Kollmorgen EB-9207 Beilage

Kollmorgen Brushless Motor Amplifier

EB-60X Series Motors

Installation and Service Manual

Edition: September 2020, Revision B

Part Number: EB-9207

Original Document

For safe and proper use, follow these instructions. Keep for future use.

Record of Document Revisions

Revision

Date

Remarks

1 Initial Release

2 11/2004 Update corporate identity, contact information

B 09/2020 Rebrand, CE and Declaration of Conformity removed

IMPORTANT NOTICE

Technical changes which improve the performance of the device may be made without prior

notice!

reproduced in any form (by photocopying, microfilm or any other method) or stored, processed, copied or

distributed by electronic means without the written permission of Kollmorgen.

SAFETY – READ ALL INSTRUCTIONS BEFORE INSTALLING THIS MOTOR

Dangerous voltages exist in this equipment. Do not attempt connecting or probing this

equipment with power on.

The fold back feature must limit the over current to no more that 300% of rated current

for a maximum period of 8 seconds.

Do not install the amplifier in a hazardous (classified) location unless the amplifier is

listed for such location. The motor is U.L. listed for class I, C, and D, but the amplifier

might not be suitable for such locations.

Do not operate the motor outside the parameters shown on the respective

performance curve.

Do not service unless area is known to be non-hazardous. Keep covers tight while

circuits are live.

Connect internal thermostat to limit motor surface temperature.

Instructions are provoded indicating that motor thermostat is an automatic resetting

device.

Upon receipt of the equipment, closely inspect the components to ensure that no

damage has occurred in shipment. If damage has occurred, notify the appropriate

carrier at once.

Save these instructions for future reference. Should any question arise regarding any

step outlined in this manual, please call the factory.

Proprietary Information of the Kollmorgen Corporation is furnished for customer user

only. No other uses are authorized without written permission of Kollmorgen.

EB-60X Installation & Service Manual | Contents

Kollmorgen | kdn.kollmorgen.com | January 2020 3

1INTRODUCTION .................................................................................................. 4

1.1 Amplifier and Power Supply Ratings....................................................... 5

2WIRING ................................................................................................................ 6

2.1 Typical Amplifier...................................................................................... 7

2.1.1 Front View ............................................................................................... 7

2.1.2 Side View ................................................................................................ 7

2.2 Typical Power Supply.............................................................................. 8

2.2.1 Front View ............................................................................................... 8

2.2.2 Side View ................................................................................................ 8

2.3 PSR4/5 & Motor Wiring ...........................................................................9

2.4 BDS4 Wiring..........................................................................................13

2.5 System Wiring .......................................................................................17

2.6 Typical Motor Connections ...................................................................19

2.7 Grounding ............................................................................................. 20

2.8 Inputs ....................................................................................................20

2.9 Preliminary Checks ...............................................................................21

2.9.1 Checking AC Input Voltage...................................................................21

2.9.2 Checking the Typical Power Supply DC Output Voltage ...................... 21

2.9.3 Zero System Resolver...........................................................................21

3. MOTOR DATA PACKAGE ................................................................................ 22

3.1 EB-60X ..................................................................................................22

3.1.1 Model Number System .........................................................................22

3.2 Outline Drawing.....................................................................................23

3.2.1 EB-606-11-BXR102 ..............................................................................23

3.3 EB-602 .................................................................................................. 24

3.3.1 Specifications CD-27026 ......................................................................24

3.3.2 Performance Curves ............................................................................. 26

3.4 EB-604 .................................................................................................. 30

3.4.1 Specifications CD 27027.......................................................................30

3.4.2 Performance Curves ............................................................................. 32

3.5 EB-606 .................................................................................................. 36

3.5.1 Specifications CD 27028.......................................................................36

3.5.2 Performance Curves ............................................................................. 38

3.6 EB-60x Typical Current and Voltage (Wave forms at Motor)................42

3.6.1 Current Phase C ................................................................................... 42

3.6.2 Voltage line A-C ....................................................................................42

3.7 EB-60x Intermittent Duty Operation ......................................................42

4INDEX.................................................................................................................46

EB-60X Installation & Service Manual | Introduction

1 INTRODUCTION

This installation and service manual is a general document and is applicable to a typical

amplifier needed to properly control the EB-60X motor series. However, since these motor

amplifiers are interfaced with motors of varying sizes having different operating

characteristics such as internal resistance, inductance, rotor inertia, etc., these amplifiers

vary with the motors with which they are compatible. Consult the manufacturer of the

amplifier for the installation and service manual pertaining to the specific amplifier used. After

the typical amplifier and a motor are connected together, the motor must perform per the

motor’s nameplate data.

The customer data (CD) and performance curve (PC) are specified documents and are

applicable only to individual motors. They contain such information as maximum operating

speed, peak current limits, and values, which make the amplifier motor combination

compatible. Do not operate the motor outside the parameters shown on the respective

performance curves.

Typical amplifiers are of the 3-phase sine wave, pulse-width modulated type. They are full

regenerative four-quadrant bi-directional velocity loop amplifiers designed to be used with

Kollmorgen’s high-performance permanent magnet brushless motors.

An unregulated 300 VDC bus, derived from full-wave rectification of a 3-phase 230 AC line by

the power supply unit, is used to power the motor amplifier.

Kollmorgen brushless motors feature the latest in permanent magnet technology; utilizing

high energy Samarium-Cobalt and Neodymium-Iron-Boron alloys. These brushless motors

consist of permanent magnet rotors and 3-phase Y-stator windings. Being brushless motors,

there are no commutators or associated brushes. These motors run as synchronous motors,

meaning the rotor speed is the same as the speed (frequency) of the rotating stator magnetic

field. A brushless resolver is utilized as the feedback device and is mounted internally as part

of the overall motor construction.

Benefits of the typical amplifier and brushless motor construction are:

Lower rotor inertia allows higher acceleration rates.

The motor is thermally more efficient since all heat is generated in the stator windings,

which are in the outside shell.

Higher speed operation and high peak horsepower are achieved. There is no

commutation limit.

Smaller physical motor size for a given HP rating.

Higher reliability and less motor maintenance. There is no commutator or brushes.

Smooth output torque.

EB-60X Installation & Service Manual | Introduction

1.1 Amplifier and Power Supply Ratings

Ratings

Input Power:

235 V

RMS

(L-L) 3-phase (±10%); isolation transformer not required –

provided short circuit (inrush) current remains limited to less than

1000 amps.115 VAC 1-phase control power.

Output Power

Power Supply DC Bus

325 VDC nominal, no load

Amplifier: at rated load

230 VRMS (L-L), Nominal ±10%

Continuous Current

(ARMS/Phase)

Intermittent Current

(5 sec. max., 30% duty cycle)

(ARMS/Phase)

As required to produce motors

rated current

200% of continuous

Ambient

Operating

Temperature:

0-55° C

Switching

Frequency

10 kHz

Cooling

Fan, convection (cold plate)

EB-60X Installation & Service Manual | Wiring

Kollmorgen | kdn.kollmorgen.com | January 2020 6

2 WIRING

Install this motor and typical amplifier per the national electrical

code.

To adhere to suitable engineering practices, connect the 115 VAC circuit so the 115 VAC is

applied first in order to activate the control and fault circuits before applying the main bus

voltage. Provide over-current protection, based on continuous rated current, per article 430 of

the NEC. If possible, adjust the amplifier accordingly. Otherwise, provide external protection.

The method of connecting the motor is by way of flying leads; where the leads of the 3-phase

motor stator are color coded and are available directly out of the motor.

Connect the motor with flying leads, where the leads of the 3-phase motor stator are color-

coded and available directly out of the motor. See the wiring diagrams for the correct method

of wiring the motor stator. Connect the BROWN, RED, and WHITE leads to the points

identified as Ma, Mb, and Mcon the power terminal block. Connect the green/yellow lead to

the ground point of the ground point of the same terminal block.

Bring the 3-phase 230 input power should be brought through a customer supplied circuit

breaker and connected to points identified as La, Lb and Lc on the power terminal block

mounted on the power supply. The system is not AC line phase sensitive. Connect the 325

VDC output, the 115 VAC, and the regeneration circuit from the power supply to the amplifier

with the strapping bars and the small 115 VAC and regen cable. Check to ensure that the

small cable is connected to the correct pins and that it is not offset to one side, and do the

following:

1. Wire the typical amplifier control terminal strips per the diagram. Dress the wiring neatly

so it does not to interfere with remounting the cover.

2. Unplug the C1, C2 and C3 point terminal strips from their connectors on the amplifier-

motor control board. This will prevent over flexing the board when wiring up the

connectors.

3. After unplugging the terminal strips from the motor control board, wire them per the

appropriate diagram.

4. Neatly dress the wire cable so that it enters the amplifier chassis and does not interfere

with the front cover. Dress signal cables separately and not with the AC or power wiring.

5. Leave sufficient length in the wiring to allow the motor control board to slide out enough

to expose the small compensation board. Insert the wired terminal strips back onto their

connectors.

The following precautions are also recommended:

1. Twist all AC leads to minimize electromagnetic emissions and pick-up. Maintain shield

over resolver leads.

2. Avoid running signal leads in close proximity to power leads, armature leads or other

sources of electromagnetic noise.

3. Minimize lead lengths as much as practical.

4. Double-check all interface wiring. Carefully inspect all connections.

5. Do not use main contactor for control functions.

Motor and resolver phasing are critical for proper operation.

EB-60X Installation & Service Manual | Wiring

2.1 Typical Amplifier

2.1.1 Front View

STABILITY

CURRENT LIMIT

COMMAND SCALE

BALANCE

CONTROL VOLTS

ENABLE

DRIVE READY

FOLDBACK

OVERTEMP

OVERCURRENT

OVERVOLTS

UNDERVOLTS

OVERSPEED

STABILITY

CURRENT LIMIT

COMMAND SCALE

BALANCE

CONTROL VOLTS

ENABLE

DRIVE READY

FOLDBACK

OVERTEMP

OVERCURRENT

OVERVOLTS

UNDERVOLTS

OVERSPEED

DRIVE ADJUSTMENTS

DRIVE INDICATORS

CUSTOMER I/O CONN.

FAN CONN. 115 VAC

RESOLVER CONN.

LOGIC SUPPLY CONN

BUS & MOTOR CONN.

OPTION CONN.

ZERO, TC1-4

A COM, TC1-3

I MON, TCI-2

SPDMON, TCI-1

SIN HI, TC2-3

COS HI, TC2-2

REF HI, TC2-1

CHASSIS GND.

Ma Mb Mc

INDUSTRIAL

DRIVES

GND.

HIGH

VOLTAGE

STATIC

SENSITIVE

COMPONENTS

2.1.2 Side View

BDS4-COMP2

POWER STAGE

UNDER P.C. CARD

SUPPORT

275

HIGH

VOLTAGE

COVER

PLATE

LOGIC

SUPPLY

CONNECTOR

RESOLVER

CONNECTOR

CUSTOMER I/O

CONNECTIONS

DRIVE

INDICATORS

DRIVE

ADJUSTMENTS

EB-60X Installation & Service Manual | Wiring

2.2 Typical Power Supply

2.2.1 Front View

C1 FAULT OUTPUT & 115 VAC

CONTROL POWER INPUT

BUS +

INDUSTRIAL

DRIVES

GND.

EXTERNAL REGEN

RESISTOR

La Lb Lc

HIGH

VOLTAGE

STATIC

SENSITIVE

COMPONENTS

BUS +

CHASSIS GND

MAIN INPUT

POWER

MAIN DC

BUS OUTPUT

PSR

D.C. BUS

REGEN

FAULT

18 & +10 VOLT CONTROL

VOLTAGE OUTPUT

D.C. BUS

REGEN

FAULT

EXTERNAL REGENERATION POWER

RESISTOR TERMINAL BLOCK

2.2.2 Side View

IMPUT DIODE

MODULE

LOGIC POWER

TRANSFORMERS

EXTERNAL REGENERATION POWER

RESISTOR TERMINAL BLOCK

D.C. BUS

REGEN

FAULT

OUTPUT & 115

VAC CONTROL

POWER INPUT

18 +10 VOLT

CONTROL

VOLTAGE OUTPUT

HIGH

VOLTAGE

COVER PLATE

REGENITIVE

POWER

TRANSISTOR

SOFT START

TRANSFORMER

OPTION

EB-60X Installation & Service Manual | Wiring

2.3 PSR4/5 & Motor Wiring

CONNECTOR C3

SHIELD

CONNECTOR C4

BDS4

Ma Mb Mc

BUS-

BUS+

POWER TERMINAL

GND

SCREW

GND

SCREW

10 4

11 5

12 6

CONNECTOR C2

EXTERNAL REGEN RESISTOR

CONNECTOR

(ALWAYS PRESENT ON PSR4/5

50 AMP & LARGER. OPTIONAL

ON PSR 4/5 12 & 20 AMPS.)

115 VAC HI

PSR4/5

Ma Mb Mc

BUS-

BUS+

POWER TERMINAL

GND

SCREW

GND

SCREW

4 1

5 2

6 3

CONNECTOR C1

115 VAC LO

+18 VDC UNREGULATED

-18 VDC UNREGULATED

COMMON

+10 VDC UNREGULATED

SEE NOTE 4

SEE NOTE 6

MACHINE

EARTH

GROUND

CIRCUIT

BREAKERS

OR FUSES

(CUSTOMER

SUPPLIED)

CONTROL POWER

115 ±15%

AC INPUT

50 - 60 Hz

(SEE NOTES 5,

7, & 11)

MAIN POWER

CONTACTOR

SEE NOTE 3

EMERGENCY

STOP

OVERLOAD RELAY

(ONLY FOR PSR 50

& 75 AMP UNITS)

(SEE NOTE 10)

FAULT CONTACTS

SEE NOTE 2

MOMENTARY

PUSHBUTTON

TO ENERGIZE

MAIN POWER

SEE NOTES 4 & 7

GRN/

YEL

(MOTOR POWER CABLE) USE DANAHER

MOTION CABLE ASSEMBLY. EXAMPLE: MODEL

NO. FOR A B-20X MOTOR IS GC-M2-4/5-XX

(SEE NOTE 9).

TO OTHER BDS4s

AND/OR BDS5s

(SEE NOTE 8)

CONNECTOR PRESENT

ON 20 AMP & LARGER

UNITS ONLY

(MOTOR SYSTEM

RESOLVER &

THERMOSTAT CABLE)

USE GOLDLINE CABLE

ASSEMBLY GC-R-4/5-XX

(SEE NOTES 1, & 9)

MAIN POWER

(3-PHASE OR

1-PHASE)

*Notes are on the following pages.

EB-60X Installation & Service Manual | Wiring

(ALL WIRES TO BE COPPER WITH MIN. TEMP. RATING OF 60° C)

The motor thermostat automatically resets when the motor cools. You

are responsible for latching this signal to inhibit operation after a motor

thermostat fault. Connect thermostat using twisted pair wire.

The PSR4/5 fault contacts (rated 115 VAC 1 amp) must be wired in

series with the overload relay. On 12 & 20 amp PSR4/5s, this contact is

normally open and closes within 250 ms after application of control and

main power. This contact opens in fault conditions. On 50&75 amp

PSR4/5s, this contact closes on application of control power and opens

in fault conditions.

Resistor is connected to high voltage. Ensure sufficient electrical

clearance when mounting. Resistor may become very hot during

operation. Do not mount near materials that are flammable or damaged

by heat. Ventilation may be required. See wiring drawing for specific

regen resistor kit. Each kit has different series/parallel resistor

connections to obtain specific resistance and power rating.

Wire sizes, breakers and fuses for PSR4/5:

•PSR4/5-X12 has a max main power input current of 12 ARMS.

•PSR4/5-X20 has a max main power input current of 20 ARMS.

•PSR4/5-X50 has a max main power input current of 50 ARMS.

•PSR4/5-X75 has a max main power input current of 75 ARMS.

The actual application may require less current. Use 600 VAC insulated

wire and refer to local electrical codes for proper wire size for the

currents listed above. Fuses for main power should be a U.L. rated time

delay type, such as, buss FRN-R series.

The power BUS between a PSR4/5 and BOS4 should use the following

wire gauge with 600 VAC insulation:

•PSR4/5-X12, 14 AWG (or larger) wire.

•PSR4/5-X20, 10 AWG wire.

•PSR4/5-X50, 8 AWG (or larger) wire.

•PSR4/5-X75, 8 AWG (or larger) wire.

All signal and control wires must be 22-18 AWG wire. The crimp

terminals for 22-18 AWG wire are supplied for use with BDS4

connectors C1, C2, C3, C4, option connector and PSR4/5 connectors

C1 & C2, for 16 AWG wire use Molex #39-00-0078 terminals.

In the BDS4 3 amp thru 20 amp and the PSR4/5 12 amp and 20 amp,

the screws in the power terminal blocks are captive. DO NOT attempt to

remove them to use ring terminals. Use locking spring spade terminals

such as Hollingsworth #XSS20954S or #SS20947SF for 16 AWG wire

and #XSS20836 or #SS20832F for 12/10 AWG wire.

All AC lines should be twisted cables.

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