Kollmorgen S300 Servo Drive Application Guide

Kollmorgen S300 Digital Servo Drive Comprehensive Guide

In today's highly automated industrial field, high-performance and highly reliable servo drive systems are the core of achieving precision motion control. The SERVOSTAR 300 (S300) series digital servo amplifier from Kollmorgen, as a mature product that has undergone multiple iterations and verifications, integrates advanced driving technology, rich interface options, and critical safety functions. It is widely used in various demanding motion control scenarios. This article is based on its official manual, providing a systematic review and in-depth analysis of its technical essence, safety standards, installation points, and application configurations.

Product Overview and Core Positioning

The S300 series is a digital servo drive family launched by Colmorgen, covering standard versions with rated currents ranging from 1.5A to 10A. This series is mainly divided into two voltage levels:

S3xx6 type (such as S303, S306, S310): suitable for wide range single-phase/three-phase power supply from 110V to 230V AC.

S3xx0 type (such as S341, S343, S346): suitable for three-phase industrial power grids ranging from 208V to 480V AC.

Its design complies with overvoltage category III (according to EN 61800-5-1) and can be directly connected to grounded TN or TT power grid systems. The driver integrates B6 bridge rectifier, input filter, and soft start circuit, and supports single-phase power supply operation (such as for debugging phase).

The core features include:

Integrated safety function: Standard safety torque off (STO) function, compliant with SIL CL 2 (IEC 62061) and PLd (ISO 13849-1) safety levels, providing functional safety restart interlock.

Powerful communication capability: onboard CANopen interface (default 500 kBaud), with reserved expansion card slots, supporting various mainstream fieldbuses such as PROFIBUS, SERCOS, EtherCAT, DeviceNet, SynqNet, etc.

Multi feedback system support: fully compatible with traditional rotary transformers (Resolvers), sine encoders (Sin/Cos, supporting protocols such as EnDat, Hiperface, BiSS), incremental encoders (ROD), and modern single cable connection technologies (SFD3, HiperFACE DSL).

Intelligent control: Built in high-performance position controller, supporting electronic gears, master-slave synchronization, point-to-point positioning, and motion task sequence.

Dynamic braking and energy management: equipped with internal braking resistors, supporting external braking resistors or optional KCM (Colmorgen capacitor module) for energy recovery and storage, optimizing system energy efficiency.

Critical safety regulations and STO functionality

Safety is the cornerstone of drive system design. The S300 manual extensively emphasizes the safety operation guidelines.

1. General safety guidelines:

Professional personnel operation: Transportation, installation, commissioning, and maintenance must be carried out by professionals with electrical engineering qualifications.

Automatic restart risk: If the parameter AENA is set to 1, the drive may automatically restart after power is restored. A "power on automatic restart" warning sign must be set on the device, and it must be ensured that personnel cannot power on when in a hazardous area.

High voltage hazard: There is a voltage of up to 900V inside the equipment. After a power outage, the dangerous voltage of the capacitor may remain for up to five minutes. Before operation, all power sources must be cut off, wait for at least five minutes, and measure the DC bus voltage to confirm it is below 50V.

Leakage current: According to IEC 61800-5-1, the leakage current of the protective earth (PE) may exceed 3.5mA. Therefore, PE connections must use cables with a cross-sectional area greater than 10mm ² or adopt double line parallel connection.

Unauthorized modification is prohibited: Any unauthorized modification by the manufacturer will result in the invalidation of warranty and all certifications.

2. In depth analysis of the Safety Torque Off (STO) function:

STO is a core safety function of S300, aimed at safely removing motor torque to prevent accidental restart of the drive shaft and protect personnel safety.

Safety level: Single channel design, certified to PLd (ISO 13849-1) and SIL CL 2 (IEC 62061), with an average probability of hazardous failure (PFH_D) of 1.50E-07/hour and a mission time (TM) of 20 years.

Working principle: By disconnecting the 24V DC safety signal connected to the X4/5 terminal (STO Enable) of the driver, the internal electronic circuit of the driver will immediately cut off the energy supply to the motor, causing the motor to enter a torque free state.

Key safety instructions:

Non electrical isolation: STO does not provide electrical isolation for power output terminals. If you need to touch the motor power terminal, you must cut off the main power and wait for discharge.

No braking capability: When STO is activated, the driver cannot provide any braking torque. For vertical suspended loads, an additional safe and reliable mechanical brake must be equipped.

Prohibited as emergency shutdown or maintenance isolation: In case of prolonged shutdown, maintenance or emergency power outage, the main switch should be used to cut off the entire system power supply.

Wiring and application: The STO Enable input must be connected to the output of a safety relay or safety controller that meets the same safety level (such as PLd/SIL 2). If STO is not required, the X4/5 terminal must be directly connected to+24V DC, and the driver cannot be used as a safety component that complies with the EU Machinery Directive.

Detailed technical specifications and mechanical and electrical installation

1. Summary of Key Technical Data:

Switching frequency: The output stage defaults to 8kHz, and can switch to 16kHz when the current is halved.

Environmental conditions: The operating environment temperature ranges from 0 ° C to+40 ° C (rated conditions), with a maximum of+55 ° C (requiring derating for use). The protection level is IP20 and it needs to be installed inside the control cabinet.

Connector and torque: It is recommended to use 2.5mm ² (230V type) or 4mm ² (480V type) cables for power terminals (X0, X8, X9), with a tightening torque of 0.5-0.6 Nm. Use thinner cables for signal terminals.

Fuse protection: Users need to provide external fuses, for example, S303/341 recommends 6A delay type (T), S306/346 recommends 10A.

2. Key points for mechanical installation:

The driver should be installed vertically to facilitate heat dissipation.

Ensure that the installation base plate has good conductivity and do not use spray painted (non-conductive) installation plates to achieve effective EMC grounding.

Adequate cooling must be ensured inside the cabinet, and the inlet air temperature must be below 40 ° C. Some models rely on natural convection, while others require fans (some are optional controlled fans).

Avoid installing equipment that generates strong magnetic fields in close proximity to the driver.

3. Electrical installation specifications:

Cable separation: Power cables and signal control cables must be laid separately, with a recommended minimum distance of 200mm to enhance anti-interference performance.

Shielding layer grounding: All shielding layers (motor cables, encoder cables, etc.) should be extensively and low impedance grounded at both ends of the driver and motor terminals, usually using the shielding busbar on the front cover plate of the driver.

Grounding system: Pay attention to distinguishing between AGND (analog ground, used for encoders and analog inputs) and DGND (digital ground, used for 24V I/O). The two are optically isolated inside the driver.

Motor connection: When the length of the motor cable exceeds 25 meters, a motor reactor (such as 3YL) must be used to limit leakage current and voltage reflection, and protect the output stage of the driver.

Rich feedback system and interface configuration

The S300 supports almost all series of motor feedback devices, which is an important manifestation of its flexibility.

1. Single cable connection (SFD3/HiperFACE DSL):

This is the most advanced connection method that integrates the power line and the digital feedback signal of the high-resolution absolute encoder into a hybrid cable, greatly simplifying wiring and improving reliability. The maximum cable length is 25 meters.

2. Dual cable connection (power and feedback separated):

Support multiple types of feedback, users need to set the FBTYPE parameter in the debugging software (DRIVE GUI) to correspond:

Rotary transformer: connected to X2, simple and reliable, with strong resistance to harsh environments.

Sine encoder: supports multiple digital protocols such as EnDat 2.1/2.2, Hiperface, BiSS (analog/digital), SSI, etc., providing high-precision absolute position information.

Incremental encoder: Supports 5V (A/B/Z) and 24V types, connected to X1, X3, or X5.

Hall sensor: used for commutation of brushless motors.

3. Encoder simulation output:

The driver can provide incremental (A quad B) or SSI format position output signals through the X5 terminal, facilitating the transmission of motor position to the higher-level control system or other drivers, achieving master-slave tracking.

Debugging, software tools, and fault diagnosis

1. Debugging software (DRIVE GUI. EXE):

This is the core tool for configuring S300, running on the Windows system. It provides a graphical interface that supports online parameter settings, real-time monitoring, oscilloscope functionality, Bode plot analysis, and automatic tuning.

Quick Start Wizard: Guide users to complete motor model selection (which can be loaded from the database), feedback type setting, basic unit conversion, and preliminary controller tuning.

Complete configuration: Provides deep access to current loop, speed loop, position loop parameters, digital/analog I/O function allocation, electronic gear ratio, motion task programming, and more.

2. Status display and button operation:

The front of the driver is equipped with a three digit LED display screen and two buttons, which can display status codes, error/warning codes, and perform basic parameter viewing and site address settings.

3. Common troubleshooting:

Communication failure: Check the null mode cable, PC interface selection, and 24V auxiliary power supply for the driver.

Motor not turning: Check if the ENABLE (X3/12) and STO Enable (X4/5) signals are both+24V, if the software enable is activated, if the motor phase sequence is correct, and if the brake is released.

Motor oscillation: It is possible that the speed loop gain (Kp) is too high, or the feedback cable shielding is poor, or the AGND is not connected.

Follow error: The current limit (Ims/Ipeak) may be set too low, or the acceleration/deceleration ramp time may be too long.

Drive overheating: Check if the load inertia ratio is too large and if the heat dissipation conditions are met.

Expansion options and system integration

The expansion card slot of S300 provides the possibility for its functional extension:

I/O-14/08: Add 14 digital inputs and 8 digital outputs for expanding signals such as limit, origin, and task triggering.

Fieldbus cards, such as PROFIBUS, DeviceNet, SERCOS, EtherCAT, etc., enable seamless integration with different PLC systems.

FB-2to1: Allow simultaneous connection of one digital main feedback and one analog auxiliary feedback.

2CAN module: Separate RS232 and CAN interfaces from the shared X6 connector into separate ports and provide CAN bus terminal resistors.