
commissioning. Please note that you yourself are responsible for safe operation. Controller ready,
Switching on the
power stage ready, Device is ready for switching on
• Before you start commissioning it must be ensured that the machine will not be damaged by AC mains supply
control deactivated
the test! Pay particular attention to the limitations of the positioning range.
• Certain motors are only intended for operation on the drive controller. Direct connection to Table 5.3  Display D1/D2 after switching on the AC mains supply
the mains supply can destroy the motor.
• The motor surfaces may become extremely hot. No temperature sensitive parts may touch
or be fastened to these areas, appropriate measures to prevent contact must be applied NOTE:
wherever necessary. yy Inputs "ISDSH" and "ENPO"
• To avoid overheating of the motor, the temperature sensor installed must be connected to the For step 1 in table Figure 5.1 at least the two inputs
terminals of the temperature monitoring system for the drive controller also during the test “ISDSH” and “ENPO” on terminal X4 must be connected.
run.
• The motor holding brake (if installed) should be checked for correct function before commis- yy Manual mode window
sioning the motor. Motor holding brakes are only designed for a limited number of emergency Step 2 in Figure 5.1 is best undertaken via the “Manual mode” window in
braking operations. Use as working brake is not allowed. DriveManager 5, details can be found in DriveManager help.
yy Configuration of inputs/outputs
If step 2 is to be implemented via the inputs on terminal X4, the sources for
“START CONTROL” and speed setpoint must be configured accordingly in
“Inputs/Outputs” in DriveManager 5.

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Power-up sequence for starting the drive D1 D2 Action Reaction Explanation


1. Deactivate the safety function “STO” Motor energised,
by setting the inputs ISDSH (STO) “Start“ enabled Technology ready
1 control active
“ISDSH” and “ENPO” 0
(see chapter "4 Electrical installation") Table 5.5  D1/D2 indication during activation of motor
ENPO (STO)
1 Details for optimising the drive on your application can be found in the DriveManager
0 help and in the ServoOne application manual.
t
0

2. Activate “START CONTROL” at the earliest ≥ 2 ms


START
5.3 Serial commissioning
2 ms after step 1 1
and specify the speed setpoint 0
An existing parameter data set can be transferred to other ServoOne junior drive
t controllers using DriveManager 5. Details can be found in the DriveManager help.
0

3. Monitor your system TECHNOLOGY READY


t
or plant and check
the drive behaviour. 1
(State 5)
5.4 Integrated control unit
0
t The built-in control unit permits diagnostics on the ServoOne junior. The control unit
0
comprises the following elements, all located on the front of the device:
t = motor dependent delay

Figure 5.1  Power-up sequence yy 2-digit 7-segment display (D1, D2)


yy 2 buttons (T1, T2)
Display reading after start of drive
D1 D2 Action Reaction Explanation

Enabling “STO“ and power


Ready for switching on Power stage ready
stage “ENPO“
Table 5.4  D1/D2 indication during activation of motor

CAUTION! Damage to the device due to incorrect operation!


• Carelessness may result in damage.
Before the next step “Enable start” you must specify a plausible setpoint, because the pre-set
setpoint is transferred to the drive directly after the motor control has started.
The following functions and displays are available:
yy Display of device states (see chapter "6.1 Device states")
The device state is displayed after switching on the control voltage. If no input is made via the
keypad for 60 seconds, the display switches back to the device state.
yy Display of device error state (see chapter "6.2 Error indication")
D1 If a device error occurs the display immediately switches to show the error code.
yy Parameter setting (indication "PA") (see section 5.4.3)
D2
Resetting device parameters to their factory setting
yy Ethernet IP address setting (indication "IP") (see section 5.4.5)
T2 Setting the Ethernet IP address and the subnet mask
T1 yy Field bus settings (indication "Fb") (see section 5.4.6)
Setting e.g. the field bus address

Figure 5.2   Integrated control unit ServoOne junior

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5.4.1 Function of buttons T1 and T2 5.4.2 Display


These buttons are used to activate the different menus and to control the corresponding The following table defines various displays and status information about the display.
functions.
Display Meaning
Button Function Comment Menu entries
T1 (left) Activation of menu (exit the device The button T1 can be held pressed for any (“PA“ in this case serves as an example, further possible entries see sections 5.4.5
status display) length of time because the display will only scroll and 5.4.6)
Scrolling through the menus/sub-menus through the menu options for the corresponding
Setting values - left segment display level. No settings will be changed. [flashing decimal points]
(D1) Selected function in action
T2 (right) Selection of chosen menu The button T2 must NOT be held pressed for any
Setting values - right segment display length of time because the display will change [two dashes]
(D2) from one menu level to the next within the menu Entry/function not available
structure and then change the parameter that
is reached at the end. You should therefore
always release the button T2 after each change [OK]
in display. Action executed successfully, no errors
T1 and T2 Menu level up After pressing T1 and T2 at the same time, the
together Accept selection value applied flashes for five seconds. During this
Acknowledge time the save procedure can still be aborted by [Error]
pressing any button, without applying the value Action via control unit not executed successfully,
set. Otherwise the new value will be saved after “Er“ flashes alternately with error number
five seconds. (see section 5.4.3)
Display device error,
General The time the button needs to be held pressed “Er“ flashes alternately with error number and error location (see “ServoOne
until an action is executed, is approx. 1 second. Application Manual“)
If there is no action by the user for a period of
60 seconds, the display returns to the device Numerical values
status display. (“10” in this case serves as an example)
In the parameter menu (PA) error numbers are shown in decimal.
Table 5.6  Function of buttons T1 and T2 All other values are displayed in hexadecimal. In these cases the 10 displayed
would represent the decimal value 16.
Table 5.7  Meaning of display

NOTE:
If no input is made via the keyboard for a period of 60 s, the display returns to
the device status display.
5.4.3 Parameter menu (PA) 5.4.5 Ethernet IP address menu (IP)
On the Parameter menu the device settings can be reset to the factory setting. An Ethernet TCP/IP port is available as a service and diagnostics interface. The IP
address is set by default to 192.168.39.5 and the subnet mask to 255.255.255.0. Both
Menu level Param- Value
Meaning Explanation can be changed using the IP address menu.
1 2 eter range
PA Pr - - Parameter reset Reset device settings to factory setting Menu level Pa-
Value
Table 5.8  Parameter menu
rame- Meaning Explanation
1 2 range
ter
IP Iu b0 00..FF IP address Setting for byte 0 of the IP address in hexadeci-
5.4.4 Error numbers update byte 0 mal format
(e.g. "05" for 192.168.39.5)
A failed user action is indicated by an error message. The message consists of an b1 00..FF IP address Setting for byte 1 of the IP address in hexadeci-
alternating display of "Er" and the error number. update byte 1 mal format
(e.g. "27" for 192.168.39.5)
NOTE: b2 00..FF IP address Setting for byte 2 of the IP address in hexadeci-
The error messages displayed during user input should not be confused with update byte 2 mal format
(e.g. "A8" for 192.168.39.5)
drive error messages. For detailed information on the error codes and on error
management refer to the "ServoOne Application Manual". b3 00..FF IP address Setting for byte 3 of the IP address in hexadeci-
update byte 3 mal format
Error number Meaning (e.g. "C0" at 192.168.39.5)
Ir - - IP reset to Reset IP address to factory setting
17 Parameter reset to factory settings failed
factory setting (192.168.39.5)
18 Parameter write access failed
Su b0 00..FF Subnet mask Setting for byte 0 of the subnet mask in hexadec-
19 Save parameter data set non volatile failed update byte 0 imal format
(e.g. "00" at 255.255.255.0)
20 Not all parameters written
b1 00..FF Subnet mask Setting for byte 1 of the subnet mask in hexadec-
21 Error while reset to factory settings
update byte 1 imal format
Table 5.9  Error numbers (e.g. "FF" at 255.255.255.0)
b2 00..FF Subnet mask Setting for byte 2 of the subnet mask in hexadec-
update byte 2 imal format
(e.g. "FF" at 255.255.255.0)
b3 00..FF Subnet mask Setting for byte 3 of the subnet mask in hexadec-
update byte 3 imal format
(e.g. "FF" at 255.255.255.0)
Sr - - Subnet mask Reset subnet mask to factory setting
reset to (255.255.255.0)
factory setting
Table 5.10  IP address menu

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Example configuration of the subnet mask Press button Tx


(X = 1, 2) repeatedly
Tx until desired menu
In this example the subnet mask is changed from 255.255.255.0 to 122.255.255.0. appears on display

Press button Tx T1 T2 T1
NOTE: Tx (X = 1, 2) once
Back
Changes on the IP address menu are only applied when the control Press any button
electronics are subsequently restarted.
T2
T1 T2
Press button T1 and T2 T1 T2
simultaneously
Back

T1
T1 T2
Back

T2
T1 T2
Back

T1
T1 T2
Back

T2

T1 T2 T1 T2
Back
Value NOT
saved
T1 T2

<5 s T1 T2
Apply

<5 s Value
saved

>5 s >5 s

Figure 5.3    Example configuration of the subnet mask


5.4.6 Field bus address menu (Fb) Example configuration of the field bus address
The functions available on this menu item depend on the device expansion module. For In this example the field bus address is changed from 1 to 23.
detailed information refer to the relevant specification.
NOTE:
Menu level Param- Value Changes on the field bus address menu are only applied when the control
Meaning Explanation
1 2 eter range electronics are subsequently restarted.
Fb Ad - 00..xx Field bus address Setting for field bus address
or (only when field bus option used), otherwise Press button Tx
(X = 1, 2) repeatedly
display "- -" Tx
-- until desired menu
appears on display
(The maximum programmable value depends on
the option) Tx
Press button Tx
T1 T2 T1
(X = 1, 2) once
Po - 0..3 Transmit power Setting for fibre-optic power output Back
or (only with Sercos II option), Press any button
-- otherwise display "- -"
Table 5.11  Field bus address menu Press button T1 and T2 T2
T1 T2 simultaneously
T1 T2
Back

T2

T1 T2 T1 T2
Back
Value NOT
saved
T1 T2

<5 s T1 T2
Apply

<5 s Value
saved

>5 s >5 s

Figure 5.4    Example configuration of the field bus address

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6 Diagnostics 6.2 Error indication
The 7-segment display shows the specific error codes. Each error code comprises the
The device states and error indications are shown on the device using the 7-segment alternating sequence ►"Er" ►error number ►error location.
display on the integrated control unit.
Display Meaning

6.1 Device states Device error

Display System status


↓ Display changes after approx. 1 s

Error number (decimal)


Device in reset state Example: 05 = Overcurrent

Self-initialisation on device startup ↓ Display changes after approx. 1 s

Error location (decimal)


*) Example: 01 = Hardware monitoring
Not ready to switch on (no DC link voltage) 1)

*) ↑ After approx. 1 s the display changes back to ER


Start inhibit (DC link OK, power stage not ready 1)
Table 6.2  Indication of the error code

Ready (power stage ready)


NOTE:
Switched on (drive powered) 2) The errors can be reset in accordance with their programmed reaction (ER) or
only via a +24 V reset (X2) (ER.). Errors marked with a dot can only be reset
when the cause of the fault has been eliminated.
Drive ready (power applied to drive and drive ready for setpoint input) 2)

Quick-stop 2) 6.3 Error codes


Error response active 2)
NOTE:
*) Not a “safe indication” as specified in EN 61800-5-2.
For detailed information on the error codes and on error management refer to
1) S. flashes when STO (Safe Torque Off) function is active, display goes out when function is inactive.
the "ServoOne device help".
2) The dot flashes when the power stage is active.

Table 6.1  Device states

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6.4 Helpline/Support & Service NOTE:


You will find detailed information on our services on our web site www.lti-mo-
tion.com in "Support & Service". You will also find all the services we offer in
Our Helpline can provide you with fast, targeted assistance if you have any technical
the “Support & Service” order catalogue. You can download the order cata-
queries relating to project planning or commissioning of the drive controller. To that end,
logue from the “Support & Service” section of our website at www.lti-motion.
please collect the following information prior to making contact:
com.
1. Type designation, serial number and software version of the devices (see Software rating plate)
2. DriveManager version in use (menu►Help ►Information... ►Version)
3. Error code displayed (on 7-segment display or DriveManager)
4. Description of the error symptoms, how it occurred and relevant circumstances
5. Save device settings to file in DriveManager
6. Name of company and contact, telephone number and e-mail address
Our Helpline will help you with fast, specific assistance if you have any technical queries
relating to project planning or commissioning your device.
The Helpline is available by e-mail or telephone:
Service hours: Mo.-Fr.: 8 a.m. - 5 p.m. (CET)
E-mail: helpline@lti-motion.com
Phone: +49 6441 966-180
If you need further assistance, our specialists at the Global Sales Support (GSS) will be
happy to help.
Internet: www.lti-motion.com → Support & Service → Trouble Ticket
Service hours: Mo.-Fr.: 8 a.m. - 5 p.m. (CET)
E-mail: salessupport@lti-motion.com
Phone: +49 6441 966-0
7 Safe Torque Off (STO)
NOTE:
You will find all information on the “STO” function in the 24-language docu-
ment “Description of the STO Safety Function” (ID no. 1100.10B.x).

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Space for personal notes


A Appendix Switching
frequency of
Ambient Rated cur-
Overload capacity

Device temperature rent IN [Aeff] Overcurrent Peak current


power stage
[kHz] max. [°C] at 1 x 230 V [Aeff] for time [s] [Aeff] for time [s]

A.1 Servocontroller current loads 4 45 8.0 16.0

SO22.008 8 40 8.0 16.0 10 2) 2) 3)

The maximum permissible drive controller output current and the peak current are 16 40 5.4 10.8
dependent on the mains voltage, the motor cable length, the power stage switching
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
frequency and the ambient temperature. If the conditions change, the maximum
2) Shutdown as per I²t characteristic
permissible servocontroller current load also changes. 3) Operation at this operating point is not possible
Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m. All current ratings with recommended mains choke.
ServoOne junior for 1 x 230 V Table A.1  Rated current and peak current BG2 to BG4 (1 x 230 V AC)
Switching Overload capacity
Ambient Rated cur-
frequency of
Device temperature rent IN [Aeff] Overcurrent Peak current ServoOne junior for 3 x 230 V
power stage
[kHz] max. [°C] at 1 x 230 V [Aeff] for time [s] [Aeff] for time [s]
Switching fre- Overload capacity
4 45 3.0 6.0 9.0 0.08 2) Ambient tem- Rated current
quency of power
perature IN [Aeff] Overcurrent Peak current
9.0 1) Device stage
SO22.003 8 40 3.0 6.0 10 2) 0.08 2)
6.0 for time for time
[kHz] max. [°C] at 3 x 230 V [Aeff] [Aeff]
9.0 1) [s] [s]
16 40 2.0 4.0 0.08 2)
4.0 4 45 3.0 6.0 9.0
4 45 9.0 1)
SO22.003 8 40 3.0 6.0 10 0.08 2)
SO22.006 8 40 5.9 11.8 10 2) 3) 3) 6.0
9.0 1)
16 40 16 40 2.0 4.0
4.0
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz". 1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
2) Shutdown as per I²t characteristic 2) Shutdown as per I²t characteristic
3) Operation at this operating point is not possible Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m.
Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m. All current ratings with recommended mains choke.
Table A.2  Rated current and peak current BG2 to BG4 (3 x 230 V AC)
Table A.1  Rated current and peak current BG2 to BG4 (1 x 230 V AC)

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Switching fre- Overload capacity ServoOne junior for 3 x 400 V


Ambient tem- Rated current
quency of power
perature IN [Aeff] Overcurrent Peak current Switching
Device stage Ambient Rated current Overload capacity
for time for time frequency of
[kHz] max. [°C] at 3 x 230 V [Aeff] [Aeff] Device temperature IN Overcurrent Peak current
[s] [s] power stage
[kHz] max. [°C] [Aeff] [Aeff] for time [s] [Aeff] for time [s]
4 45 17.7
4 45 2.0 4.0 6.0
17.7 1)
SO22.006 8 40 5.9 11.8 10 0.08 2)
11.8 6.01)
SO24.002 8 40 2.0 4.0 102) 0.082)
4.0
17.7 1)
16 40
11.8 6.01)
16 40 0.7 1.4
1.4
4 45 8.0 16.0 24.0
4 45 5.5 7.1 10.5
24.0 1)
SO22.008 8 40 8.0 16.0 10 0.08 2)
16.0 10.51)
SO24.004 8 40 3.5 7.0 102) 0.082)
7.0
24.0 1)
16 40 5.4 10.8
10.8 10.51)
16 40 2.9 5.8
5.8
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
2) Shutdown as per I²t characteristic 4 45 8.5 13.0 19.5
Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m.
19.51)
SO24.007 8 40 6.5 13.0 102) 0.082)
Table A.2  Rated current and peak current BG2 to BG4 (3 x 230 V AC) 13.0
19.51)
16 40 4.0 8.0
8.0
4 40 13 26 39
391)
SO24.012 8 40 12 24 102) 0.102)
28.8
391)
16 40 10.5 15.8
16.8
4 40 20 40 60
601)
SO24.016 8 40 16 32 102) 0.102)
33.6
601)
16 40 9 14.4
15.3
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
2) Shutdown as per I²t characteristic
Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m.

Table A.3  Rated current and peak current BG2 to BG5 (3 x 400 V AC)
ServoOne junior for 3 x 460 V Switching fre- Overload capacity
Ambient Rated current
quency of power
Switching fre- temperature IN Overcurrent Peak current
Ambient Rated current Overload capacity Device stage
quency of power
temperature IN Overcurrent Peak current [kHz] max. [°C] [Aeff] [Aeff] for time [s] [Aeff] for time [s]
Device stage
[kHz] max. [°C] [Aeff] [Aeff] for time [s] [Aeff] for time [s] 4 40 20 40 60

4 45 2.0 4.0 6.0 60 1)


SO24.016 8 40 15 30 102) 0.102)
31.5
6.0 1)

SO24.002 8 40 2.0 4.0 102) 0.082) 60 1)


4.0 16 40 6.5 10.4
11
6.01)
16 40 0.7 1.4 1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
1.4
2) Shutdown as per I²t characteristic
4 45 4.8 6.2 9.2 Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m.

9.2 1)
Table A.4  Rated current and peak current BG2 to BG5 (3 x 460 V AC)
SO24.004 8 40 3.5 6.2 102) 0.082)
6.2
9.21)
16 40 2.2 4.4
4.4 ServoOne junior for 3 x 480 V
4 45 7.4 11.8 17
Switching Overload capacity
17 1) Ambient Rated current
8 40 6.5 11.8 frequency of
SO24.007 102)
11.8 0.08 2)
temperature IN [Aeff]
Device power stage Overcurrent Peak current
17 1)
16 40 2.4 4.8 [kHz] max. [°C] at 480 V [Aeff] for time [s] [Aeff] for time [s]
4.8
4 40 11.5 23 34.5 4 45 2.0 4.0 6.0

34.5 1) 6.0 1)
8 40 10.5 21 SO24.002 8 40 1.7 3.4 10 2) 0.08 2)
SO24.012 102) 25.2 0.102) 3.4

34.5 1) 16 40 3) 3) 3)
16 40 8.0 12
12.8
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz". 2) Shutdown as per I²t characteristic
2) Shutdown as per I²t characteristic 3) Operation at this operating point is not possible
Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m. Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m.

Table A.4  Rated current and peak current BG2 to BG5 (3 x 460 V AC) Table A.5  Rated current and peak current BG2 to BG5 (3 x 480 V AC)

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Switching
Ambient Rated current Overload capacity A.2 Technical data ServoOne junior
frequency of
Device temperature IN [Aeff] Overcurrent Peak current
power stage
[kHz] max. [°C] at 480 V [Aeff] for time [s] [Aeff] for time [s] SO22.003, SO22.006 and SO22.008
4 45 4.6 6.0 8.8 Designation
8.8 1) SO22.003 SO22.006 SO22.008
SO24.004 8 40 2.6 5.2 10 2) 0.08 2)
5.2
Technical data
16 40 3) 3) 3)

Output, motor side


4 45 7.0 10.7 16
Voltage 3 phase UMains
SO24.007 8 40 6.5 10.7 10 2) 16 0.08 2)
16 1) Rated current effective (lN) 3 A 1) 2)
5.9 A 1) 2) 8 A 1) 2)
16 40 1.9 3.8
3.8
Peak current (2 x IN / 3 x IN) see tables A.1 and A.2
4 40 11 22 33 1)
Rotating field frequency 0 ... 400 Hz
33 1)
SO24.012 8 40 10 20 10 2) 0.1 2) Switching frequency of power stage 4, 8, 16 kHz
24
33 1)
Input, mains side
16 40 7.5 11.3
12
Mains voltage (1 x 230 V AC / 3 x 230 V AC) -20%/+15%
4 40 20 40 60
Device connected load
60 1) 1.3 kVA 1) 2.6 kVA 1) 3.5 kVA 1)
8 40 14 28 (with mains choke)
SO24.016 10 2) 29.4 0.1 2)
60 1) 1 x 230 V AC 5.4 A 10.6 A 14.4 A
16 40 6 9.6 Current consumption
10.2 (with mains choke)
3 x 230 V AC 3.3 A 6.5 A 8.8 A
1) With activation of the function "Automatic power stage switching frequency change to 4 kHz".
2) Shutdown as per I²t characteristic Asymmetry of mains voltage ±3% max.
3) Operation at this operating point is not possible
Permissible mains frequency 50/60 Hz ±10%
Data apply for a motor cable length ≤ 10 m. Maximum permissible motor cable length 30 m.
Power loss at IN 75 W 1) 150 W 1) 200 W 1)
Table A.5  Rated current and peak current BG2 to BG5 (3 x 480 V AC)
1) Data referred to output voltage 230 V AC and switching frequency 8 kHz,
2) For rated current refer to table A.1 or table A.2 !
3) On design with integrated braking resistor (SO2x.xxx.xxxx.1xxx). Connection of an external braking resistor is not permitted.
4) Braking resistor always integrated. Connection of an external resistor is permissible.

Table A.6  Technical data SO22.003, SO22.006 and SO22.008


SO24.002, SO24.004 and SO24.016
Designation
SO22.003 SO22.006 SO22.008 Designation
Technical data SO24.002 SO24.004 SO24.007 SO24.012 SO24.016
Technical data
DC link
Output, motor side1)
Brake chopper switch-on threshold 390 V DC 1)
Voltage 3 phase UMains
DC link capacitance 880 µF 1320 µF 1760 µF
Rated current effective (lN) 2 A 1) 2)
3.5 A 1) 2)
6.5 A 1) 2) 13 A 1) 2) 16 A 1) 2)
Minimum ohmic resistance of an exter-
72 Ω 4)
72 Ω 3)
72 Ω 3)
nally installed braking resistor Peak current (2 x IN / 3 x IN) see table A.3 and A.4 and A.5
Brake chopper continuous power Rotating field frequency 0 ... 400 Hz
2.1 kW
with external braking resistor
Switching frequency of power
Peak brake chopper with external 4, 8, 16 kHz
2.1 kW stage
braking resistor
Input, mains side
Internal braking resistor 550 Ω (PTC) 4) 100 Ω 3) 90 Ω 3)
Mains voltage (3 x 400 V AC / 3 x 460 V AC / 3 x 480 V AC) ±10%
Dependent on the effective utilisation of the
Brake chopper continuous power
0 W controller in the specific application see chapter Device connected load
with internal braking resistor 1.5 kVA 1) 2.7 kVA 1) 5.0 kVA 1) 8.1 kVA 1) 10.2 kVA 1)
3.15.2 (with mains choke)
Peak brake chopper with internal
400 W 1500 W 1700 W Current consumption
braking resistor 2.2 A 1) 3.9 A 1) 7.2 A 1) 13.5 A 1) 16.8 A 1)
(with mains choke)
1) Data referred to output voltage 230 V AC and switching frequency 8 kHz,
2) For rated current refer to table A.1 or table A.2 !
Asymmetry of mains voltage ±3% max.
3) On design with integrated braking resistor (SO2x.xxx.xxxx.1xxx). Connection of an external braking resistor is not permitted. Frequency 50/60 Hz ±10%
4) Braking resistor always integrated. Connection of an external resistor is permissible.
Power loss at IN 42 W 1) 80 W 1) 150 W 1) 263 W 1) 316 W 1)
Table A.6  Technical data SO22.003, SO22.006 and SO22.008
DC link
1) Data referred to output voltage 400 V AC and switching frequency 8 kHz,
2) For rated current refer to table A.3 and A.4 and A.5!
NOTE: 3) On design with integrated braking resistor (SO2x.xxx.xxxx.1xxx). Connection of an external braking resistor is not permitted.
For more information on the brake chopper switch-on threshold also refer to 4) Braking resistor always integrated. Connection of an external resistor is permissible.
chapter "4.15 Brake chopper connection". 5) On design BG5 with integrated braking resistor (SO2x.xxx.xxxx.1xxx). Connection of an external braking resistor is only permitted if int. braking resistor is
disconnected. Parallel operation of both resistors is not permitted!

Table A.7  Technical data SO24.002 to SO24.016

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Designation A.3 Ambient conditions


SO24.002 SO24.004 SO24.007 SO24.012 SO24.016
Technical data Ambient conditions ServoOne junior
Brake chopper switch-on Protection IP20 except terminals (IP00)
650 V DC 1)
threshold
Accident prevention regulations According to local regulations (in Germany e.g. BGV A3)
DC link capacitance 220 µF 330 µF 440 µF 680 µF 1120 µF
Up to 1000 m above MSL, over 1000 m above MSL with power reduction
Mounting height
Minimum ohmic resistance of (1 % per 100 m, max. 2000 m above MSL)
an externally installed braking 230 Ω 180 Ω 3) 72 Ω 3) 35 Ω 3) 25 Ω 3) Pollution degree 2
resistor
Built-in unit, only for vertical installation in a switch cabinet with min. IP4x
Brake chopper continuous power Type of installation
1.8 kW 2.3 kW 5.9 kW 12 kW 16.9 kW protection, when using STO safety function min. IP54
with external braking resistor
Table A.8  Ambient conditions ServoOne junior
Peak brake chopper with external
1.8 kW 2.3 kW 5.9 kW 12.1 kW 16.9 kW
braking resistor

Internal braking resistor 7500 Ω (PTC) 4) 420 Ω 3) 90 Ω 3) 90 Ω 5) 90 Ω 5)


Climatic conditions ServoOne junior
Brake chopper continuous power Dependent on the effective utilisation of the controller in the
0 W As per EN 61800-2, IEC 60721-3-2 class 2K3 1)
with internal braking resistor specific application see chapter 3.15.2
in transit Temperature -25 °C to +70 °C
Peak brake chopper with internal
200 W 1) 1000 W 1) 4700 W 1) 4700 W 1) 4700 W 1)
braking resistor Relative humidity 95% at max. +40 °C
1) Data referred to output voltage 400 V AC and switching frequency 8 kHz, As per EN 61800-2, IEC 60721-3-1 class 1K3 and 1K4 2)
2) For rated current refer to table A.3 and A.4 and A.5!
3) On design with integrated braking resistor (SO2x.xxx.xxxx.1xxx). Connection of an external braking resistor is not permitted. in storage Temperature -25 °C to +55 °C
4) Braking resistor always integrated. Connection of an external resistor is permissible. Relative humidity 5 to 95%
5) On design BG5 with integrated braking resistor (SO2x.xxx.xxxx.1xxx). Connection of an external braking resistor is only permitted if int. braking resistor is
disconnected. Parallel operation of both resistors is not permitted! As per EN 61800-2, IEC 60721-3-3 class 3K3 3)
-10 °C to +45 °C (4 kHz), up to 55 °C with power reduction (2%/°C)
Table A.7  Technical data SO24.002 to SO24.016 in operation Temperature
-10 °C to +40 °C (8, 16 kHz), up to 55 °C with power reduction (2%/°C)
Relative humidity 5 to 85% without condensation
NOTE: 1) The absolute humidity is limited to max. 60 g/m³. This means, at 70 °C for example, that the relative humidity may only be max. 40%.
2) The absolute humidity is limited to max. 29 g/m³. So the maximum values for temperature and relative humidity stipulated in the table must not occur
For more information on the brake chopper switch-on threshold also refer to
simultaneously.
chapter "4.15 Brake chopper connection". 3) The absolute humidity is limited to max. 25 g/m³. That means that the maximum values for temperature and relative humidity stipulated in the table must
not occur simultaneously.

Table A.9  Climatic conditions ServoOne junior


Mechanical conditions ServoOne junior A.4 UL certification
As per EN 61800-2, IEC 60721-3-2 class 2M1
The description of all measures to maintain UL approbation is to be found in the
Frequency [Hz] Amplitude [mm] Acceleration [m/s²]
document "UL-Certification" (ID No: 0927.01B.x-xx).
Vibration limit in transit 2 ≤ f < 9 3.5 Not applicable

9 ≤ f < 200 Not applicable 10

200 ≤ f < 500 Not applicable 15

As per EN 61800-2, IEC 60721-3-2 class 2M1


Shock limit in transit
Drop height of packed device max. 0.25 m

As per EN 61800-2, IEC 60721-3-3 class 3M1

Frequency [Hz] Amplitude [mm] Acceleration [m/s²]


Vibration limit of the
system1)
2 ≤ f < 9 0.3 Not applicable

9 ≤ f < 200 Not applicable 1

1) Note: The devices are only designed for stationary use.

Table A.10  Mechanical conditions ServoOne junior

CAUTION! Damage to the device due to incorrect operation!


• Failure to observe the ambient conditions may result in
damage.
• No continuous vibration!
The drive controllers must not be installed in areas where they would be permanently
exposed to vibration.
• Control cabinet min. IP54 for STO!
According to EN ISO 13849-2 the switch cabinet must have IP54 protection or higher on
using the STO (Safe Torque OFF) safety function.
• Observe cooling conditions!
Forced cooling by external air flow necessary. Air must be able to flow unhindered through
the device (air flow at least 1.2 m/s). If a temperature cut-out occurs, the cooling conditions
must be improved

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Glossary Control unit............................................................................................... 46, 47, 48, 53
Cooling
Cooling air............................................................................................................. 13
Cooling conditions........................................................................................... 13, 63
Heat sink............................................................................................................... 43
Symbols
7-segment display.......................................................................... 18, 19, 20, 21, 53, 54 D
Date of production........................................................................................................ 7
A Device error..................................................................................................... 47, 48, 53
Ambient conditions......................................................................................... 13, 28, 62 Device power connection...................................................................................... 60, 61
Device setting................................................................................................. 31, 49, 54
Diagnostics............................................................................................... 32, 33, 46, 53
B Dimensions................................................................................................................. 14
Backing plate.............................................................................................................. 13 Display.................................................................................................................. 27, 48
Brake chopper................................................................................................ 39, 61, 62 DriveManager................................................................................. 27, 33, 37, 44, 45, 54
Braking resistor................................................................................... 39, 40, 41, 60, 61
Continuous braking power........................................................................ 39, 40, 42
Peak braking power............................................................................ 39, 42, 61, 62
E
Button............................................................................................ 18, 19, 20, 21, 46, 48 Earthing measures...................................................................................................... 17
Earth leakage circuit breaker....................................................................................... 28
Electrical installation......................................................................................... 13, 17, 22
C Electrical isolation concept.......................................................................................... 26
Cabinet......................................................................................... 13, 25, 34, 36, 62, 63 EMC
Cable Effective EMC installation................................................................................ 13, 22
Cable cross-section........................................................................................ 28, 37 EN 61000.................................................................................................................... 28
Cable laying........................................................................................................... 17 EN 61800............................................................................ 17, 25, 27, 28, 37, 53, 62, 63
Cable length.................................................................................. 28, 38, 57, 58, 59 Encoder
Cable type.................................................................................................. 17, 31, 36 Encoder cable........................................................................................... 34, 35, 38
Capacitor charge......................................................................................... 9, 17, 28, 41 Encoder connection.............................................................................................. 34
Clearances and creepages......................................................................................... 28 EnDat........................................................................................................ 34, 35, 36
Climatic conditions...................................................................................................... 62 High-resolution encoder............................................................................ 18, 19, 36
CoDeSys..................................................................................................................... 33 HIPERFACE®........................................................................................................ 36
Commissioning............................................................................. 29, 30, 33, 43, 45, 54 Ready made encoder cables................................................................................. 35
Connection diagram.............................................................................................. 20, 21 SinCos............................................................................................................. 34, 36
Control.................................................................................................................. 45, 46 SSI.................................................................................................................. 35, 36
Control connections / Control terminals......................................... 18, 19, 20, 21, 25, 31 EN ISO 13849....................................................................................................... 13, 63
Control supply......................................................... 18, 19, 20, 21, 24, 26, 27, 32, 44, 47 ENPO.................................................................................................................... 31, 46

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Error code................................................................................................. 47, 49, 53, 54


Error number............................................................................................................... 49
M
Ethernet interface................................................................................. 18, 19, 20, 21, 33 Mains choke................................................................................................................ 28
Mains supply......................................................................................................... 28, 45
F Connected load..................................................................................................... 29
Mains connection................................................................................ 18, 19, 24, 25
Field bus Mains fuses..................................................................................................... 28, 29
Field bus address............................................................................................. 47, 51 Mechanical conditions................................................................................................ 63
Field bus settings.................................................................................................. 47 Mechanical installation................................................................................................ 13
Filter Minimum clearance..................................................................................................... 15
Mains filter........................................................................................... 13, 22, 24, 28 Model.......................................................................................................................... 33
Radio frequency interference suppression filter..................................................... 22 Motor
For your safety.............................................................................................................. 9 LSH motor................................................................................................. 34, 37, 38
LST motor....................................................................................................... 34, 37
H motor brake.............................................................................. 18, 19, 20, 21, 32, 45
Motor cable........................................................................................................... 23
H1 (Control LED).............................................................................................. 17, 18, 27
Motor connection.................................................................................................. 37
Helpline/Support & Service......................................................................................... 54
Motor dataset........................................................................................................ 44
Motor temperature monitoring............................................................. 18, 19, 20, 21
I Motor temperature sensor..................................................................................... 37
IEC 60721............................................................................................................. 62, 63 Klixon......................................................................................................... 35, 41
IEC 60755................................................................................................................... 28 KTY................................................................................................................. 35
IEC 61131.................................................................................................................... 33 PTC............................................................................................... 35–39, 61, 62
IEC 61800............................................................................................................. 22, 28 Ready made motor cable...................................................................................... 38
Industrial area.............................................................................................................. 22
Initial commissioning................................................................................................... 43
Initialisation.................................................................................................................. 44
N
Neutral point............................................................................................................... 28
Intended use............................................................................................................... 10
Notes for operation..................................................................................................... 13
Interference immunity.................................................................................................. 22
IP address............................................................................................................. 47, 49
ISDSH......................................................................................................................... 32 O
IT network................................................................................................................... 28 Option 1............................................................................................... 18, 19, 20, 21, 33
Option 2............................................................................................... 18, 19, 20, 21, 33
L Order code.................................................................................................................... 6
Overvoltage category.................................................................................................. 28
Layout................................................................................................................... 18, 19
Leakage current.......................................................................................................... 25
P ISDSH................................................................................................................... 46
STO....................................................................................................................... 46
Parameter setting........................................................................................................ 47 Subnet mask................................................................................................... 47, 49, 50
Pollution degree.................................................................................................... 13, 62 Supply voltages........................................................................................................... 27
Power connection................................................................................................. 18, 38 Switching frequency........................................................................................ 27, 60, 61
Power stage................................................................. 31, 37, 38, 41, 45, 46, 53, 60, 61 Switching frequency change........................................................................... 57, 58, 59
Project planning.......................................................................................................... 54 Switching in the motor cable....................................................................................... 38
Protection.................................................................................................. 13, 42, 62, 63 Switching on sequence............................................................................................... 46
Protective earth conductor.......................................................................................... 25
Protective earth conductor connection...................................................... 18, 19, 25
Protective Extra Low Voltage (PELV)........................................................................... 26 T
Technical data................................................................................................. 28, 41, 60
R Temperature evaluation............................................................................................... 37
TN system................................................................................................................... 28
Rated current.................................................................................................. 57, 58, 59 TT system................................................................................................................... 28
Rating plate............................................................................................................. 7, 54
Residential area........................................................................................................... 22
Residual current device (RCD)..................................................................................... 28 U
Resolver.......................................................................................................... 34, 35, 38 UL certification............................................................................................................ 63
Resolver connection.................................................................................. 18, 19, 35
Responsibility.............................................................................................................. 11 W
Wall mounting............................................................................................................. 13
S
Safety X
Safety function...................................................................................................... 55
X1................................................................................................... 18, 20, 21, 23, 27, 37
Safety Extra Low Voltage (SELV)................................................................................. 26
X2....................................................................................... 17, 18, 19, 20, 21, 24, 27, 53
Safety function.......................................................................................... 13, 46, 62, 63
X3.................................................................................................. 18, 19, 20, 21, 24, 27
Scope of supply............................................................................................................ 7
X4............................................................................................. 18, 19, 20, 21, 25, 31, 32
Scope of the user manual............................................................................................. 5
X5........................................................................................................ 18, 19, 20, 21, 37
Serial number.......................................................................................................... 7, 54
X6............................................................................................ 18, 19, 20, 21, 34, 35, 37
Shield connection plate......................................................................................... 23, 24
X7...................................................................................... 18, 19, 20, 21, 34, 35, 36, 37
Shielding measures..................................................................................................... 17
X8............................................................................................................. 18, 19, 20, 21
Specimen setup.......................................................................................................... 22
X9........................................................................................................ 18, 19, 20, 21, 33
Start-up current.......................................................................................................... 27
X13....................................................................................................... 18, 19, 20, 21, 32
STO............................................................................................................................. 55
Stop categories
Stop category 0 (STO)................................................................... 13, 31–32, 53, 62
STO (Safe Torque OFF)

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