Kollmorgen S700 Servo Drive S748... S772 Instruction Manual

S700
Digital Servo Amplifier S748…S772

Instruction Manual
Edition 12/2014
Translation of the original instruction manual.
Valid for Hardware Revision 02.20
Keep all manuals as a product component

during the life span of the product.
Pass all manuals to future users and owners
of the product.
File s748_e.***
Record of Document Revisions:
Revision Remarks
07/2009 First edition
09/2009 Repair, disposal, standards, directives, GOST-R
11/2009 Safety expansion cards S1/S2, UL listed, FAN option card F2
Part number scheme, safety approved, emergency Stop examples moved to WIKI, S1/S2 cards
updated, new DriveGUI icon, bridge DGND-GND (dig-I/O) changed, notes holding brake, climatic
09/2011
classes, WIKI links updated, 2CAN module, company name&address, encoder emulation X1,
BiSS-C
06/2012 Expansion card FB-2to1 new, Stop/Emergency Stop/Emergency Off updated
Feedback - ENCVON note, FBTYPE 34, CE declaration of conformity, formal improvements,
07/2013 BiSS C Renishaw, according to IEC 82079, safety cards S1/S2 replaced by S3/S4, diagram "Be-
havior in the event of an error" updated.
08/2013 Correction S2-2 (S4) safety card (SLP not possible)
11/2013 Hint automatic restart, fault table, switch off behaviour in case of faults, VBUSBAL=4
05/2014 Warning symbols updated, SSI emulation timing updated, safe to touch voltage 40V->60V
07/2014 Wiring thermo sensor updated (Feedback)
Note drive feedback restrictions with Safety Cards, CE declaration of conformity removed,
12/2014
GOST-R removed, Safety certificates removed, HWR, export classification
Hardware Revision (HR)
usable
Hardware Revi- Export
Firmware Remarks
sion Classification
Revision
01.01 ³ 5.00 AL-3A225 Starting version (STO and Safety pending)
02.10 ³ 5.18 AL-3A225 STO and Safety Cards S1/S2 approved
02.20 ³ 5.18_ND1 AL-3A225 New data structure
02.20 ³ 5.18_ND0 - New data structure
WINDOWS is a registered trademark of Microsoft Corporation

HIPERFACE is a registered trademark of Max Stegmann GmbH
SERCOS is a registered trademark of sercos® international e.V.
EnDat is a registered trademark of Dr.Johannes Heidenhain GmbH
EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH
Technical changes which improve the performance of the device may be made without prior notice!
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by photocopying, microfilm or any
other method) or stored, processed, copied or distributed by electronic means without the written permission
of Kollmorgen Europe GmbH.
Kollmorgen 12/2014 Contents
Page
1 General
1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4 Standards used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.5 Abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2 Safety
2.1 You should pay attention to this . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 Use as directed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.3 Prohibited use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.4.4 Maintenance, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.4.5 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.4.6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.4.7 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3 Approvals
3.1 Conformance with UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2 CE conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.3 European Directives and Standards for the machine builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Package
4.1 Package supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.3 Part number scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5 Technical description
5.1 The S748/772 family of digital servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2.1 Rated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.2.2 Inputs / outputs, aux. voltage supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2.3 Connectors/Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2.4 Recommended tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2.5 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.2.6 Ambient conditions, ventilation, mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.7 Conductor cross-sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3 LED display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.4 Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.5 Motor holding brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
5.6 Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.7 Switch-on and switch-off behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5.7.1 Behavior in standard operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.7.2 Behavior in the event of an error (with standard setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204 . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.8.1 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.8.2 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.8.3 Emergency Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
S748-S772 Instructions Manual 3

Contents 12/2014 Kollmorgen
Page
5.9 Safety Function STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.9.1 Safety characteristic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.9.2 Enlosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.9.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.9.4 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.9.5 Use as directed STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.9.6 Prohibited Use STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.9.7 Technical data and pinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.9.8 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.9.9 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.10 Shock-hazard protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.10.1 Leakage current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.10.2 Residual current protective device (RCD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.10.3 Isolating transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6 Mechanical Installation
6.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.2 Guide to mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.4.1 Mounting the shielding plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.4.2 Backplane mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7 Electrical installation
7.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
7.2 Guide to electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
7.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7.3.1 Shielding connection to the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.3.2 Technical data for connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
7.4 Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
7.5 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.6 Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.7 Connection Diagram (Overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
7.8 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
7.8.1 Connection to various mains supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
7.8.2 Mains supply connection (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
7.8.3 24V auxiliary supply (X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
7.9 DC bus link (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
7.9.1 DC Bus topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7.9.2 External brake resistor (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7.10 Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
7.10.1 Motor Power Connection (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
7.10.2 Motor holding brake (X8, X9B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
4 S748-S772 Instructions Manual

Kollmorgen 12/2014 Contents
Page
7.11 Feedback Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7.11.1 Resolver (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
7.11.2 Sine Encoder with BiSS analog (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
7.11.3 Sine Encoder with BiSS digital (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
7.11.4 Sine Encoder with EnDat 2.1 (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7.11.5 Encoder with EnDat 2.2 (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.11.6 Sine Encoder with HIPERFACE (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.11.7 Sine Encoder with SSI (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.11.8 Sine Encoder without data channel (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
7.11.9 Sine Encoder with Hall (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.11.10 ROD (AquadB) 5V, 1.5MHz (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
7.11.11 ROD (AquadB) 5V, 350kHz (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
7.11.12 ROD (AquadB) 5V, 350kHz with Hall (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
7.11.13 ROD (AquadB) 24V (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
7.11.14 ROD (AquadB) 24V with Hall (X3, X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
7.11.15 SSI Encoder (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
7.11.16 Hall sensors (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
7.12 Electronic Gearing, Master-slave operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.12.1 Signal source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
7.12.2 Connection to stepper motor controllers (step and direction) . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.12.3 Master-slave operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.13 Encoder Emulation, position output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.13.1 Incremental encoder output - A quad B (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
7.13.2 SSI encoder output (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
7.14 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
7.14.1 Analog Inputs (X3B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
7.14.2 Digital Inputs (X3A, X3B, X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
7.14.3 Digital Outputs (X3A, X3B, X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.15 RS232 interface, PC connection (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
7.16 CANopen interface (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
7.17 EtherNET interface (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
7.18 Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
8 Setup
8.1 Important notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.2 Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
8.2.1 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
8.2.2 Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
8.2.3 Hardware requirements, operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
8.2.4 Installation under WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
8.3 Quickstart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
8.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
8.3.2 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
8.3.3 Important Screen Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
8.3.4 Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
8.3.5 Motion Service (Jog Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
8.3.6 More Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
8.4 Multi axis system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
8.5 Keypad operation / LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
8.5.1 Keypad operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
8.5.2 Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
8.5.3 Standard menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
8.5.4 Advanced menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
8.6 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
8.7 Warning messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
8.8 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Contents 12/2014 Kollmorgen
Page
9 Expansions
9.1 Expansion cards for slot 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
9.1.1 Guide to installation of expansion cards in slot 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
9.1.2 Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
9.1.3 Expansion card -PROFIBUS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
9.1.4 Expansion card -SERCOS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
9.1.5 Expansion card - DEVICENET - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
9.1.6 Expansion card -SYNQNET-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
9.1.7 Expansion card - FB-2to1 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
9.1.8 Expansion module -2CAN- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
9.2.2 Option "F2", controlled Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
9.2.3 Expansion card "PosI/O" and "PosI/O-Monitor" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.3.2 Option "F2", controlled Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
9.3.3 Expansion cards "PosI/O" & "PosI/O-Monitor" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.3.4 Expansion card "Safety 2-2" (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
9.3.5 Expansion card "Safety 1-2" (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
10 Appendix
10.1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
10.2 Order codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
10.2.1 Servo amplifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
10.2.2 Memory Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
10.2.3 Expansion cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
10.2.4 Mating connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
10.3 Repair-/Disposal request Telefax form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
10.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Kollmorgen 12/2014 General
1 General
1.1 About this manual
This manual describes the S748/772 series of digital servo amplifiers (standard version:
48A ...72A rated current). S701 to S724 amplifiers are described in an additional product
manual.
A more detailed description of the expansion cards that are currently available and the
digital connection to automation systems can be found, together with our application
notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements:
WINDOWS, Internet Browser, Acrobat Reader) in different languages.
Technical data and dimensional drawings of accessories such as cables, brake resistors,
mains supplies, etc., can be found in the accessories manual.
This documentation (PDF) can be printed out on any standard commercial printer. A prin-
ted copy of the documentation is available from us at extra cost.
More background information can be found in our "Product WIKI", available at
www.wiki-kollmorgen.eu.
1.2 Hints for the online edition (PDF format)

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

General 12/2014 Kollmorgen
1.3 Symbols used
Symbol Indication
Indicates a hazardous situation which, if not avoided, will result
DANGER in death or serious injury.
Indicates a hazardous situation which, if not avoided, could re-
WARNING sult in death or serious injury.
Indicates a hazardous situation which, if not avoided, could re-
CAUTION sult in minor or moderate injury.
This is not a safety symbol. Indicates situations which, if not
avoided, could result in property damage.
This is not a safety symbol. This symbol indicates important
notes.
Warning of a danger (general). The type of danger is specified by the
warning text next to it.
Warning of danger from electricity and its effects.
Warning of hot surfaces.
Warning of suspended loads.
1.4 Standards used
Standard Content
ISO 4762 Hexagon socket head cap screws
ISO 13849 Safety of machinery: Safety-related parts of control systems
ISO 12100 Safety of machinery: Basic concepts, general principles for design
IEC 60085 Electrical insulation - Thermal evaluation and designation Maintenance
IEC 60204 Safety of Machinery: Electrical equipment of machinery
IEC 60364 Low-voltage electrical installations
IEC 60439 Low-Voltage Switchgear and Controlgear Assemblies
IEC 60529 Protection categories by housing (IP Code)
IEC 60664 Insulation coordination for equipment within low-voltage systems
IEC 60721 Classification of environmental conditions
IEC 61000 Electromagnetic compatibility (EMC)
IEC 61131 Programmable controllers
Electrical equipment of industrial machines – Serial data link for real-time
IEC 61491
communications between controls and drives.
Functional safety of electrical/electronic/programmable electronic
IEC 61508
safety-related systems
IEC 61800 Adjustable speed electrical power drive systems
Functional safety of electrical/electronic/programmable electronic
IEC 62061
safety-related systems
IEC 82079 Preparation of instructions for use - Structuring, content and presentation
UL Standard for Safety for Insulation Coordination Including Clearances
UL 840
and Creepage Distances for Electrical Equipment
UL 508C UL Standard for Safety Power Conversion Equipment
IEC International Electrotechnical Commission UL Underwriters Laboratories
ISO International Organization for Standardization

Kollmorgen 12/2014 General
1.5 Abbreviations used
Abbrev. Meaning
AGND Analog ground
xAF Fuse, x Amps, fast
xAM Fuse, x Amps, medium
xAT Fuse, x Amps, slow
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Europeenne
CLK Clock signal
COM Serial interface for a Personal Computer
DGND Digital ground (for 24V and digital I/O)
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IGBT Insulated-gate bipolar transistor
LED Light-emitting diode
MB Megabyte
NI Zero pulse
PC Personal computer
PL Performance Level
PLC Programmable logic control
PWM Pulse-width modulation
RAM Volatile memory
RBrake / RB Brake resistor (sometimes called "regen resistor")
RBext External brake resistor
RBint Internal brake resistor
RES Resolver
ROD Digital encoder (A quad B)
SDI Safe direction
SIL Safety Integrity Level
SIL CL Safety Integrity Level Claim Limit
SLI Safe limited increments
SLP Safe limited position
SLS Safe limited speed
SOS Safe operating stop
SS1 Safe stop 1
SS2 Safe stop 1
SSI Synchronous serial interface
SSR Safe speed range
STO Safe torque off (former AS)
V AC Alternating voltage
V DC DC voltage
VDE Society of German Electrical Technicians

Safety 12/2014 Kollmorgen
2 Safety
2.1 You should pay attention to this
Read the documentation!
Read the available documentation before installation and commissioning. Improper hand-
ling of the servo amplifiers can cause harm to people or damage to property. The opera-
tor must therefore ensure that all persons entrusted to work on the S748/772 have read
and understood the manual and that the safety notices in this manual are observed.
Check the Hardware Revision!
Check the Hardware Revision Number of the product (see product label). This revision
number must match the Hardware Revision Number on the cover page of the manual. If
the numbers do not match up, visit the Tech-WIKI (http://www.wiki-kollmorgen.eu). The
'Download' section contains the various manual versions based on the hardware version
number.
Pay attention to the technical data!
Adhere to the technical data and the specifications on connection conditions (rating plate
and documentation). If permissible voltage values or current values are exceeded, the
servo amplifiers can be damaged.
Observe electrostatically sensitive components!
The servo amplifiers contain electrostatically sensitive components which may be dama-
ged by incorrect handling. Discharge your body before touching the servo amplifier. Avoid
contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the servo
amplifier on a conductive surface.
Perform a risk assessment!
The manufacturer of the machine must generate a risk assessment for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property. Additional requirements on specialist staff may also
result from the risk assessment.
Automatic restart
The drive might restart automatically after power on, voltage dip or interruption of the
supply voltage, depending on the parameter setting. Risk of death or serious injury for
humans working in the machine. If the parameter AENA is set to 1, then place a warning
sign to the machine (Warning: Automatic Restart at Power On) and ensure, that power on
is not possible, while humans are in a dangerous zone of the machine. In case of using
an undervoltage protection device, you must observe EN 60204-1:2006 chapter 7.5.

Kollmorgen 12/2014 Safety
Specialist staff required!

Only properly qualified personnel are permitted to perform such tasks as transport,
assembly, setup and maintenance. Qualified specialist staff are persons who are familiar
with the transport, installation, assembly, commissioning and operation of drives and who
bring their relevant minimum qualifications to bear on their duties:
Transport : only by personnel with knowledge of handling electrostatically
sensitive components.
Unpacking: only by electrically qualified personnel.
Installation : only by electrically qualified personnel.
Setup : only by qualified personnel with extensive knowledge of electrical
engineering and drive technology
The qualified personnel must know and observe IEC 60364 / IEC 60664 and national
accident prevention regulations.
Hot surface!
The surfaces of the servo amplifiers can be hot in operation. Risk of minor burns!
The surface temperature can exceed 80°C. Measure the temperature, and wait until the
motor has cooled down below 40°C before touching it.
Earthing!
It is vital that you ensure that the servo amplifiers are safely earthed to the PE (protective
earth) busbar in the switch cabinet. Risk of electric shock. Without low-resistance eart-
hing no personal protection can be guaranteed and there is a risk of death from electric
shock.
High voltages!
The equipment produces high electric voltages up to 900V. During operation, servo
amplifiers may have uncovered live sections, according to their level of enclosure protec-
tion. Capacitors can have dangerous voltages present up to eight minutes after switching
off the supply power. There is a risk of death or severe injury from touching exposed con-
tacts. Keep all covers and cabinet doors closed during operation. Touching the equip-
ment is allowed during installation and commissioning for properly qualified persons only.
There is a danger of electrical arcing when disconnecting connectors, because capacitors
can still have dangerous voltages present up to eight minutes after switching off the
supply power. Risk of burns and blinding. Wait at least eight minutes after disconnecting
the servo amplifiers from the main supply power before touching potentially live sections
of the equipment (such as contacts) or removing any connections. Always measure the
voltage in the DC bus link and wait until the voltage is below 60V before handling compo-
nents.
Reinforced Insulation!
Thermal sensors, motor holding brakes and feedback systems built into the connected
motor must have reinforced insulation (according to IEC61800-5-1) against system com-
ponents with power voltage, according to the required application test voltage. All
Kollmorgen components meet these requirements.
Never modify the servo amplifiers!
It is not allowed to modify the servo amplifiers without permission by the manufacturer.
Opening the housing causes loss of warranty and all certificates become unvalid.
Warning signs are added to the device housing. If these signs are damaged, they must
be replaced immediately.

2.2 Use as directed

Servo amplifiers are safety components that are built into electrical plant or machines,
and can only be operated as integral components of such plant or machines.
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property.
If the servo amplifiers are used in residential areas, in business/commercial areas, or in
small industrial operations, then additional filter measures must be implemented by the
user.
Cabinet and Wiring
The servo amplifiers must only be operated in a closed control cabinet, taking into
account the ambient conditions defined on page 26. Ventilation or cooling may be neces-
sary to keep the temperature within the cabinet below 40°C.
Use only copper conductors for wiring. The conductor cross-sections can be derived from
the standard IEC 60204 (for AWG: NEC Table 310-16, 60°C or 75°C column).
Power supply
Servo amplifiers in the S748/772 series (overvoltage category III acc. to EN 61800-5-1)
can be supplied from 3-phase grounded (earthed) industrial supply networks (TN-system,
TT-system with grounded neutral point, no more than 42kA symmetrical rated current at
208V-10%, 230V, 240V, 400V or 480V+10%). Connection to other types of supply networks
(with an isolating transformer) is described on page 60. In case of mains voltage asym-
metry >3% a mains choke must be used.
Periodic overvoltages between phases (L1, L2, L3) and the housing of the servo
amplifier must not exceed 1000V crest. In accordance with IEC 61800, voltage spikes (<
50µs) between phases must not exceed 1000V. Voltage spikes (< 50µs) between a
phase and the housing must not exceed 2000V.
Motors
The S748/772 family of servo amplifiers is exclusively intended for driving suitable
brushless synchronous servomotors, asynchronous motors and DC motors with control of
torque, speed and/or position.
The rated voltage of the motors must be at least as high as the DC bus link voltage divi-
ded by 2 produced by the servo amplifier (UnMotor³ UDC/ 2).
Safety
Observe the chapter "use as directed" on page 36 when you use the safety function STO.
To achieve PL e or SIL CL3, the safe switching of the pulse inhibitor must be tested peri-
odically by analyzing the feedback signal from the safety control (ð p. 44).
Observe the user documentation for safety cards S1-2(S3) / S2-2(S4) when you use a
safety expansion card.

2.3 Prohibited use

Other use than described in chapter 2.2 is not intended and can lead to damage of per-
sons, equipment or things.
The use of the servo amplifier in the following environments is prohibited:
- potentially explosive areas
- environments with corrosive and/or electrically conductive acids, alkaline solutions,
oils, vapors, dusts
- directly on non-grounded supply networks or on asymmetrically grounded supplies
with a voltage >240V.
- on ships or off-shore applications
Commissioning the servo amplifier is prohibited if the machine in which it was installed,
- does not meet the requirements of the EC Machinery Directive
- does not comply with the EMC Directive or with the Low Voltage Directive
- does not comply with any national directives
The control of holding brakes by the S748/772 alone may not be used in applications,
where functional safety is to be ensured with the brake.
2.4 Handling
2.4.1 Transport
l Transport by qualified personnel in the manufacturer’s original recyclable packaging
l Avoid shocks while transporting
l Transport temperature: -25 to +70°C, max. rate of change 20K / hour,
class 2K3 acc. to EN61800-2, EN 60721-3-1
l Transport humidity: max. 95% relative humidity, no condensation,
l If the packaging is damaged, check the unit for visible damage. In such an event, in-
form the shipper and the manufacturer.
The servo amplifiers contain electrostatically sensitive components, that can be damaged
by incorrect handling. Discharge yourself before touching the servo amplifier. Avoid
contact with highly insulating materials, such as artificial fabrics and plastic films. Place
the servo amplifier on a conductive surface.
2.4.2 Packaging
l Recyclable cardboard with inserts
l Dimensions: 390 x 600 x 400 mm
l Labeling: name plate on outside of box

2.4.3 Storage
l Storage only in the manufacturer’s original recyclable packaging
l Max. stacking height: 3 cartons
l Storage temperature: -25 to +55°C, max. rate of change 20K / hour,
l Storage humidity: 5 … 95% relative humidity, no condensation,
l Storage duration:
Less than 1 year: without restriction.
More than 1 year: capacitors must be re-formed before setting up and operating the
servo amplifier. To do this, remove all electrical connections and apply single-phase
230V AC for about 30 minutes to the terminals L1 / L2.
2.4.4 Maintenance, Cleaning
The devices do not require any maintenance, opening the devices invalidates warranty.
Cleaning : — if the casing is dirty: clean with Isopropanol or similar
NOTICE: Do not immerse or spray
— Dirt inside the unit: must be cleaned by the manufacturer
— For dirty protective grill on fan: clean with a dry brush
2.4.5 Disassembling
Observe the sequence below, if a servo amplifier has to be disassembled (e.g. for repla-
cement).
1. Electrical disconnection
a. Switch off the main switch of the switchgear cabinet and the fuses that supply
the system.
b. Warning: Contacts can still have dangerous voltages present up to 10 min
after switching off mains voltage. Risk of electric shock!
Wait at least eight minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections. To be sure, measure the voltage in the
DC Bus link and wait until it has fallen below 60V.
c. Remove the wiring. Disconnect the earth (ground) connection at last.
2. Check temperature
CAUTION
During operation the heat sink of the servo amplifier may reach
temperatures above 80°C (176°F). Risk of minor burns! Before touching
the device, check the temperature and wait until it has cooled down below
40°C (104°F).
3. Disassembling
Remove the fan housing and disassemble the servo amplifier (reverse of the procedure
described in chapter "Mechanical installation).

2.4.6 Repair
Repair of the servo amplifier must be done by the manufacturer. Opening the devices
means loss of the guarantee. Use the telefax form on page 153 for repair request. You'll
receive the current dispatch information.
Disassemble the equipment as described in chapter 2.4.5 and send it in the original
packaging to the address given in the dispatch information.
2.4.7 Disposal
In accordance to the WEEE-2002/96/EC-Guidelines we take old devices and accessories

back for professional disposal. Transport costs are the responsibility of the sender. Use
the telefax form on page 153 for disposal request. You'll receive the current dispatch
information.
Disassemble the equipment as described in chapter 2.4.5 and send it in the original
packaging to the address given in the dispatch information.

This page has been deliberately left blank.

Kollmorgen 12/2014 Approvals
3 Approvals
3.1 Conformance with UL
This servo amplifier is listed under UL file number E217428.
UL-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. stan-
dards (in this case UL 840 and UL 508C).
This standard describes the fulfillment by design of minimum requirements for electrically
operated power conversion equipment, such as frequency converters and servo ampli-
fiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons,
being caused by such equipment. The technical conformance with the U.S. standard is
determined by an independent UL inspector through the type testing and regular che-
ckups.
Apart from the notes on installation and safety in the documentation, the customer does
not have to observe any other points in direct connection with the UL-certification of the
equipment.
UL 508C
UL 508C describes the fulfillment by design of minimum requirements for electrically ope-
rated power conversion equipment, such as frequency converters and servo amplifiers,
which is intended to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfillment by design of air and insulation creepage spacings for
electrical equipment and printed circuit boards.
UL Markings
l Use 60°C or 75°C copper wire only for every model of this section.
l Tightening torque and wire size for field wiring terminals.
X0 8-2 AWG, TQ Lb In. 40.
X8 8-2 AWG, TQ Lb In. 40.
l For use in a pollution degree 2 environment only.
l These devices provide solid state motor overload protection at 130% of full load
current.
l Integral solid state short circuit protection does not provide branch circuit protection.
Branch circuit protection must be provided in accordance with the National Electrical
Code and any additional local codes.
l These devices are not provided with motor over-temperature sensing.
l Suitable for use on a circuit capable of delivering not more than 42kA rms symmetri-
cal amperes” for a max. Voltage of 480 Vac.
l Supply circuit protection:
Model Fuse class Voltage Rating Max. Fuse and SCC Rating
S7480 RK5, CC, J, T 600V AC 60A / 200kA
S7720 RK5, CC, J, T 600V AC 80A / 200kA
l For use on a solidly grounded wye source only.

Approvals 12/2014 Kollmorgen
3.2 CE conformance
The servo amplifiers have been tested by an authorized testing laboratory in a defined
configuration, using the system components that are described in this documentation.
Any divergence from the configuration and installation described in this documentation
means that you will be responsible for carrying out new measurements to ensure confor-
mance with regulatory requirements.
Kollmorgen declares the conformity of the products S748, S772 with the following directi-
ves
l EC Machinery Directive (2006/42/EC)
l EC EMC Directive (2004/108/EC)
l EC Low Voltage Directive (2006/95/EC)
The servo amplifier meets the noise immunity requirements to the 2nd environmental
category (industrial environment). For noise emission the amplifier meets the requirement
to a product of the category C2 (motor cable £ 10m). With a motor cable length of 10m or
longer, the servo amplifier meets the requirement to the category C3.
This product can cause high-frequency interferences in non industrial environments. This
can require measures for interference suppression like additional external EMC filters.
3.3 European Directives and Standards for the machine builder

Servo amplifiers are safety components that are intended to be incorporated into electri-
cal plant and machines for industrial use. When the servo amplifiers are built into machi-
nes or plant, the amplifier must not be used until it has been established that the machine
or equipment fulfills the requirements of the
l EC Machinery Directive (2006/42/EC)
l EC EMC Directive (2004/108/EC)
l EC Low Voltage Directive (2006/95/EC)
Standards to be applied for conformance with the EC Machinery Directive (2006/42/EC)
IEC 60204-1 (Safety and Electrical Equipment in Machines)
ISO 12100 (Safety of Machines)
must implement appropriate measures to ensure that unforeseen movements cannot
cause injury or damage to any person or property.
The machine/plant manufacturer must check whether other standards or EC Directives
must be applied to the machine/plant.
Standards to be applied for conformance with the EC Low Voltage Directive(2006/95/EC)
IEC 60204-1 (Safety and Electrical Equipment in Machines)
IEC 60439-1 (Low-voltage switchgear and controlgear assemblies)
Standards to be applied for conformance with the EC EMC Directive (2004/108/EC)
IEC 61000-6-1 / 2 (Interference Immunity in Residential & Industrial Areas)
IEC 61000-6-3 / 4 (Interference Generation in Residential & Industrial Areas)
The manufacturer of the machine/plant is responsible for ensuring that it meets the limits
required by the EMC regulations. Advice on the correct installation for EMC can be found
in this documentation.
We only guarantee the conformance of the servo system with the standards cited in this
chapter if the components (motor, cables, chokes etc.) are those supplied by us.

Kollmorgen 12/2014 Package
4 Package
4.1 Package supplied
When an amplifier from the S748/772 series is ordered (order numbers ðp.151), the fol-
lowing is supplied:
— Servo amplifier S748/772, shielding plate, shield clamps
— Instruction Manual
— Online documentation and setup software DRIVEGUI.EXE on CD-ROM
— Mating connectors X3A, X3B, X4, X9A, X9B
The mating SubD connectors are not part of the package!
Accessories : (must be ordered separately, if required; description see accessories
manual)
— Motor cable as a cut-off length
— Feedback cable (prefabricated)
or both feedback connectors separately, with the feedback cable as a cut-off length
— External brake resistor BAR(U)
— Communication cable to the PC (ð p.93) for setting parameters from a PC
— Power cable, control cables, fieldbus cables (as cut-off lengths)
— Mains choke if mains voltage is more than 3% asymmetrical
4.2 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.
Output current
Servo amplifier type Serial number Comments
in cont. operation
Electrical supply Enclosure max. ambient Hardware Software

2D bar code
Installed load Rating temperature Revision Version

Package 12/2014 Kollmorgen
4.3 Part number scheme

The part number is identical with the order code.
S 7 7 2 0 2 - EI F2 PM - NA1 - 0002
Family Firmware Options

S7 S700 NA no option
(EtherCAT&CANopen)
Current Rating
48 48 Arms
72 72 Arms
Expansion Cards Slot 3
NA no expansion card in slot 3,
Voltage Rating EtherCAT&CANopen onboard
0 208...480V F2 Fan controller
PM PosI/O
PA PosI/O-Monitor
electr./mech. Options S33 Safety card S1-2, SIL 3
2 Standard S43 Safety card S2-2, SIL 2
F coated PCBs
Expansion Cards Slot 1 Expansion Cards Slot 2

NA no expansion card in Slot 1, NA no expansion card in Slot 2,
EtherCAT&CANopen onboard EtherCAT&CANopen onboard
2C Module 2CAN mounted F2 Fan controller
DN DEVICENET PM PosI/O
PB PROFIBUS PA PosI/O-Monitor
SE SERCOS II
SN SYNQNET
EI I/O Extension
FB FB-2to1 at X1
1 is void with standard

2 is void with standard, additional coding defines customer specific specials.
3 described in separate documentation
Example: S77202-EIF2PM-NA-000
S7 S700 series
72 72A rated current
0 Supply voltage 208...480V
2 no electrical/mechanical option
EI I/O Extension card in Slot 1
F2 Fan controller in Slot 2
PM PosI/O expansion card in Slot 3
NA Standard Firmware (EtherCAT & CANopen onboard)
000 no customer specific specials

Kollmorgen 12/2014 Technical description
5 Technical description
5.1 The S748/772 family of digital servo amplifiers
Standard version
l Large supply voltage range: 3 x 208V-10% … 3 x 480V+ 10%
(with mains voltage below 300V set parameters NONBTB=3 and VBUSBAL=1.)
l CANopen onboard
l EtherCAT onboard
l RS232 and 24V pulse direction interface onboard
l Resolver-, Encoder-, AquadB Encoder-, ComCoder-evaluation onboard
l Position controller onboard
l STO (Safe Torque Off) onboard (up to SIL CL3, PLe)
l 3 frontside slots for expansion cards
l Memory Card slot onboard
l Synchronous servomotors, linear motors, asynchronous motors, and DC motors can
be used
Power section
l Directly on grounded 3-phase supply, 208V-10% … 480V+10%, 50/60 Hz
l TN-network or TT-network with grounded neutral point, 42kA max. symmetrical cur-
rent rating, connection to other supply types only via isolating transformer, ðp.60
l Overvoltage category III acc. to EN 61800-5-1
l B6 bridge rectifier, integral supply filter and soft-start circuit
l Single-phase supply operation possible (e.g. for setup)
l Fusing (e.g. fusible cutout) to be provided by the user
l Shielding All shielding connections are made directly on the amplifier
l Output stage IGBT module with floating current measurement
l Brake circuit with dynamic distribution of the generated power between
several amplifiers on the same DC bus link circuit.
External brake resistors if required.
l DC bus link voltage 260...900 V DC, can be connected in parallel.
l Interference suppression filters are integrated for the electrical supply feed and the
24V auxiliary supply voltage (with motor cable £ 10m for C2 as per IEC 61800-3, with
motor cable < 10m for C3 as per IEC 61800-3).

Technical description 12/2014 Kollmorgen
Integrated safety
l Appropriate insulation/creepage distances and electrical isolation ensure safe electri-
cal separation, as per IEC 61800-5-1, between the power input / motor connections
and the signal electronics.
l Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring.
l Temperature monitoring of the servo amplifier and motor (if our motors and prefabri-
cated cables are used).
l Safe stop (SIL CL3 according to IEC 62061, PLe according to ISO 13849-1) ð p. 35.
l Slot for optionalsafety card with more safety functions for the safe drive operation,
ð p. 142
Auxiliary supply voltage 24V DC

l Electrically isolated, internal fusing, from an external 24V DC power supply unit.
l Separate 24V supply input for internal electronic supply
l Separate 24V supply input for motor holding brake supply
l Separate 24V supply input for digital outputs
Operation and parameter setting

l With our user-friendly setup software DRIVEGUI.EXE, for setup via the serial interfa-
ce of a PC.
l If no PC is available: direct operation by two keys on the servo amplifier and a 3-cha-
racter LED display.
l Fully programmable via RS232 interface.
l Read/write access to parameter records and firmware via memory card.
Completely digital control

l Digital current controller (space vector, pulse-width modulation, 62.5 µs)
l Adjustable digital speed controller (62.5 µs)
l Integrated position controller, with adaptation possibilities for all applications (250 µs,
optionally 125µs)
l Integrated 24V step/direction interface for connecting a servomotor to a stepper con-
troller
Inputs/Outputs
l 2 programmable analog inputs ð p. 88
l 4 programmable digital inputs ð p. 89
l 2 programmable digital inputs/outputs (direction selectable) ð p. 91
l programmable logical combinations of digital signals
l 1 input Enable ð p. 78
l 2 inputs STO Enable ð p. 90
l 2 outputs STO Status ð p. 92

Expansions
Slot 1
Expansion cards in slot 1 can be combined with F2 Option in slot 2. More combinations of
slot 1 and slot 2 expansion cards are not possible.
l I/O-14/08 expansion card, ð p. 116
l PROFIBUS expansion card, ð p. 119
l sercos® II expansion card, ð p. 120
l DeviceNet expansion card, ð p. 122
l SynqNet expansion card, ð p. 125
l FB-2to1 expansion card, ð p. 127
l -2CAN- expansion module, separated connectors for CAN bus and RS232 ð p. 129
Slot 2
l PosI/O expansion card, ð p. 132
l PosI/O-Monitor expansion card, ð p. 132
l F2 Option, controlled fan, later insertion not possible, ð p. 119, can be combined
with expansion cards in slot 1.
Slot 3
l PosI/O expansion card, ð p. 136
l PosI/O-Monitor expansion card, ð p. 136
l F2 Option, controlled fan, later insertion not possible, ð p. 141
l Safety expansion cards (S4) S2-2 (SIL CL2), ð p. 142
l Safety expansion cards (S3) S1-2 (SIL CL3), ð p. 140
Several third-party expansion cards (ModBus, LightBus, FIP-IO etc. please contact the
manufacturer for further information)
Macro programming
More information can be found in our Product-WIKI (www.wiki-kollmorgen.eu).
l 62.5µs / 250µs / 1ms / 4ms / 16ms / IDLE / IRQ
l 128 kByte memory
l IEC 61131 structured text
l 400 easy instructions every 62.5 µs
l CAN objects for multi axis control

5.2 Technical data

5.2.1 Rated Data
Electrical data DIM S748 S772

Rated supply voltage 3 x 208V-10% … 3 x
V~
(grounded supply, phase to phase) 480V+10%, 50/60 Hz
Rated input power for continuous operation kVA 35 50
Permitted switch on/off frequency 1/h 30
Auxiliary voltage supply — ð p.25
Rated DC bus link voltage V= 290 - 675
Rated output current (rms value, ± 3%)
at 3x208V Arms 48 72
Peak output current (for approx.5s, ± 3%) Arms 96 140
Switching frequency of output stage kHz 8
Voltage rise speed dU/dt, (measured without connected motor, see hints on page 64!)
at 3x208V kV/µs 2.1
Technical data for brake circuit — ð p.29
Threshold for overvoltage switch-off VDC ð p.29
Motor inductance min.
at 3x208V mH 0.38 0.26
at 3x230V mH 0.42 0.29
at 3x400V mH 0.74 0.51
at 3x480V mH 0.88 0.61
Consult our customer
Motor inductance max. mH
support
Form factor of the output current
— 1.01
(rated conditions, min. load inductance)
Bandwidth of current controller kHz > 1.2 (bis 5)
Residual voltage drop at rated current V 6
Thermal dissipation, output stage disabled, max. W 24
Thermal dissipation at rated current (without brake dissipation)
at 3x230V W 555 885
at 3x400V W 635 1005
at 3x480V W 685 1135
Noise emission max. dB(A) 62 68
Mechanical data
Weight kg 13
Height, without connectors and shielding plate mm 386
Height, with connectors and shielding plate mm 505
Width mm 190
Depth, without connectors mm 244
Depth, with connectors mm 285
* In case of mains voltage below 300V, set parameters NONBTB=3 and VBUSBAL=1.

5.2.2 Inputs / outputs, aux. voltage supply
Interface electr. data

Analog inputs 1 / 2 ±10V
Max. common-mode voltage ±10V
as per EN 61131-2 Type 1,
Digital control inputs
max. 30VDC, 15mA
as per EN 61131-2 Type 1,
Digital control outputs
max. 30VDC, 100mA
max. 30VDC, max 42VAC
BTB/RTO output, relay contacts
500mA
24V-IO for digital outputs 20V … 30V
Auxiliary supply voltage, electrically isolated
Electronics 24V (-0% +15%)
Current electronics* 2A
Holding Brake 24V (-0% +15%)
Output current brake min./max. 0.15A / 3A
* = with fan but without option card
5.2.3 Connectors/Terminals
max. cross permiss. permiss.

Connector/Terminals Type
section*1 current*2 voltage*3
X0 Mains Terminals 35mm² 125A 1000V
X1 Encoder input SubD15poles (female) 0.5mm² 1A <100V
X2 Resolver input SubD 9poles (female) 0.5mm² 1A <100V
X3A, B Control signals Mini-Combicon connector 1.5mm² 4A 160V
X4 Aux. voltage, STO Mini-Combicon connector 1.5mm² 4A 160V
X5 optional, Encoder
SubD 9poles (male) 0.5mm² 1A <100V
emulation, ROD/SSI
X6 PC interface, CAN SubD 9poles (male) 0.5mm² 1A <100V
FTP CAT.5, 26AWGx4P
X7A, B EtherNET RJ45 connector
as per EN50173
X8 DC Bus link, Motor,
Terminals 35mm² 125A 1000V
Brake Resistor
X9A, B Motor brake Mini-Combicon connector 1.5mm² 4A 160V
*1 single-line connection
*2 single-line connection with recommended conductor cross section (chapter 5.2.7)
*3 rated voltage with pollution level 2
5.2.4 Recommended tightening torques
Connection Tightening torque

X0 with up to 25mm² wire 2.5 Nm
X0 with 35mm² wire 4.5 Nm
X3A, B Cage clamps
X4 Cage clamps
X8with up to 25mm² wire 2.5 Nm
X8 with 35mm² wire 4.5 Nm
Cage clamps
X9A
Mounting flange: 0.5 Nm
Grounding bolt 3.5 Nm

5.2.5 Fusing
Internal fusing, wire fuse or electronic
Circuit S748…S772
24V Electronics 4A
24V Motor brake 4A
Brake resistor electronic
External fusing by user (US fuses in brackets)

Tips and detailed information can be found in the Product-Wiki (follow the link on
www.wiki-kollmorgen.eu) on page "Fuses".
S748 S772
AC Supply FN1/2/3 60 A* 80 A*
24V Electronics FH1/2 8 A** 8 A**
24V Motor Brake FH3/4 8 A** 8 A**
Brake Resistor FB1/2 125 A*** 125 A***
* EU fuses gRL or gL 400V/500V

US fuses: class RK5/CC/J/T, 600VAC 200kA, time-delay
** e.g. wire fuses or micro fuse or Automatic Circuit Brakers
*** EU fuses: Bussmann HLS, 690V/125A
US fuses: Bussmann FWP-xxA14F, Size 14x51mm with 800Vdc UL approval
5.2.6 Ambient conditions, ventilation, mounting position
Storage hints ð p.13

Transport hints ð p.13
0...+40°C under rated conditions
Ambient temperature in operation
+40...+55°C with power derating 2.5% / K
Humidity in operation rel. humidity 85%, no condensation
up to 1000 meters a.m.s.l. without restriction
Site altitude 1000…2500 meters a.m.s.l. with power derating
1.5% / 100meters
Pollution Level Pollution level 2 as per IEC 60664-1
Vibrations Class 3M1 according to IEC 60721-3-3
Enclosure Protection IP 20 according to IEC 60529
Mounting Position vertical ð p.49
Ventilation built-in fan.
The servo amplifier shuts down (error F01/F13, see p.112, motor has no torque) in case
of excessively high temperature in the control cabinet. Make sure that there is sufficient
forced ventilation within the control cabinet.

5.2.7 Conductor cross-sections
Following IEC 60204 (B2), we recommend for single-axis systems:

Interface Cross section Techn. requirements
S748: 16 mm²
AC connection 600V,80°C
S772: 25 mm²
S748: 25 mm² 1000V, 80°C,
DC bus link
S772: 25 mm² shielded for lengths >0.50m
S748: 35 mm² 1000V, 80°C,
Brake resistor
S772: 35 mm² shielded for lengths >0.50m
S748: 16 mm² 600V,80°C,
Motor cables
S772: 25 mm² shielded, C<150pF/m
Resolver, motor thermal control, twisted pairs,
4x2x0.25 mm²
max.100m* shielded, C<120pF/m
Encoder, motor thermal control,
7x2x0.25 mm² twisted pairs, shielded
max. 50m*
ComCoder, motor thermal con-
8x2x0.25 mm² twisted pairs, shielded
trol, max. 25m
Set points, AGND, max 30m 0.25 mm² twisted pairs, shielded
Control signals, BTB, DGND,
0.5 mm²
max. 30m
600V, 80°C, shielded,
Holding brake (Motor) min. 0.75 mm²
check voltage drop
+24 V Electronics, max 30m max. 1.5 mm² check voltage drop
+24 V Motor brake, max 30m max. 1.5 mm² check voltage drop
For multi-axis systems, observe the specific operating conditions for your system.
To reach functional safety with the max. permitted cable length, observe cable
requirements ð p. 55.
* Kollmorgen North America supplies cables up to 39 meters
* Kollmorgen Europe supplies cables up to max. length
5.3 LED display

A 3-character LED display indicates the status of the amplifier after switching on the 24V
supply (ð p.111). When the keys on the front panel are used, the parameter and function
numbers are shown, as well as the numbers for any errors and warnings that may occur
(ð p.112ff).
5.4 Grounding system

AGND analog inputs, internal analog ground
DGND 24V-IO, digital inputs and outputs, optically isolated.
GND internal digital ground, encoder Emulation, RS232, CAN
XGND 24V supply, STO Enable
BRGND 24V supply for the motor holding brake

5.5 Motor holding brake

A 24V holding brake in the motor can be controlled directly by the amplifier. A special 24V
supply voltage (X9B) is used. Brakes with up to 3A can be controlled directly.
CAUTION
This function does not ensure functional safety! Danger by falling load (in
case of suspended load, vertical axes). An additional mechanical brake is
required for funktional safety, which must be safely operated, e.g. via the
Safety Card S1-2 (see p. 140).
The brake only works with sufficient voltage level (ð p.25). Check voltage drop, measure
the voltage at brake input and check brake function (brake and no brake).
The brake function must be enabled through the BRAKE setting (screen page: Motor). In
the diagram below you can see the timing and functional relationships between the
ENABLE signal, speed setpoint, speed and braking force. All values can be adjusted with
parameters, the values in the diagram are default values.
During the internal ENABLE delay time of 100ms (DECDIS), the speed setpoint of the
servo amplifier is internally driven down an adjustable ramp to 0V. The output for the
brake is switched on when the speed has reached 5 rpm (VELO), at the latest after 5 s
(EMRGTO). The release delay time (tbrH) and the engage delay time (tbrL) of the holding
brake that is built into the motor are different for the various types of motor (see motor
manual), the matching data are loaded from the motor database when the motor is selec-
ted. A description of the interface can be found on page 64.

5.6 Dynamic Braking

During braking with the aid of the motor, energy is fed back into the servo amplifier. This
generated energy is dissipated as heat in the brake resistor. The brake resistor is swit-
ched in by the brake circuit.
The setup software can be used to adapt the brake circuit (thresholds) according to the
electrical supply voltage.
Our customer service can help you with the calculation of the brake power that is neces-
sary for your system. A simple method is described in the "Product Wiki" which is acces-
sible at www.wiki-kollmorgen.eu. A description of the interface can be found on page 63.
Functional description:
1.- Individual amplifiers, not coupled through the DC bus link circuit (DC+, DC-)
When the energy fed back from the motor has an average or peak power that exceeds
the preset level for the brake power rating, then the servo amplifier generates the warning
“n02 brake power exceeded” and the brake circuit is switched off.
The next internal check of the DC bus link voltage (after a few milliseconds) detects an
overvoltage and the output stage is switched off, with the error message “Overvoltage
F02” (ð p.112).
The BTB/RTO contact (terminals X3B/14,15) will be opened at the same time (ð p.92)
2.- Several servo amplifiers coupled through the DC bus link (DC+, DC-)
Using the built-in brake circuit, several amplifiers of the same series can be operated off a
common DC bus link (observe page 62), without requiring any additional measures.
90% of the combined power of all amplifiers is always available for peak and continuous
power. The switch-off on overvoltage takes place as described under 1. (above) for the
amplifier that has the lowest switch-off threshold (resulting from tolerances).
Technical data of the brake circuits depend on the mains voltage (VBUSBAL).
Technical Data Brake Circuit Supply voltage (VBUSBAL)

4*: 480V
Rated data DIM 1: 230V 2: 400V 3*: 480V
S748/772
Switch-on threshold of brake circuit V 400 720 840 790
Overvoltage F02 V 455 800 900 900
Pulse brake power kW 16 50 70 70
External brake resistor (RBe) for S748 Ohm 15
External brake resistor (RBe) for S772 Ohm 10
Continuous brake power external (RBe) kW 8
* Kollmorgen recommends setting VBUSBAL=4 in case of 480V mains supply, with this
setting the optimized calculation method is used.
Suitable external brake resistors can be found in our accessories manual.

5.7 Switch-on and switch-off behavior

This chapter describes the switch-on and switch-off behavior of the S748/772 and the
steps required to achieve operational stopping or emergency stop behavior that complies
with standards.
The ASCII commands ACTFAULT (error response, also depends on the specific error,
see ERRCODE) and STOPMODE (Enable signal response) dictate how the drive will
behave.
ACTFAULT / Behavior (see also ASCII reference in the online help of the setup soft-
STOPMODE ware)
0 Motor coasts to a standstill in an uncontrolled manner
1 (default) Motor is braked in a controlled manner
Behavior during a power failure

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

If the undervoltage threshold is undershot in the DC bus link (the threshold value
depends on the type of servo amplifier), the error message “UNDERVOLTAGE, F05" is
displayed. The drive response depends on the ACTFAULT/STOPMODE setting.
Behavior with enabled “holding brake” function
Servo amplifiers with an enabled holding brake function have a special procedure for
switching off the output stage ( ð p. 28). Removing the ENABLE signal triggers electrical
braking.
As with all electronic circuits, the general rule applies that there is a possibility of the inter-
nal “holding brake” module failing. Functional safety, e.g. with hanging load (vertical
axes), requires an additional mechanical brake which must be safely operated, e.g. via
the Safety Card S1-2.
Behavior of the safety function STO
With the functional safe restart lock STO, the drive can be secured on standstill using its
internal electronics so that even when power is being supplied, the drive shaft is protec-
ted against unintentional restart. The chapter “Safety function STO” describes how to use
the STO function. See page 35 onwards.

5.7.1 Behavior in standard operation
The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc. see online
help). The diagram below illustrates the correct functional sequence for switching the
servo amplifier on and off.
Devices which are equipped with a selected “Brake” function use a special sequence for
switching off the output stage (ð p.28).
The built-in safety function STO can be used to switch off the drive, so that functional
safety is ensured at the drive shaft (ð p. 35).
In case of a built-in safety card, wait for the Ready Acknowledge (X30 Pin 16) of the
safety card before enabling the servo amplifier again.

5.7.2 Behavior in the event of an error (with standard setting)
The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help).
CAUTION
Some faults (see ERRCODE ) force the output stage to switch-off
immediately, independant from the ACTFAULT setting. Danger of injury
by uncontrolled coasting of the load. An additional mechanical brake is
required for funktional safety, which must be safely operated
The diagram shows the startup procedure and the procedure that the internal control
system follows in the event of motor overtemperature, assuming that the standard para-
meter settings apply. Fault F06 does not switch-off the output stage immediately, with
ACTFAULT=1 a controlled emergeny brake is started first.
(F06 = error messages "Motor Temperature")
Even if there is no intervention from an external control system (in the example, the
ENABLE signal remains active), the motor is immediately braked using the emergency
stop ramp if this error is detected and assuming that no changes have been made to the
factory setting (ACTFAULT=1).
In case of a built-in safety card, wait for the Ready Acknowledge (X30 Pin 16) of the
safety card before enabling the servo amplifier again.

5.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204

With the functional safe, certified function STO (see page 35 onwards) the drive can be
secured on standstill (torque-free) using its internal electronics so that even when power
is being supplied, the drive shaft is protected against unintentional restart (SIL CL3
according to IEC 62061, PLe according to ISO 13849-1).
With built-in “Safety” expansion card, more safe drive functions in accordance with IEC
61800-5-2 (see page 142 ff) are provided.
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to implement

the stop and emergency stop categories. If necessary, change the parameters via the
terminal screen of the setup software and store the data in the EEPROM.
Examples for implementation can be found in the Product WIKI on page "Stop and
Emergency Stop Function".
5.8.1 Stop
The Stop function is used to shut down the machine in normal operation. The Stop
functions are defined by IEC 60204.
Category 0: Shut-down by immediate switching-off of the energy supply to the
drive machinery (i.e. an uncontrolled shut-down); this can be done
with the built-in STO functionality (see page 35)
Category 1: A controlled shut-down , whereby the energy supply to the drive
machinery is maintained to perform the shut-down, and the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, whereby the energy supply to the drive
machinery is maintained.
The Stop Category must be determined by a risk evaluation of the machine. In addition,
suitable means must be provided to guarantee a reliable shut-down.
Category 0 and Category 1 Stops must be operable independently of the operating mode,
whereby a Category 0 Stop must have priority. Stop functions must be implemented by
disconnection of the appropriate circuitry, and have priority over assigned start
functions.
If necessary, provision must be made for the connection of protective devices and
lock-outs. If applicable, the Stop function must signal its status to the control logic. A reset
of the Stop function must not create a hazardous situation.

5.8.2 Emergency Stop
The Emergency Stop function is used for the fastest possible shutdown of the machine
in a dangerous situation. The Emergency Stop function is defined by IEC 60204. Princi-
ples of emergency stop devices and functional aspects are defined in ISO 13850.
The Emergency Stop function will be triggered by the manual actions of a single person.
It must be fully functional and available at all times. The user must understand instantly
how to operate this mechanism (without consulting references or instructions).
The Stop Category for the Emergency Stop must be determined by a risk evaluation of
the machine.
In addition to the requirements for stop, the Emergency Stop must fulfil the following
requirements:
l Emergency Stop must have priority over all other functions and controls in all opera-
ting modes.
l The energy supply to any drive machinery that could cause dangerous situations
must be switched off as fast as possible, without causing any further hazards ( Stop
Category 0) or must be controlled in such a way, that any movement that causes
danger, is stopped as fast as possible (Stop Category 1).
l The reset must not initiate a restart.
5.8.3 Emergency Off
The Emergency Off function is used to switch-off the electrical power supply of the
machine. This is done to prevent users from any risk from electrical energy (for example
electrical impact). Functional aspects for Emergency Off are defined in IEC 60364-5-53.
The Emergency Off function will be triggered by the manual actions of a single person.
The result of a risk evaluation of the machine determines the necessity for an Emergency
Off function.
Emergency Off is done by switching off the supply energy by electro-mechanical swit-
ching devices. This results in a category 0 stop. If this stop category is not possible in the
application, then the Emergency Off function must be replaced by other measures (for
example by protection against direct touching).

5.9 Safety Function STO

A frequently required application task is the safe torque off and the protection of person-
nel against unintentioned restarting of drives. The S748/772 servo amplifier offers, even
in the basic version, a two channel STO function (Safe Torque Off). The function blocks
the trigger pulses of the power transistors (pulse inhibitor).
Advantages of the safety function STO :
— the DC bus link remains charged up, since the mains supply line remains active
— only low voltages are switched, so there is no contact wear
— very little wiring is required
— single or dual channel control possible
— SIL2 or SIL3 solutions possible
The STO safety function corresponds to stop category 0 (uncontrolled stopping) acc. to
EN 60204-1. The safety function STO can be operated from external safety switch gears
(relays), from a safe external control (semiconductor output or driven contact) or from the
built-in safety card S1-2 or S2-2 (see p. 142).
The STO safety concept is certified by the TÜV. The safety circuit concept for realizing
the safety function "Safe Torque Off" in the servo amplifiers S748/772 is suited for
SIL CL3 according to IEC 62061 and PLe according to ISO 13849-1.
SIL2 / PLd solutions can be implemented with single-channel or dual-channel control with
simple safety switching devices.
A SIL3 / PLe solution requires a safety control that periodically tests the safe switching of
the pulse inhibitor by analyzing the feedback (status) signals.
5.9.1 Safety characteristic data
The subsystems (servo amplifiers) are totally described for safety technics with the
characteristic data SIL CL, PFHD and TM.
Device Operation mode EN 13849-1 EN 62061 PFHD [1/h] TM [Year]
STO single channel PLd, Cat. 3 SIL CL 2 7,05E-08 20
STO dual channel PLd, Cat. 3 SIL CL 2 7,05E-08 20
dual channel with
STO PLe, Cat. 4 SIL CL 3 1,38E-09 20
periodical testing
5.9.2 Enlosure
Since the servo amplifier meets enclosure IP20, you must select the enclosure ensuring a
safe operation of the servo amplifier referring to the enclosure. The enclosure must meet
IP54 at least.
5.9.3 Wiring
When using STO wiring leads outside the control cabinet, the cables must be laid durably
(firmly), protected from outside damage (e.g. laying in a cable duct), in different sheathed
cables or protected individually by grounding connection. Wiring remaining within the
demanded enclosure must meet the requirements of the standard IEC 60204-1.

5.9.4 Important notes
WARNING
The function STO does not provide an electrical separation from the
power output. Risk of electric shock! If access to the motor power
terminals is necessary, the S748/772 must be disconnected from mains
supply considering the discharging time of the intermediate circuit.
In case of single channel control:
If the STO is automatically activated by a control system, then make sure that the output
of the control is supervised for possible malfunction. This can be used to prevent a faulty
output from unintentionally activating the function STO. Since STO is used in a
single-channel system, erroneous engaging will not be recognized.
Controlled braking
When STO is engaged during operation by separating input STO1-Enable and
STO2-Enable from 24 VDC, the motor runs down out of control and the servo amplifier
displays the error F27. There is no possibility of braking the drive controlled. Risk from
uncontrolled movement!
If a controlled braking before the use of STO is necessary, the drive must be braked and
the inputs STO1-ENABLE and STO2-Enable have to be separated from +24 VDC
time-delayed.
Keep to the following functional sequence when STO is used :
1. Brake the drive in a controlled manner (speed setpoint = 0V)
2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)
3. If there is a suspended load, block the drive mechanically
4. Activate STO (STO1-Enable and STO2-Enable = 0V
5.9.5 Use as directed STO
The STO function is exclusively intended to provide functional safety, by preventing the
restart of a system. To achieve this functional safety, the wiring of the safety circuits must
meet the safety requirements of IEC 60204, ISO 12100, IEC 62061 respectively ISO
13849-1.
In case of single channel control: if STO is automatically activated by a control system,
then make sure that the output of the control is monitored for possible malfunction.
To achieve PLe or SIL CL3, the safe switching of the pulse inhibitor must be tested peri-
odically by analyzing the feedback signal from the safety control (ð p. 44).
5.9.6 Prohibited Use STO
The STO function must not be used if the drive is to be made inactive for the following
reasons :
1. Cleaning, maintenance and repair operations, long inoperative periods:
In such cases, the entire system should be disconnected from the supply by the
personnel, and secured (main switch).
2. Emergency-stop situations:
In an emergency-off situation, switched off the main contactor (by the
emergency-off button).

5.9.7 Technical data and pinning
Input voltage 20V..30V

Input current 33mA – 40mA (Ieff)
Peak current 100mA (Is)
Response time (falling edge at STO input STO1: 1ms
until energy supply to motor is interrupted) STO2: 2ms
A SIL3 / PLe solution requires a safety control that periodically tests the safe switching of
the pulse inhibitor by analyzing the status signals.

5.9.8 Functional description
In case of use of the STO function the inputs STO1- Enable and STO2-Enable must be
connected to the exits of a safety control or a safety relay, which meets at least to the
requirements of the SIL CL2 according to IEC 62061 and PLd according to ISO 13849-1
(see the connection diagrams from page 40).
Possible states of the servo amplifier in connection with STO:
STO1-ENABLE Motor has SIL CL2 or 3

ENABLE Display
STO2-ENABLE torque safety
0V 0V -S- no yes
0V +24 V F27 no yes
+24 V 0V normal status e.g. 06 no no
+24 V +24 V normal status e.g. E06 yes no
SIL2/PLd Single Channel Control
With the single-channel control of the STO (SIL2/PLd) safety function, both switch-off
paths STO1-Enable and STO2-Enable are switched by one output of a safety switching
device (e.g. safety relay), see example ð p. 40.
In case of single channel usage of STO, erroneous engaging will not be recognized. The-
refore the output of the control must be supervised for possible malfunction.
SIL2/PLd Dual Channel Control
With the dual-channel control of the STO (SIL2/PLd) safety function, the switch-off paths
STO1-Enable and STO2-Enable are switched separately by two outputs of a safety swit-
ching device (e.g. safety relay), see example on ð p. 41.
SIL3/PLe Dual Channel Control
With the dual-channel control of the STO safety function, the switch-off paths
STO1-Enable and STO2-Enable are switched separately by two outputs of a safety con-
trol, see example on ð p. 42.
To achieve PL e or SIL CL 3, the safe switching of the pulse inhibitor must be tested peri-
odically by analyzing the feedback (status) signals from the safety control (ð p. 44).
When wiring the STO inputs within one enclosure it must be paid attention to the fact that
the used cables and the enclosure meet the requirements of IEC 60204-1.
If the wiring leads outside the demanded enclosure, the cables must be laid durably
(firmly), and protected from outside damage (see chapter 5.9.3).
If STO function is not needed in the application, then the inputs STO1-ENABLE and
STO2-ENABLE must be connected directly with +24VDC. STO is passed by now and
cannot be used. Now the servo amplifier is not a safety component referring to the EC
Machine Directive.

5.9.8.1 Safe operation sequence
WARNING
If the STO function is activated, the amplifier cannot hold the load, the
motor no longer supplies torque. Risk of injury from suspended load!
Drives with suspended loads must also be safely blocked using a
mechanical means (e.g. with the motor holding brake).
CAUTION
When STO is engaged during operation by separating input STO1-Enable
and STO2-Enable from 24 VDC, the motor runs down out of control and
the servo amplifier displays the error F27. There is no possibility of
braking the drive controlled. Risk from uncontrolled movement!
If a controlled braking before the use of STO is necessary, the drive must be braked and
the inputs STO1-ENABLE and STO2-Enable have to be separated from +24 VDC
time-delayed.
1. Brake the drive in a controlled manner (speed setpoint = 0V)

2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)
3. If there is a suspended load, block the drive mechanically
4. Activate STO (STO1-Enable and STO2-Enable = 0V)
The diagram shows how STO should be used to ensure a safe stop of the drive and error
free operation of the servo amplifier.

5.9.8.2 Control circuit single channel SIL CL2/PLd (example)
The example shows a circuit diagram with one axis connected to an emergency stop cir-
cuit. The STO of the drives is switched by a protective screen. A single channel switch-off
is used. The safety switch gears used in the example are manufactured by Pilz and fulfill
at least the PLd acc. to ISO 13849-1. Further information to the safety switch gears is
available from Pilz. The use of safety switch gears of other manufacturers is possible, if
these also fulfill the SIL CL 2 according to IEC 62061 and PLd according to ISO 13849-1.
Emergency-stop circuit
acc. to ISO 13849-1
PLe
Safety function STO, SIL CL2 / PLd, single channel, 1 drive
Consider the wiring instructions on page 35.

5.9.8.3 Control circuit dual channel SIL CL2/PLd (example)
cuit. The STO of the drives is switched by a protective screen. A dual channel switch-off
is used. The safety switch gears used in the example are manufactured by Pilz and fulfill
at least the PLd acc. to ISO 13849-1. Further information to the safety switch gears is
available from Pilz. The use of safety switch gears of other manufacturers is possible, if
these also fulfill the SIL CL 2 according to IEC 62061 and PLd according to ISO 13849-1.
acc. to ISO 13849-1
PLe
Safety function STO, SIL CL2 / PLd, dual channel, 1 drive
Consider the wiring instructions on page 35.

5.9.8.4 Control circuit dual channel SIL CL3/PLe (example)
cuit. The STO of the drives is switched by a protective screen. A dual channel switch-off
is used. The safe switching of the pulse inhibitor must be tested periodically by analyzing
the feedback signals (status) in the safety control.
The safety controller used in the example is manufactured by Pilz and fulfills at least the
PLe acc. to ISO 13849-1. Further information to the safety controllers are available from
Pilz. The use of safety controlelrs of other manufacturers is possible, if these also fulfill
the SIL CL 3 according to IEC 62061 and PLe according to ISO 13849-1.
acc. to ISO 13849-1
PLe
Safety function STO, SIL CL3 / PLe, dual channel, 1 drive
Consider the wiring instructions on page 35

5.9.8.5 Mains supply circuit (example)
S748/772
5.9.9 Functional test
5.9.9.1 SIngle or Dual Channel control, SIL CL2 / PLd
With initial starting and after each interference into the wiring of the drive or after
exchange of one or several components of the drive the function of STO must be tested.
1. Method:
1. Stop drive, with setpoint 0V, keep servo amplifier enabled (Enable=24V).
DANGER: Do not enter hazardous area!
2. Activate STO1-Enable and STO2-Enable e.g. by opening protective screen
(voltage at X4A/3=0V and X4B/6=0V).
Correct behavior: the BTB/RTO contact opens, the net contactor releases and the servo
amplifier displays error F27.
2. Method:
1. Stop all drives, with setpoint 0V, disable servo amplifier (Enable=0V).
2. Activate STO1-Enable and STO2-Enable e.g. by opening protective screen
(voltage at X4A/3=0V and X4B/6=0V).
Correct behavior: the servo amplifier displays -S-.

5.9.9.2 SIL CL3 / PLe Dual Channel control
To achieve PLe / SIL CL3, the safe switching of the pulse inhibitor must be tested
periodically by analyzing the feedback signal from a safety control:
l At the start of a system
l At the restart after triggering a protective device
l At least every 8 hours by the operator.
The inputs STO1-ENABLE and STO2-ENABLE are switched in turns according to a defi-
ned test sequence. The switching states of the pulse inhibitor are available at the status
outputs of the S748/772 and are analyzed by a safety control.
The test sequence for the functional test of the safe pulse inhibitor must be performed as
shown in the following time chart.
Prerequisites for the start of the test sequence:
l Operational readiness BTB/RTO = “1"
l Enable signal ENABLE = “0"
l STO1-ENABLE and STO2-ENABLE = “0"
Legend:
STO1-ENABLE: digital input, 1st switch-off path STO2-ENABLE: digital input, 2nd switch-off path
STO1-STATUS: digital output, switching state of pulse inhibitor 1st switch-off path
STO2-STATUS: digital output, switching state of pulse inhibitor 2nd switch-off path
T1 … T5: Test sequence
Start: Start of test sequence End: End of test sequence

5.10 Shock-hazard protection

5.10.1 Leakage current
Leakage current via the PE conductor results from the combination of equipment and
cable leakage currents. The leakage current frequency pattern comprises a number of
frequencies, whereby the residual-current circuit breakers definitively evaluate the 50Hz
current. As a rule of thumb, the following assumption can be made for leakage current on
our low-capacity cables at a mains voltage of 400 V, depending on the clock frequency of
the output stage:
Ileak = n x 20mA + L x 1mA/m at 8kHz clock frequency at the output stage
Ileak = n x 20mA + L x 2mA/m at a 16kHz clock frequency at the output stage
(where Ileak=leakage current, n=number of amplifiers, L=length of motor cable)
At other mains voltage ratings, the leakage current varies in proportion to the voltage.
Example: 2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:
2 x 20mA + 25m x 1mA/m = 65mA leakage current.
Since the leakage current to PE is more than 3.5 mA, in compliance with IEC 61800-5-1
the PE connection must either be doubled or a connecting cable with a cross-section
>10mm² must be used. Use the PE terminals and the PE bolt in order to fulfil this
requirement.
The following measures can be used to minimize leakage currents.
— Reduce the length of the engine cable
— Use low-capacity cables (see p.55)
— Remove external EMC filters (radio-interference suppressors are integrated)
5.10.2 Residual current protective device (RCD)
In conformity with IEC 60364-4-41 – Regulations for installation and IEC 60204 – Electri-
cal equipment of machinery, residual current protective devices (called RCD below) can
be used provided the requisite regulations are complied with. The S748/772 is a 3-phase
system with a B6 bridge. Therefore, RCDs which are sensitive to all currents must be
used in order to detect any D.C. fault current.
Rated residual currents in the RCD
Protection against "indirect contact" for stationary and mobile equipment,
10 -30 mA
as well as for "direct contact".
50 -300 mA Protection against "indirect contact" for stationary equipment
Recommendation: In order to protect against direct contact (with motor cables shorter
than 5 m) we recommend that each servo amplifier be protected individually using a
30mA RCD which is sensitive to all currents.
If you use a selective RCD, the more intelligent evaluation process will prevent spurious
tripping of the RCD.
5.10.3 Isolating transformers
When protection against indirect contact is absolutely essential despite a higher leakage
current, or when an alternative form of shock-hazard protection is sought, the S748/772
can also be operated via an isolating transformer (schematic connection see p.60). A
ground-leakage monitor can be used to monitor for short circuits.
Be advised to keep the length of wiring between the transformer and the servo amplifier
as short as possible.


Kollmorgen 12/2014 Mechanical Installation
6 Mechanical Installation
6.1 Important notes
WARNING
There is a danger of electrical shock by high EMC level which could result
in injury, if the servo amplifier (or the motor) is not properly
EMC-grounded. Do not use painted (i.e. non-conductive) mounting
plates. In unfavourable circumstances, use copper mesh tape between
the earthing bolts and earth potential to deflect currents.
Protect the servo amplifier from impermissible stresses. In particular, do not let any
components become bent or any insulation distances altered during transport and
handling. Avoid contact with electronic components and contacts.
The servo amplifier will switch-off itself in case of overheating. Ensure that there is an
adequate flow of cool, filtered air into the bottom of the control cabinet, or use a heat
exchanger. Please refer to page 26.
Don't mount devices, which produce magnetic fields, directly beside the servo amplifier.
Strong magnetic fields could directly affect internal components. Install devices which
produce magnetic field with distance to the servo amplifiers and/or shield the magnetic
fields.
6.2 Guide to mechanical installation

The following notes should help you to carry out the mechanical installation.
In a closed control cabinet. Please refer to page 26.

Site The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p.49.
Check that the ventilation of the servo amplifier is unimpeded, and

Ventilation keep within the permitted ambient temperature ð p.26. Keep the re-
quired space clear above and below the servo amplifier ð p.49.
Assemble the servo amplifier and power supply close together, on the
Assembly
conductive, grounded mounting plate in the cabinet.
For EMC-compliant shielding and grounding ð p.59.

Grounding
Ground the mounting plate, motor housing and CNC-GND of the
Shielding
control system. Notes on connection techniques ð p.54.

Mechanical Installation 12/2014 Kollmorgen
6.3 Dimensions

Kollmorgen 12/2014 Mechanical Installation
6.4 Assembly
6.4.1 Mounting the shielding plate
Material: unscrew existing screws and re-use them

Tool required : standard screw driver (cross)

Mechanical Installation 12/2014 Kollmorgen
6.4.2 Backplane mounting
Material: four M5 hexagon socket screws to ISO 4762

Tool required : 4 mm Allen key

Kollmorgen 12/2014 Electrical installation
7 Electrical installation
7.1 Important notes
WARNING
There is a danger of electrical arcing when disconnecting connectors,
because capacitors can still have dangerous voltages present up to ten
minutes after switching off the supply power.
Risk of burns and blinding. The contacts become damaged.
Never undo any electrical connections to the servo amplifier while it is
live. Wait at least ten minutes after disconnecting the installations from
the main supply power before touching potentially live sections of the
equipment (e.g. contacts) or undoing any connections.
To be sure, measure the voltage in the DC Bus link and wait until it has
fallen below 60V. Control and power connections can still be live, even if
the motor is not rotating.
Wrong mains voltage, unsuitable motor or wrong wiring will damage the amplifier.
Check the combination of servo amplifier and motor. Compare the rated voltage and
current of the units. Implement the wiring according to the connection diagram on p. 53.
Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or
+DC, –DC is not exceeded by more than 10% even in the most unfavorable
circumstances (see IEC 60204-1).
Excessively high external fusing will endanger cables and devices. The fusing of the AC
supply input and 24V supply must be installed by the user, best values are given on p.26.
Hints for use of Residual-current circuit breakers (FI) ð p.45.
Correct wiring is the basis for reliable functioning of the servo system.
Route power and control cables separately. We recommend a distance of at least
200mm. This improves the interference immunity. If a motor power cable is used that
includes cores for brake control, the brake control cores must be separately shielded.
Ground the shielding at both ends. Ground all shielding with large areas (low impedance),
with metalized connector housings or shield connection clamps wherever possible. Notes
on connection techniques can be found on page 54.
Feedback lines may not be extended, since thereby the shielding would be interrupted
and the signal processing could be disturbed. Lines between amplifiers and external
brake resistor must be shielded. Install all cables with an adequate cross-section, as per
IEC 60204 (ð p.27) and use the requested cable material (ð p. 55) to reach max. cable
length.
The servo amplifier's status must be monitored by the PLC to acknowledge critical
situations. Wire the BTB/RTO contact in series into the emergency stop circuit of the
installation. The emergency stop circuit must operate the supply contactor.
It is permissible to use the setup software to alter the settings of the servo amplifier. Any
other alterations will invalidate the warranty.

Electrical installation 12/2014 Kollmorgen
7.2 Guide to electrical installation

The following notes should help you to carry out the electrical installation.
Cable selection Select cables in accordance with IEC 60204 ð p.27.
For EMC-compliant shielding and grounding ð p.59.

Grounding
Ground the mounting plate, motor housing and CNC-GND of the
Shielding
control system. Notes on shield connection techniques ð p.54.
NOTE: Route power leads and control cables separately.

Wiring Wire the BTB/RTO contact in series into the emergency stop
circuit of the system.
1. Connect the digital control inputs and outputs.
2. Connect the analog input source, if required.
3. Connect the feedback device.
4. Connect the expansion card
— (see corresponding notes from page 115).
5. Connect the motor cable
— Connect shielding at both ends.
6. Connect motor-holding brake, connect shielding at both ends.
7. Connect external brake resistor (with fusing)
8. Connect the auxiliary supply
— (maximum permissible voltage values ð p.26).
9. Connect the main electrical supply
— (maximum permissible voltage values ð p.26), hints for use of
Residual-current circuit breakers (FI) ð p.45
10.Connect the PC (ð p.93).
Final check of the implementation of the wiring against the wiring

Final check
diagrams that have been used.

7.3 Wiring
The installation procedure is described as an example. A different procedure may be
appropriate or necessary, depending on the application of the equipments.
We provide further know-how through training courses (on request).
DANGER
Severe electric shock injuries or death may be sustained when working
on installations which have not been disconnected.
Only professional staff who are qualified in electrical engineering are
allowed to install the servo amplifier.
Only install and wire up the equipment when it is not live, i.e. when
neither the electrical supply nor the 24 V auxiliary voltage nor the supply
voltages of any other connected equipment is switched on.
Take care that the cabinet is safely disconnected (with a lock-out,
warning signs etc.). The individual voltages will be switched on for the first
time during setup.
The ground symbol X , which you will find in all the wiring diagrams, indicates that you
must take care to provide an electrically conductive connection with the largest feasible
surface area between the unit indicated and the mounting plate in the control cabinet.
This connection is for the effective grounding of HF interference, and must not be
confused with the PE-symbol W (PE = protective earth, safety measure as per IEC
60204).
Use the following connection diagrams:

Overview : page 59
Restart lock STO : page 40
Mains power : page 61
Motor : page 64
Feedback : page 66ff
Electronic Gearing / Master Slave
Master-Slave : page 83
Pulse-Direction : page 84
Digital and analog inputs and outputs : page 88ff
RS232 / PC : page 93
CAN Interface : page 94
EtherNET Interface : page 95
Expansion cards for slot 1:
I/O-14/08 : page 118
PROFIBUS : page 119
sercos® II : page 121
DeviceNet : page 122
SynqNet : page 126
FB-2to1 : page 127
2CAN : page 129
PosI/O & PosI/O-Monitor : page 132ff
PosI/O & PosI/O-Monitor : page 136ff
Safety : page 142ff

7.3.1 Shielding connection to the front panel
Remove the outside shroud of the cable

and the shielding braid on the desired core
length. Secure the cores with a cable tie.
Remove the outside shroud of the line on a

length from for instance 30mm without da-
maging the shielding braid.
Strip all wires and fit wire end ferrules.
Use cable ties to attach the cable to the

side (1) shroud or bottom (2) shielding plate
of the servo amplifier, securing the braided
shield of the cable to the shroud of the
servo amplifier with a cable tie.
Alternatively you can use shield connection

terminal clamps (see accessories manual).
These hook into the bottom shroud and en-
sure optimum contact between the shield
and the shroud.
Wire the plug-in terminal blocks as shown in

the connection diagram.

The motor cable shield is connected via a
shield connection clamp to the bottom shiel-
ding plate (3). Clamp and shielding plate
are part of delivery.

7.3.2 Technical data for connecting cables
For further information on the chemical, mechanical and electrical characteristics of the
cables please refer to the accessories manual or contact our customer service.
Observe the rules in the section "Conductor cross-sections" on page 27. To reach the
max. permitted cable length, you must use cable material that matches the capacitance
requirements listed below.
Capacitance (phase to shield)

Motor cable less than 150 pF/m
Resolver/Encoder cable less than 120 pF/m
Example: Motor cable
Technical data
For a detailed description of Kollmorgen cable types and how to assemble them, please
refer to the accessories manual.
Chokes
With motor cables longer than 25m the use of a motor choke 3YLN may be necessary
depending on the system. Contact our customer support.
If mains voltage is more than 3% asymmetrical, a mains choke 3L with 2% uk must be

used. See Accessories Manual.

7.4 Components of a servo system
Mains
PC
Drive cut-out
S748/S772
EtherNET
PLC
Brake Resistor
Feedback cable
Power Cable
Brake Cable
24V PSU
Motor
Mains
Cables drawn bold are shielded. The required accessories are described in our
accessories manual.

7.5 Block diagram

The block diagram below just provides an overview.

7.6 Connector assignments

7.7 Connection Diagram (Overview)

Reference Safety Instructions (ð p.10)
and Use As Directed (ð p.12) ! S748/S772
ð p.88
ð p.66ff
ð p.67 ð p.89
ð p.64
ð p.65
ð p.89
ð p.63
ð p.91
ð p.61 ð p.94
ð p.93
ð p.61

7.8 Electrical supply

7.8.1 Connection to various mains supply networks
WARNING
There is a danger of electrical shock with serious personal injury or death
if the servo amplifier isn't properly grounded. An isolating transformer is
required for 400V to 480V networks that are asymmetrically grounded or
not grounded as shown below.
S748/772
S748/772 S748/772
S748/772 S748/772
S748/772 S748/772
S748/772 S748/772
S748/772 S748/772

7.8.2 Mains supply connection (X0)
— Directly to 3-phase supply network, filter is integrated, supply networks ð p.60

— Fusing (e.g. fusible cut-outs) to be provided by the user ð p.26
— Screw driver for plus-minus-screws (Combiprofile Slotted/Pozidriv) size 2
S748/772
If mains voltage is more than 3% asymmetrical, a mains choke 3L with 2% uk must be

used. See Accessories Manual. For EMC reasons the choke should be mounted
electrically isolated to the cabinet.
S748/772
7.8.3 24V auxiliary supply (X4)
— External 24V DC power supply, electrically isolated, e.g. via an isolating transformer
— Required current rating ð p.24
— Integrated EMC filter for the 24V auxiliary supply
S748/772

7.9 DC bus link (X8)

Terminals X8/-DC and X8/+DC. Can be connected in parallel, whereby the brake power
is divided between all the amplifiers that are connected to the same DC bus link circuit.
In case of mains supply from the same mains (identical mains supply voltage) three servo
amplifiers S748/772 may be connected by the DC bus link.
The servo amplifiers can be destroyed, if DC bus link voltages are different. Only servo
amplifiers with mains supply from the same mains (identical mains supply voltage) may
be connected by the DC bus link. The setting of VBUSBAL must be identical with all
devices on the bus.
The sum of the rated currents for all of the servo amplifiers connected in parallel to an
S748/772 must not exceed 96 Arms (140 Apeak).
Use unshielded single cores (cross section see p. 27) with a max. length of 500mm. Use
shielded cables for longer lengths.
Fusing information are explained in detail in the "Product Wiki", available at
www.wiki-kollmorgen.eu, on the WIKI page "DC Bus link in parallel".
S748/772 S748/772
S748/772

7.9.1 DC Bus topology
Without intermediate circuit fuses, other devices can become damaged or destroyed if,
for example, a device fails due to an internal short circuit. If a device fails due to a
short-circuit, only its intermediate fuses are tripped and the rest of the network continues
uninterrupted. Fuses cannot avoid damage by current peaks completely.
Fuse types: see section "Fuses" on page 26.
The solid busbars can conduct large currents. For this reason, almost as many servo
amplifiers as desired can be connected in parallel in this form.
S700 S700 S700 S700 S700 S700
DC DC DC DC DC DC
7.9.2 External brake resistor (X8)
An external brake resistor can be connected to X8 (-RB, +RB). Fuse types: see section
"Fuses" on page 26. Information for brake circuit and technical data can be found on
page 29.
If you want to link the DC bus with neighbored S748/772 servo amplifiers, see connection
example on page 62, Chapter "DC Bus link".
S748/772

7.10 Motor connection

7.10.1 Motor Power Connection (X8)
The S748/772 drive is able to protect the connected motor from overloading, if the para-
meters are set correctly and the thermal protection sensor is connected and supervised.
With Kollmorgen motors the valid data are automatically set by the internal motor data-
base. With motors from other manufacturers the data from the nameplate must be ente-
red to the referring fields in the motor view of the setup software DriveGUI.
Together with the motor supply cable and motor winding, the power output of the servo
amplifier forms an oscillating circuit. Characteristics such as cable capacity, cable length,
motor inductance, frequency and voltage rise speed (see Technical Data, p. 24) deter-
mine the maximum voltage in the system.
The dynamic voltage rise can lead to a reduction in the motor’s operating life and, on
unsuitable motors, to flash overs in the motor winding.
— Only install motors with insulation class F (acc. to IEC 60085) or above
— Only install cables that meet the requirements on p.27 and p.55
Use screw driver for plus-minus-screws (Combiprofile Slotted/Pozidriv) size 2

Standard applications up to 25m cable length
S748/772
Application with cable length >25m and special conditions

With long motor cables overvoltage may endanger the motor winding. For cable lengths
above 25m a motor choke 3YLN may be wired into the motor cable, close to the amplifier.
Contact our customer support.
S748/772

7.10.2 Motor holding brake (X8, X9B)
The motor holding brake can be controller by the servo amplifier. An external 24V supply
voltage delivers the required electrical power for the connected brake.
CAUTION
The brake function does not ensure functional safety! Danger by falling
load (in case of suspended load, vertical axes). An additional mechanical
brake is required for functional safety, which must be safely operated,
e.g. via the Safety Card S1-2 (see p. 140).
Observe the requirements to the supply voltage listed on page 25.
S748/772

7.11 Feedback Systems

Every closed servo system will normally require at least one feedback device for sending
actual values from the motor to the servo drive. Depending on the type of feedback
device used, information will be fed back to the servo amplifier using digital or analog
means. Up to three feedback devices can be used at the same time.
S748/772 supports the most common types of feedbacks whose functions must be assig-
ned in the setup software DRIVEGUI.EXE with the parameters
FBTYPE (screen page FEEDBACK), primary Feedback
EXTPOS (screen page POSITION CONTROLLER), secondary Feedback
GEARMODE (screen page ELECTRONIC GEARING), secondary Feedback (ð p.76)
Scaling and other settings must always be made in the software. For a detailed descrip-
tion of the ASCII parameters, please refer to the online help of the setup software.
The table below provides an overview of the supported feedback types, their correspon-
ding parameters and a reference to the relevant connection diagram in each case.
primary secondary
Connec- Wiring
Feedback type FBTYPE EXTPOS
tor diagram
Resolver X2 ð p.67 0 -
SinCos Encoder BiSS (B) analog X1 ð p.68 23, 24 -
SinCos Encoder BiSS (B, C2)) digital X1 ð p.69 20, 22, 33 11, 12
SinCos Encoder ENDAT 2.1 X1 ð p.70 4, 21 8
Encoder ENDAT 2.2 X1 ð p.71 32, 34 13
SinCos Encoder HIPERFACE X1 ð p.72 2 9
SinCos Encoder SSI (linear) X1 ð p.73 26 1) -
SinCos Encoder w/o data channel X1 ð p.74 1, 3, 7, 8 6, 7
SinCos Encoder + Hall X1 ð p.75 5, 6 -
ROD* 5V without zero, 1.5MHz X1 ð p.76 30, 31 30
ROD (AquadB) 5V with zero, 350kHz X1 ð p.77 17, 27 10
ROD (AquadB) 5V with zero + Hall X1 ð p.78 15 -
ROD (AquadB) 24V without zero X3 ð p.79 12, 16 2
ROD (AquadB) 24V without zero + Hall X3/X1 ð p.80 14 -
SSI X1 ð p.81 251) 25
Hall X1 ð p.82 11 -
Step/Direction 24V X3 ð p.84 - 1
Sensorless (w/o Feedback) - - 10 -
with expansion card "PosI/O" or "PosI/O-Monitor"
ROD (AquadB) 5V with zero X5 ð p.133 131), 191) 3
ROD (AquadB) 5V with zero + Hall X5/X1 ð p.134 18 -
SSI X5 ð p.135 91) 5
SinCos Encoder SSI (linear) X1 ð p.136 28 -
Step/Direction 5V X5 ð p.137 - 4
* ROD is an abbreviation for “incremental encoder”.
1)
Switch on the encoder supply voltage on X1: set ENCVON to 1
2)
BiSS C support for Renishaw sncoders, Hengstler encoders are not supported.
The expansion card FB2to1 (see p. 127) enables simultaneous connection of a digital
primary and of an analog secondary feedback to the connector X1.

7.11.1 Resolver (X2)
Connection of a Resolver (2 to 36-poles) as a feedback system (primary, ð p.66). The

thermal control in the motor is connected via the resolver cable to X2 and evaluated
there.
If cable lengths of more than 100m are planned, please consult our customer service.
FBTYPE: 0
S748/772 SubD9 12pol.round
The pin assignment shown on the encoder side relates to the Kollmorgen motors.

7.11.2 Sine Encoder with BiSS analog (X1)
Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feed-

back system (primary, ð p.66).
The thermal control in the motor is connected via the encoder cable to X1 and evaluated
there. All signals are connected using our pre-assembled encoder connection cable. If
cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 350 kHz
Type FBTYPE EXTPOS GEARMODE Up

5V analog (BiSS B) 23 - - 5V +/-5%
12V analog (BiSS B) 24 - - 7,5...11V
SubD 15 17pol.round
S748/772

7.11.3 Sine Encoder with BiSS digital (X1)
Wiring of a single-turn or multi-turn digital encoder with BISS interface as a feedback sys-
tem (primary and secondary, ð p.66).
Frequency limit : 1.5 MHz

5V digital (BiSS B) 20 11 11 5V +/-5%
12V digital (BiSS B) 22 11 11 7,5...11V
5V digital (BiSS C, Renishaw) 33 12 12 5V +/-5%
SubD 15 17pol.round
S748/772

7.11.4 Sine Encoder with EnDat 2.1 (X1)
Wiring of a single-turn or multi-turn sine-cosine encoder with EnDat 2.1 interface as a

feedback system (primary and secondary, ð p.66). Preferred types are the optical enco-
ders ECN1313 / EQN1325 and the inductive encoders ECI 1118/1319 or EQI 1130/1331.
cable lengths of more than 50m are planned, please consult our customer service. Fre-
quency limit (sin, cos): 350 kHz
Type FBTYPE EXTPOS GEARMODE

ENDAT 2.1 4 8 8
ENDAT 2.1 + Wake&Shake 21 8 8
SubD15 17pol.round
S748/772

7.11.5 Encoder with EnDat 2.2 (X1)
Wiring of a single-turn or multi-turn encoder with EnDat 2.2 interface as a feedback sys-
tem (primary and secondary, ð p.66). The thermal control in the motor is connected via
the encoder cable to X1 and evaluated there. All signals are connected using our
pre-assembled encoder connection cable.
Frequency limit: 1.5 MHz

5V ENDAT 2.2 32 13 13 5V +/-5%
12V ENDAT 2.2 34 13 13 7,5...11V
SubD15 17pol.round
S748/772

7.11.6 Sine Encoder with HIPERFACE (X1)
Wiring of a single-turn or multi-turn sine-cosine encoder with HIPERFACE interface as a

feedback system (primary and secondary, ð p.66).
there. All signals are connected using our pre-assembled encoder connection cable.

HIPERFACE 2 9 9

7.11.7 Sine Encoder with SSI (X1)
Wiring of sine-cosine encoder with SSI interface as a linear feedback system

(primary, ð p.66).

SinCos SSI 5V linear 26 - -
SubD 15
S748/772

7.11.8 Sine Encoder without data channel (X1)
Wiring of a sine-cosine encoder without data channel as a feedback (primary and secon-
dary, ð p.66). Every time the 24V auxiliary voltage is switched on, the amplifier needs
start-up information for the position controller (parameter value MPHASE). Depending on
the feedback type either wake&shake is executed or the value for MPHASE is read out of
the amplifier's EEPROM.
WARNING
With vertical load the load could fall during wake&shake, because the
brake is not active and torque is not sufficient to hold the load.
Don't use wake&shake with vertical load (hanging load).
there. If lead lengths of more than 50m are planned, please consult our customer service.
Type FBTYPE EXTPOS GEARMODE Up Remarks

SinCos 5V 1 6 6 5V +/-5% MPHASE from EEPROM
SinCos 12V 3 7 7 7,5...11V MPHASE from EEPROM
SinCos 5V 7 6 6 5V +/-5% MPHASE wake & shake
SinCos 12V 8 7 7 7,5...11V MPHASE wake & shake
S748/772 SubD 15

7.11.9 Sine Encoder with Hall (X1)
Feedback devices (incremental or sine-cosine), which don't deliver an absolute informa-

tion for commutation, can be used as complete feedback system combined with an addi-
tional Hall encoder (primary, ð p.66).
The thermal control in the motor is connected to X1 and evaluated there.
All signals are connected to X1 and evaluated there. If cable lengths of more than 25m
are planned, please consult our customer service.

SinCos 5V with Hall 5 - - 5V +/-5%
SinCos 12V with Hall 6 - - 7,5...11V
S748/772 SubD15

7.11.10 ROD (AquadB) 5V, 1.5MHz (X1)
Wiring of a 5V incremental encoder (ROD, AquadB) as a feedback (primary or secon-

dary, ð p.66). Every time the 24V auxiliary voltage is switched on, the amplifier need
start-up information for the position controller (parameter value MPHASE). Depending on
the setting of FBTYPE a wake&shake is executed or the value for MPHASE is taken out
of the servo amplifier's EEPROM.
WARNING
Frequency limit (A, B): 1,5MHz
Type FBTYPE EXTPOS GEARMODE Remarks

AquadB 5V 31 30 30 MPHASE from EEPROM
AquadB 5V 30 30 30 MPHASE wake & shake
S748/772 SubD15

7.11.11 ROD (AquadB) 5V, 350kHz (X1)
Wiring of a 5V incremental encoder (ROD, AquadB) as a feedback (primary or secon-

dary, ð p.66). Every time the 24V auxiliary voltage is switched on, the amplifier need
start-up information for the position controller (parameter value MPHASE). With this feed-
back type the amplifier executes a wake&shake every time.
WARNING
The thermal control in the motor is connected to X1 and evaluated there. If lead lengths of
more than 50m are planned, please consult our customer service.
Frequency limit (A, B): 350 kHz
S748/772 SubD15

7.11.12 ROD (AquadB) 5V, 350kHz with Hall (X1)
Wiring of a ComCoder as a feedback unit (primary, ð p.66). For the commutation hall
sensors are used and for the resolution an incremental encoder.
The thermal control in the motor is connected to X1 and evaluated there. With our Com-
Coder cable all signals are connected correctly. If cable lengths of more than 25m are
planned, please consult our customer service. With separate feedback devices (Encoder
and Hall are two devices) the wiring must be done similar to chapter 7.11.9, but the ampli-
fier's pinout is identical to the wiring diagram shown below.
Frequency limit (A,B): 350 kHz

AquadB 5V + Hall 15 - -

7.11.13 ROD (AquadB) 24V (X3)
Wiring of a 24V incremental encoder (ROD AquadB) as a feedback system (primary or

secondary, ð p.66). This uses the digital inputs DIGITAL-IN 1 and 2 on connector X3.
Every time the 24V auxiliary voltage is switched on, the amplifier need start-up informa-
tion for the position controller (parameter value MPHASE). With this feedback type the
amplifier executes a wake&shake is executed every time the 24V auxiliary voltage is swit-
ched on.
WARNING
The thermal control in the motor is connected to X1 or X2. If cable lengths of more than
25m are planned, please consult our customer service.
Frequency limit: 100 kHz, transition time tv £ 0.1µs

S748/772

7.11.14 ROD (AquadB) 24V with Hall (X3, X1)
Wiring of a 24V incremental encoder (ROD, AquadB) and Hall sensors as a feedback unit
(primary, ð p.66). For the commutation hall sensors are used and for the resolution an
incremental encoder.
The thermal control in the motor is connected to X1 and evaluated there. If cable lengths
of more than 25m are planned, please consult our customer service.
Frequency limit X3: 100 kHz, X1: 350 kHz

AquadB 24V + Hall 14 - -
S748/772

7.11.15 SSI Encoder (X1)
Wiring of a synchronous serial absolute-encoder as a feedback system (primary or

secondary, ð p.66). The signal sequence can be read in Gray code or in Binary (stan-
dard) code. The thermal control in the motor is connected to X1 and evaluated there. If
Frequency limit: 1.5MHz
Resolution/turn: max. 16 Bit
Turns: max. 16 Bit

SSI 25 25 25
S748/772

7.11.16 Hall sensors (X1)
Wiring of Hall sensors as a feedback unit (primary, ð p.66).

The thermal control in the motor is connected to X1 and evaluated there. If cable lengths
of more than 25m are planned, please consult our customer service.
Frequency limit: 350 kHz

Hall 11 - -
S748/772

7.12 Electronic Gearing, Master-slave operation

In the case of the “electronic gearing” functionality (see setup software and description of
GEARMODE parameter), the servo amplifier is controlled by a secondary feedback
device as a slave.
It is possible to set up master/slave systems, use an external encoder as a setpoint enco-
der or connect the amplifier to a stepper motor control.
The amplifier is parameterized using the setup software (electronic gearing, parameter
GEARMODE).
The resolution (number of pulses per revolution) can be adjusted.
If input X1 is used without the X1 power supply (pins 2, 4, 10, 12), e.g. master-slave
operation with other servoamplifiers, the monitoring of this power supply must be
switched off in order to prevent error message F04 from appearing. To do this, you must
change Bit 20 of the DRVCNFG2 parameter (see ASCII object reference in the online
help).
7.12.1 Signal source
The following types of external encoders can be used as master signal source for electro-
nic gearing:
Frequency Connec- Wiring

secondary Feedback type GEARMODE
limit tor diagram
SinCos Encoder BISS digital 1.5MHz X1 ð p.69 11, 12
SinCos Encoder ENDAT 2.1 350kHz X1 ð p.70 8
Encoder ENDAT 2.2 1.5MHz X1 ð p.71 13
SinCos Encoder HIPERFACE 350kHz X1 ð p.72 9
SinCos Encoder without data channel 350kHz X1 ð p.74 6, 7
ROD* (AquadB) 5V 1.5MHz X1 ð p.76 30
ROD* (AquadB) 5V 350kHz X1 ð p.77 10
ROD* (AquadB) 24V 100kHz X3 ð p.79 2
SSI 5V 1.5MHz X1 ð p.81 25
Step/direction 5V 1.5MHz X1 ð p.84 27
Step/direction 24V 100kHz X3 ð p.84 1
With a "PosI/O" or "PosI/O-Monitor" expansion card in slot 2 or 3, the following additional
encoder types can be used:
Frequency Connec- Wiring

secondary Feedback type GEARMODE
limit tor diagram
SSI 5V 1.5MHz X5 ð p.135 5
ROD* (AquadB) 5V 1.5MHz X5 ð p.137 3
Step/direction 5V 1.5MHz X5 ð p.137 4
* ROD is an abbreviation for incremental encoder

7.12.2 Connection to stepper motor controllers (step and direction)
You can connect the servo amplifier to a third-party stepper-motor controller.

Parameter setting for the slave amplifier is carried out with the aid of the setup software
(electronic gearing). The number of steps can be adjusted, so that the servo amplifier can
be adapted to match the step-direction signals of any stepper controller. Various monito-
ring signals can be generated.
Using an A quad B encoder provides better EMC noise immunity.
7.12.2.1 Step/Direction with 5 V signal level (X1)
Wiring of the servo amplifier (SubD connector X1) to a stepper-motor controller with a 5V
signal level. Frequency limit: 1.5 MHz
Type GEARMODE
Step/direction 5V 27
S748/772
7.12.2.2 Step/Direction with 24 V signal level (X3)
Wiring of the servo amplifier to a stepper-motor controller with a 24 V signal level. Used
are the digital inputs DIGITAL-IN 1 and 2 on connector X3.
Frequency limit: 100 kHz,
Type GEARMODE
Step/direction 24V 1
S748/772

7.12.3 Master-slave operation
7.12.3.1 Connection to an S748/772 master, 5V signal level (X1)
You can link two S748/772 amplifiers together in master-slave operation. One slave
amplifier can be controlled by the master, via the encoder output X1 (see p. 86).
Master: position output to X1 (screen page "Encoder emulation")
Slave: screen page "Electronic gearing" (GEARMODE)
Example for Master-Slave operation with two S748/772 amplifiers (ROD emulation):
Slave GEARMODE: 30 Master ENCMODE:9
S748/772 S748/772
If using SSI emulation, then the master must be set to ENCMODE 10 and the slave to
GEARMODE 25.
7.12.3.2 Connection to an S748/772 Master, 5V signal level (X5)
If an expansion card PosI/O or PosI/O-Monitor (see p.132 ff) is built-in, you can use the
encoder emulation via X5. With this interface up to 16 Slaves can be connected to one
Master, because no internal termination resistors are built-in with X5. Wiring see p.137.

7.13 Encoder Emulation, position output

7.13.1 Incremental encoder output - A quad B (X1)
Fast incremental encoder interface. Select encoder function ROD (A Quad B) Encoder
(“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft posi-
tion from the cyclic- absolute signals of the resolver or encoder, generating incremen-
tal-encoder compatible pulses from this information. Pulse outputs on the SubD connec-
tor X1 are 2 signals, A and B, with 90° phase difference (i.e. in quadrature, hence the
alternative term “A quad B” output), with a zero pulse.
The resolution (before multiplication) can be set:
Encoder function Feedback system Resolution

Zero pulse (NI)
(ENCMODE) (FBTYPE) (ENCOUT)
0, Resolver 32...4096
once per turn
9, ROD => X1 256...524288
>0, Encoder etc. (only at A=B=1)
(28 … 219)
With built in safety card only binary resolutions up to 212 are possible.
Use the NI-OFFSET parameter to adjust + save the zero pulse position within one
mechanical turn. The drivers operate off an internal supply voltage.
The maximum permissible cable length is 100 meters.
Connections and signals for the incremental encoder interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the
shaft's end)
S748/772

7.13.2 SSI encoder output (X1)
SSI interface (synchronous serial absolute-encoder emulation). Select encoder function

SSI (“Encoder Emulation” screen page, ENCMODE 10). The servo amplifier calculates
the motor shaft position from the cyclic-absolute signals of the resolver or encoder. From
this information a SSI date (Stegmann patent specification DE 3445617C2) is provided.
Max 32 bits are transferred. The leading data bit contains the number of revolutions and
are selectable from 12 to 16 bits. The following max. 16 bits contain the resolution and
are not variable.
The following table shows the allocation of the SSI date depending upon selected number
of revolutions:
Revolution Resolution (variable)
SSIREVOL
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit
13 12 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
12 11 10 9 8 7 6 5 4 3 2 1 0
11 10 9 8 7 6 5 4 3 2 1 0
The signal sequence can be output in Gray code or in Binary (standard) code.
The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the
setup software.
The drivers operate off an internal supply voltage.
Connection and signals for the SSI interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the end
of the motor shaft)
S748/772

7.14 Digital and analog inputs and outputs

7.14.1 Analog Inputs (X3B)
The servo amplifier is fitted with two programmable differential inputs for analog set-
points. AGND (X3B/13) must always be joined to the GND of the controls as a ground
reference.
Technical characteristics
— Differential-input voltage max. ± 10 V
— Ground reference AGND, terminal X3B/13
— Input resistance 150 kW
— Common-mode voltage range for both inputs ± 10 V
— Update rate 62.5 µs
S748/772
Analog-In 1 input (terminals X3B/10-9)

Differential input voltage max. ± 10 V, resolution 16 Bit (accuracy 13 Bit), scalable.
Standard setting: speed setpoint
Analog-In 2 input (terminals X3B/12-11)
Differential input voltage max. ± 10 V, resolution 16 Bit (accuracy 13 Bit), scalable.
Standard setting: torque setpoint
Application examples for setpoint input Analog-In 2:
— adjustable external current limit
— reduced-sensitivity input for setting-up/jog operation
— pre-control / override
If an input was freshly assigned to a pre-programmed function, then the data set must be
saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the
amplifier setup software for example).
Defining the direction of rotation
Standard setting : clockwise rotation of the motor shaft (looking at the shaft end)
— Positive voltage between terminal X3B/10 (+ ) and terminal X3B/9 ( - ) or
— Positive voltage between terminal X3B/12 (+ ) and terminal X3B/11 ( - )
To reverse the direction of rotation, swap the connections to terminals X3B/10-9 or
X3B/12-11 respectively, or change the COUNT DIRECTION parameter in the “Feedback”
screen page.

7.14.2 Digital Inputs (X3A, X3B, X4)
S748/772
* DIGITAL-IN 21 and 22 must be defined as inputs using the setup software (“Digital I/O” screen
page).
7.14.2.1 Connectors X3A, X3B
Input ENABLE
— PLC compatible (IEC 61131-2 type 1), floating, reference ground is DGND
— High: 15...30 V / 2...15 mA , Low: -3...5 V / <1mA
— Update rate: Software 250 µs
The output stage of the servo amplifier is enabled by applying the ENABLE signal (Termi-
nal X3A/1, active high). Enable is possible only if inputs STOx-Enable have a 24 V signal
(see page 35ff). In the disabled state (low signal) the connected motor has no torque.
A software enable by means of the setup software is also required (AND link), although
this can also be permanently enabled (“Basic Setup” screen page of the DRIVEGUI.EXE
setup software).
Programmable digital inputs (X3):
You can use the digital inputs X3A/2...7 to initiate pre-programmed functions that are sto-
red in the servo amplifier. A list of these pre-programmed functions can be found on the
“Digital I/O” screen page of our setup software.
If an input was freshly assigned to a pre-programmed function, then the data set must be
saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the
amplifier setup software for example).

Digital Inputs DIGITAL-IN 1...2 (X3A/2,3):

These inputs are particularly fast and are therefore suitable for latch functions or for
high-speed feedback signals, for example.
— High: 15...30 V / 2...15 mA , Low: -3...5 V / <1mA
— Update rate: Hardware 2µs

The PSTOP and NSTOP limit switch evaluation functions, for instance, can be assigned
to these inputs. Choose the function you require in the setup software (“Digital I/O”
screen page).
— High: 15...30 V / 2...15 mA, Low: -3...5 V / <1mA

Pins 6 and 7 on X3A can be used as either inputs or outputs. Choose the function you
require in the setup software (“Digital I/O” screen page).
— High: 15...30 V / 2...15 mA, Low: -3...5 V / <1mA
Depending on the selected function the inputs are high or low active.
7.14.2.2 Connector X4
You can thus achieve a restart lock for functional safety by using the STOx-enable inputs
in conjunction with an external safety circuit.
Inputs STO1-ENABLE (X4/7), STO2-Enable (X4/5)
— Floating, reference ground is XGND
— 20V...30V / 33mA...45mA
These inputs are not compatible with IEC 61131-2.
These additional digital inputs release the power output stage of the amplifier as long as a
24 V signal is applied to these inputs. If one STOx-Enable input goes open-circuit, then
power will no longer be supplied to the motor, the drive will lose all torque and coast
down to a stop.
Failsafe braking of the drive, if required, must be provided by means of an additional
mechanical brake, since electrical braking by the drive is no longer possible.
You can find further information and connection examples on page 35ff.

7.14.3 Digital Outputs (X3A, X3B, X4)
— Power supply at terminals X3A/8 (24V-IO) and X3B/16 (DGND)
— All digital outputs are floating
— 24V-IO : 20V DC … 30V DC
DIGITAL-OUT1 / 2 : PLC compatible (IEC 61131-2 type 1), max. 100mA
STO1/2-Status : PLC compatible (IEC 61131-2 type 1), max. 100mA
BTB/RTO : Relay output, max. 30V DC or 42V AC, 0.5A
— Update rate : 250 µs
S748/772
* DIGITAL-OUT 1 and 2 must be defined as outputs using the setup software (“Digital I/O” screen
page).

7.14.3.1 Connectors X3A, X3B
Ready-to-operate contact BTB/RTO (X3B/14,15)

Operational readiness (terminals X3B/14 and X3B/15 ) is signaled by a floating relay
contact. The contact is closed when the servo amplifier is ready for operation, and the
signal is not influenced by the enable signal, the I²t-limit, or the brake threshold.
All faults cause the BTB/RTO contact to open and the output stage to be switched off (if
the BTB/RTO contact is open, the output stage is inhibited -> no power output). A list of
the error messages can be found on page 112.
Programmable digital outputs DIGITAL-OUT 1 / 2 (X3A/6,7):

Pins 6 and 7 on X3A can be used as either inputs or outputs. Choose the function you
require in the setup software. The outputs are floating outputs, so the 24 V switching vol-
tage must be provided by an external supply via X3A/8.
If they are programmed as digital outputs, messages from pre-programmed functions sto-
red in the servo amplifier can be output here.
A list of these pre-programmed functions can be found on the “I/O digital” screen page of
our setup software.
If an output is to be freshly assigned to a pre-programmed function, then the parameter
set must be saved in the EEPROM of the servo amplifier and a reset has to be carried out
(with the amplifier setup software for example).
7.14.3.2 Connector X4
Status messages STO1-Status (X4/8) and STO2-Status (X4/6):

Pin 6 and 8 on X4 report the status of the STO-Enable inputs. The outputs are floating
outputs, so the 24 V switching voltage must be provided by an external supply via X3A/8.

7.15 RS232 interface, PC connection (X6)

Operating, position control, and motion-block parameters can be set up by using the
setup software on an ordinary commercial PC (see p.99).
Connect the PC interface (X6) of the servo amplifier to a serial interface on the PC via a
null-modem cable, while the supply to the equipment is switched off.
Do not use a null-modem power link cable!
S748/772
This interface has the same electrical potential as the CANopen interface.
The interface is selected and set up in the setup software.
Further notes on page 98.
With the optional expansion module -2CAN- the two interfaces for RS232 and CAN,
which otherwise use the same connector X6, are separated onto two connectors
ð p.129).
Interface cable between the PC and servo amplifiers of the S748/772 series:
(View : looking at the solder side of the SubD sockets on the cable)

7.16 CANopen interface (X6)

The interface for connection to the CAN-bus (default : 500 kBaud). The integrated profile
is based on the CANopen DS301 communication profile and the DS402 drive profile.
The following functions are available in connection with the position controller:
Jogging with variable speed, homing run (zeroing to reference), start motion task, start
direct task, digital setpoint provision, data transmission functions and many others.
Detailed information can be found in the CANopen manual. The interface is at the same
electrical potential as the RS232 interface. The analog setpoint inputs can still be used.
With the optional expansion module -2CAN- the two interfaces for RS232 and CAN,
which otherwise use the same connector X6, are separated onto two connectors
ð p.129).
S748/772
CAN-bus cable
To meet ISO 11898, a bus cable with a characteristic impedance of 120 W should be
used. The maximum usable cable length for reliable communication decreases with
increasing transmission speed. As a guide, you can use the following values which we
have measured, but they are not to be taken as assured limits:
Cable data: Characteristic impedance 100-120 W
Cable capacitance max. 60 nF/km
Lead loop resistance 159.8 W/km
Cable length, depending on the transmission rate
Transmission rate (kBaud) max. cable length (m)

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

7.17 EtherNET interface (X7)

This interface with its two RJ-45 connectors can be used for communicating with various
fieldbus devices depending on the used firmware version:
l EtherCAT(standard, CAN over EtherCAT)
The interface is deactivated, if a field bus extension card is inserted to an extension slot.
The protocol that has been installed with the firmware must be enabled (ASCII command
ETHMODE).
Standard setting: if an EtherCAT connection is detected while booting the servo amplifier,
then EtherCAT is activated, otherwise CANopen (see p. 94) is activated
With the Download Tool (on the product CDROM and within the download area of our
website) the different firmware versions can be loaded into the servo amplifier.
The communication status is indicated by the built-in LEDs.
LED1
LED2
LED3
LED4
Connector LED# Name Function

ON = receive valid (IN port)
LED1 LINK_IN
OFF= not valid, power off or reset.
X7A ON = network cyclic
LED2 CYCLIC BLINK = network not cyclic
OFF = power off or reset
ON = receive valid (OUT port)
LED3 LINK_OUT
OFF = not valid, power off or reset
X7B ON = repeater on, network cyclic
LED4 REPEATER BLINK = repeater on, network not cyclic
OFF = repeater off, power off or reset
Pinout
X7A Signal X7B Signal
1 Transmit + 1 Receive +
2 Transmit - 2 Receive -
3 Receive + 3 Transmit +
4 n.c. 4 n.c.
5 n.c. 5 n.c.
6 Receive - 6 Transmit -
7 n.c. 7 n.c.
8 n.c. 8 n.c.

7.18 Memory Card

In the top of the servo amplifier
there is a card reader for memory
cards. The firmware and a full set of
parameters (with control buttons
and setup software) can be stored
on the memory card and reloaded
onto the servo amplifier. MMC and
SD cards are supported.
This function means that a replace-
ment device or identical shafts in
standard production machines can
be set up very quickly and easily.
Uploads and Downloads from and to the memory card can be started with the keypad or
with the setup software using. Operating with ASCII commands is described in the Pro-
duct-WIKI on page "Memory Card".
Always switch off the S748/772 before inserting or removing the memory card.
If an absolute encoder is used, homing must be carried out before the parameters are
loaded onto a new device.
To run new firmware on an amplifier without a PC connection, proceed as follows:
1. Save the firmware to be programmed onto a memory card under the name
“default.s19" (S-record format) or ”default.bin" (binary format).
2. Disconnect the power to the amplifier (24 V supply OFF) and insert the card in the
memory card slot on the amplifier.
3. Press and hold down both operating keys ( ) and switch on the 24 V
supply voltage to the amplifier. “—” appears in the display to indicate that the
monitor program has been activated. In case of access problems the drive display
shows the letters “CCC”. The interrupted command proceeds after re-insertion of
the memory card.
4. Press both operating keys again to start the update process. The progress of
the update can be monitored in the display:
- First, the firmware is downloaded from the card to the internal memory.
- During this phase, the display counts from 0 to 100.
- Next, the internal firmware memory is deleted. During this phase, 100 is
displayed permanently.
- Once the firmware memory has been deleted, the firmware is written.
This phase is indicated in the display by the display counting backwards from
100 to 0.
5. Once programming has been completed, the firmware is started automatically.
The parameter file can also be loaded automatically on a restart. If a parameter file with
the name “default.par” has already been saved on the memory card, it will be loaded by
the firmware at this point. This allows fully automatic updating of the firmware/parameters.

Kollmorgen 12/2014 Setup
8 Setup
The procedure for setup is described as an example. Depending on the application, a dif-
ferent procedure may be appropriate or necessary. In multi-axis systems, set up each
servo amplifier individually.
Before setting up, the manufacturer of the machine must generate a risk assessment for
the machine, and take appropriate measures to ensure that unforeseen movements can-
not cause injury or damage to any person or property.
8.1 Important notes
DANGER
The equipment produces potentially lethal voltages up to 900 V. Risk of
electric shock. Only professional personnel with extensive knowledge in
the fields of electrical engineering and drive technology are allowed to
setup the servo amplifier. Check that all connection components that are
live in operation are safely protected against bodily contact.
WARNING
There is a danger of electrical arcing when disconnecting connectors,
because capacitors can still have dangerous voltages present up to ten
minutes after switching off the supply power.
Risk of burns and blinding. The contacts become damaged.
Never undo any electrical connections to the servo amplifier while it is
live. Wait at least ten minutes after disconnecting the servo amplifier from
the main supply power before touching potentially live sections of the
equipment (e.g. contacts) or undoing any connections.
To be sure, measure the voltage in the DC Bus link and wait until it has
fallen below 60V.
WARNING
The drive might restart automatically after power on, depending on the
parameter setting. Risk of death or serious injury for humans working in
the machine. If the parameter AENA is set to 1, then place a warning sign
to the machine (Warning: Automatic Restart at Power On) and ensure,
that power on is not possible, while humans are in a dangerous zone of
the machine.
If the servo amplifier has been stored for more than 1 year, it will be necessary to re-form
the capacitors in the DC bus link circuit.
To do this, disconnect all electrical connections and apply single-phase 208...240 V AC to
terminals L1 / L2 of the servo amplifier for about 30 minutes. This will re-form the
capacitors.
Additional information on setting up the equipment:

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

Setup 12/2014 Kollmorgen
8.2 Setup software

This chapter describes the installation of the setup software DRIVEGUI.EXE for the
S748/772 digital servo amplifiers.
We offer training and familiarization courses on request.
8.2.1 Use as directed
The setup software is intended to be used for altering and saving the operating parame-
ters for the S748/772 series of servo amplifiers. The attached servo amplifier can be set
up with the help of this software, and during this procedure the drive can be controlled
directly by the service functions.
Only professional personnel who have the relevant expertise described on page 11 are
permitted to carry out online parameter setting for a drive that is running.
Sets of data that have been stored on data media are not safe against unintended alter-
ation by other persons. Unexpected move could be the result if you use unchecked data.
After loading a set of data you must therefore always check all parameters before enab-
ling the servo amplifier.
8.2.2 Software description
The servo amplifiers must be adapted to the requirements of your machine.

Usually you will not have to carry out this parameter setting yourself on the amplifier, but
on a PC, with the assistance of the setup software. The PC is connected to the servo
amplifier by a null-modem cable (serial, see p.93). The setup software provides the com-
munication between the PC and S748/772.
You can find the setup software on the accompanying CD-ROM and in the download
area of our website.
With very little effort you can alter parameters and instantly observe the effect on the
drive, since there is a continuous (online) connection to the amplifier. At the same time,
important actual values are read out from the amplifier and displayed on the monitor of
the PC (oscilloscope functions).
Any interface modules (expansion cards) which may be built into the amplifier are auto-
matically recognized, and the additional parameters which are required for position con-
trol or motion-block definition are made available.
You can save sets of data on data media or on the memory card (archiving) and load
them again. You can also print out the data sets.
We supply you with motor-specific default sets of data for the most common combinations
of servo amplifier and motor. In most applications you will be able to use these default
values to get your drive running without any problems.
An extensive online help with integrated description of all variables and functions supp-
orts you in each situation.

8.2.3 Hardware requirements, operating systems
The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of
the PC by a null-modem cable (not a null-modem link cable!) (ð p.93).
Connect / disconnect the interface cable only when the electrical supply is switched off for
both the PC and the servo amplifier.
The interface in the servo amplifier has the same potential level as the CANopen inter-
face.
Minimum hardware requirements for the PC:
Processor : at least Pentium® II or comparable
Graphics adapter : Windows compatible, color
Drives : hard disk with at least 10 MB free space
CD-ROM drive
Interface : one free serial interface (COM1 … COM10)
or USB with an USB->Serial converter
Operating systems WINDOWS 2000, XP, VISTA, 7

DRIVEGUI.EXE will run under WINDOWS 2000, XP, VISTA and 7.
Emergency operation is feasible through an ASCII terminal emulation (without graphical
user interface).
Interface settings : 38400 bps, databit 8, no parity, stopbit 1, no flow control
Operating systems Unix, Linux
The functioning of the software has not been tested for WINDOWS running within Unix or
Linux.
8.2.4 Installation under WINDOWS
The CD-ROM includes an installation program for the setup software.

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

Connect the interface cable to a serial interface on your PC (COM1 to COM10) and to the
serial interface of the servo amplifier S748/772 (ð p.93).

8.3 Quickstart
8.3.1 Preparation
Unpacking, Mounting and Wiring the Servo Amplifier

1. Unpack servo amplifier and accessories
2. Observe safety instructions in the manuals
3. Mount the servo amplifier as described in chapter 6
4. Wire the servo amplifier as described in chapter 7 or apply the minimum wiring for drive
testing as described in chapter 8.3.1
5. Install the software as described in chapter 8.2
6. You need this information concerning the drive components:
- rated mains supply voltage
- motor type (motor data, if the motor type is not listed in the motor database:
see online help)
- feedback unit built into the motor (type, poles/lines/protocol etc.)
- moment of inertia of the load
Documents
You need access to these documents (located on the product CD-ROM, you can
download the latest editions from our website):
l Instruction manual (this manual)
l CANopen communication profile manual
l EtherCAT communication profile manual
l Accessories manual
Depending on the installed expansion card you need one of these documents:
l Operating Manual Safety Expansion Card Sx
l PROFIBUS DP communication profile manual
l DeviceNet communication profile manual
l sercos® communication profile manual
You need Acrobat Reader to read the PDFs, an installation link is on every screen of the
product CD-ROM.

Minimum Wiring for Drive Test

This wiring does not fulfill any requirements to safety or functionality of your application, it
just shows the required wiring for drive testing without load.
Power ON Power
X3B/16
X3B/14 X3B/15
Enable
X3A/1
24V ON
X4/7
X4/3 X4/5
X4/2
+ X4/1
24V DC
-
Power
Brake Resistor
M Feedback

8.3.2 Connect
l Connect the interface cable to a serial interface on your PC and to the serial interface
X6 of the servo amplifier. USB to serial converter can be used optionally.
l Switch on the 24 V power supply for the servo amplifier.
l Wait about 30 seconds, until the front display of the servo amplifier displays the cur-
rent class (e.g. for 48 A) If the power supply voltage is switched on, too, a lea-
ding P is displayed (e.g. for Power, 48 A).
If a fault code ( ) or a warning ( ) or a status message (./_ / E/S) appears in
the display, you will find the description on page 112 / 113.
If a fault message appears, fix the problem.
Double-Click the DRIVEGUI.EXE icon on your Windows desktop to

start the software.
You can work offline or online with

DRIVEGUI.EXE.
Work ONLINE now.
If the communication is start-

ed for the first time, you have
to setup the communication
parameters.
Choose the communication
system and the interface,
where the servo amplifier is
connected to.
Click OK.
The software tries to communicate with these parameters. If it's not successful, you
receive this error message:
Frequent causes:
- wrong interface chosen
- wrong connector chosen at the servo amplifier
- interface is used by another software
- 24 V auxiliary voltage for the servo amplifier not wor-
king
- interface cable broken or wrong wiring
Quit the error message. The software starts in the offline mode now, that requires the
manual selection of the amplifier's type. Quit this selection by closing the window.
Fix the communication problem. Restart the software in Online mode.

If communication works, you see the start screen. Select "Setup Wizard" in the navigation
frame.
Make sure, that the amplifier is disabled (Input Enable connector X3A pin 1 must be 0 V
or open)!
8.3.3 Important Screen Elements
Help Function
The Online-Help gives detailed information to all parameters the servo amplifier can work
with.
Key F1 Starts online help for the actual screen page.

Menu bar Help Starts online help with the first page.
Context Help. Click the help symbol first. Then click the function for
which you need help.
Tool Bar
Save to EEPROM, required if you changed parameters.
Reset, required if you changed configuration parameters.
Operation Mode,
use "0: Digital Velocity" mode for drive testing.
Status Bar
The status bar shows a green Online symbol, indicating that the communication works.

8.3.4 Setup Wizard
The Setup Wizard leads you through the necessary steps for configuring your servo
amplifier. Depending on the selected application, only the active screen pages are
necessary.
For a quick setup / drive

test, select the setup
type "Quick Motor/Drive
Setup".
Start the Wizard.
8.3.4.1 Basic Setup
Basic parameters are

set here.
Mains Voltage: Select the connected mains voltage level

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

8.3.4.2 Units/Mechanical
The user units for all in-

put fields in the setup
software can be prese-
lected here.
Position, Velocity, Acceleration

Select usable units for your application referring to the moved load.
Mechanical Conversion
The relationship between motor shaft revolution (pole pair pitch with linear motors) and
motion distance of the load is specified here. Gear ratio can be calculated here as well.
Detailed information can be found in the online help.
Use the tool based on sample applications for calculating the resolution value:
Calculate PGEARI/PGEARO for..." button
If your application does not corre-

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

8.3.4.3 Motor (rotatory) / Feedback
Simplified setting of the motor

related parameters.
Feedback: Select the feedback system used in the motor.

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

motor related parameters.
Feedback: Select the feedback system used.

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

8.3.4.5 Save Parameters and Restart
You are going to finish the Setup Wizard and you have changed several basic parame-
ters. Depending on the parameters you changed, two possible reactions will occur now:
Configuration parameters changed
A warning appears, that you have to restart the amplifier, this is called "coldstart".
Click "YES".
The parameters are saved
to the amplifier's EEPROM
automatically and a reset
command restarts the am-
plifier (takes some se-
conds).
Other parameters changed
No warning appears. Save the parameters to the EEPROM of the servo amplifier manu-
ally by clicking the symbol in the tool bar. A coldstart of the amplifier is not neces-
sary. Select the screen "Motion Service" in the navigation frame.
8.3.5 Motion Service (Jog Mode)
Be aware that the actual position of the load permits the subsequent moving operations.
The axis could move to the hardware limit-switch or the mechanical stop. Make sure that
a jerk or a fast acceleration of the load cannot cause any damage. Observe the "safe re-
duced speed" requirements for your application!
l Switch on the power supply for the drive.
l STOx-Enable: Apply +24 V to STO1-Enable [X4/5] and STO2-Enable [X4/7]
l Hardware-Enable: Apply +24 V to the input Enable [X3A/1]. If STO-Enable is miss-
ed or the sequence was wrong, the front display shows .
l EN
Software-Enable: Click the symbol in the tool bar. Now the front display
shows an E and the current class (e.g. for Enable, 48A). Click the symbol
DIS
to switch off the output stage (disable).
Jog
(Digital Velocity Mode):
You can move the drive with
constant speed. Enter the
desired speed.
The drive moves with the
preset speed when the + or
– button is pressed. It stops
when the button is released.
Actual errors and warnings are listed on the screen "Status". A description of errors/war-
nings can be found in the online help or on p.112ff.
Now you have setup and tested the basic functions of the drive successfully.

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

8.4 Multi axis system

With a special cable you can connect up to 255 servo amplifiers to your PC: cable type
-SR6Y- (for four amplifiers) or -SR6Y6- (for six amplifiers) see Accessories Manual.
Adr.: Adr.: Adr.: Adr.:

Cable -SR6Y- 00 01 02 03
COMx
Baudrate identical for all amplifiers,
RS232
see table below
With the PC connected to only one amplifiers you can select every amplifier in the system
via the set station address with the setup software.
Station address for CAN-bus
You can use the keypad on the front panel to preset the station addresses for the indivi-
dual amplifiers and the baud rate for communication (ð p.111). Usually the setup soft-
ware is used to set all parameters.
Baud rate for CAN-bus
After changing the station address and baud rate you must turn the 24V auxiliary supply
for the servo amplifier off and on again.
Coding of the Baud rate in the LED display :
Coding Baud rate in kbit/s Coding Baud rate in kbit/s
1 10 25 250
2 20 33 333
5 50 50 500
10 100 66 666
12 125 80 800
100 1000
8.5 Keypad operation / LED display

This section illustrates the two possible operating menus and the use of the keys on the
front panel. Normally, the S748/772 only presents the standard menu for your use. If you
want to operate the amplifier via the detailed menu, you must keep the right key pressed
while switching on the 24V supply.

8.5.1 Keypad operation
The two keys can be used to perform the following functions:
Key symbol Functions

press once : move up one menu item, increase number by one
press twice in rapid succession : increase number by ten
press once : decrease number by one
press twice in rapid succession : decrease number by ten
hold right key pressed, and then press left key as well :
to enter a number, “Return” function
8.5.2 Status display
8.5.3 Standard menu
ð p.109

8.5.4 Advanced menu
To operate the amplifier via the detailed menu, you must keep the right key pressed while
switching on the 24 V supply.
ð p.99
ð p.109

8.6 Error messages

Any errors that occur are shown in coded form by an error number in the LED display on
the front panel. The servo amplifier reaction depends on the fault and on the setting of
parameter ACTFAULT.
Faults can be reset by hardware reset of the servo amplifier or depending on the fault
(see ERRCODE) by ASCII command CLRFAULT.
Number Explanation (=> ASCII Reference ERRCODE)

E/P Status Messages Status messages, no error, see p. 110
... Status Message Amplifier is updating the startup configuration
- Status Message Status message, no error, programming mode
-S- STO-Enable STOx-Enable input is 0V (with disabled drive only)
CCC Memory Card Access problems memory card
F01 Heat Sink Temperature Heat sink temperature too high (default: 80°C)
Overvoltage in DC bus link. Limit depends on the
F02 Overvoltage
electrical supply voltage
F03 Following Error Message from the position controller
F04 Feedback Cable break, short-circuit, short to ground
F05 Undervoltage Undervoltage in DC bus link (default: 100 V)
F06 Motor Temperature Motor temperature too high or temp. sensor defect
F07 Internal Voltages Internal supply voltages not ok
F08 Overspeed Motor runs away, speed is too high
F09 EEPROM Checksum error
F10 Reserved Reserved
F11 Brake Cable break, short-circuit, short to ground
F12 Motor Phase Motor phase missing (e.g. cable break), in process
F13 Ambient Temperature Ambient temperature too high
Fault in the power output stage, also with wrong
F14 Output Stage
motor cable or insufficient cable shielding
F15 I²t max. I²t maximum value exceeded
F16 Mains BTB/RTO 2 or 3 phases missing in the mains supply feed
Error in the analog-digital conversion, normally
F17 A/D Converter
caused by extreme electromagnetic interference
F18 Brake Circuit Brake circuit faulty or incorrect setting
F19 Phase error Mains phase missed
Slot error, depends on the type of expansion card
F20 Slot Error
(see ASCII object reference)
F21 Handling Error Handling error on the expansion card
F22 Reserved Reserved
F23 CAN-Bus Off Severe CAN bus communication error
F24 Warning Warning is displayed as fault
F25 Commutation Error Commutation error
F26 Limit Switch Hardware limit switch error on homing move
Operational error with STO, inputs for STO-Enable
F27 STO
and ENABLE have been set at the same time
F28 Fieldbus Error Fieldbus error (see ASCII command reference)
F29 Fieldbus Error Fieldbus error (see ASCII command reference)
F30 Emergency Timeout Timeout emergency stop
Safety card error. Error code follows:
F31 Safety Supervision
oXX=error number, iYY=error subindex
F32 System Error System software not responding correctly
More information to the messages and trouble shooting can be found in the ASCII Object
Reference and in the Online Help).

8.7 Warning messages

Faults which occur, but which do not cause a switch-off of the amplifier output stage
(BTB/RTO contact remains closed), are indicated in the LED display on the front panel by
a coded warning number.
Some warning messages result in a controlled shut-down of the drive (braking by emer-
gency stop ramp).
The servo amplifier reaction depends on the warning (see STATCODE).
Number Designation Explanation (=> ASCII Reference STATCODE)

E/P Status Messages Status messages, no warning, see p. 110
... Status Message Amplifier is updating the startup configuration
-S- STO-Enable STO-Enable input is 0V (with disabled drive only)
- Status Message Status message, no warning, programming mode
n01 I²t I²t threshold exceeded
n02 Brake power Reached preset brake power limit
n03 S_fault Exceeded preset following error limit
n04 Response monitoring Response monitoring (fieldbus) has been activated
n05 Supply phase Mains supply phase missing
n06 SW limit switch 1 Software limit switch 1 underrun
n07 SW limit switch 2 Software limit switch 2 overrun
n08 Motion task error A faulty motion task was started
No reference point (Home) set at start of motion
n09 No reference point
task
n10 PSTOP PSTOP limit-switch activated
n11 NSTOP NSTOP limit-switch activated
Only for ENDAT or HIPERFACE® :
Motor default values discrepancy between motor number saved in the
n12
loaded encoder and the amplifier, motor default values loa-
ded
n13 Expansion card 24V DC supply for I/O expansion card not ok
SinCos commutation (wake & shake) not comple-
n14 SinCos feedback ted, will be canceled when amplifier is enabled and
wake & shake carried out
n15 Reserve Reserve
n16 Summarized warning Summarized warning for n17 to n31
n17 Fieldbus-sync CAN sync is not logged in
n18 Multiturn overflow Max. number of motor turns exceeded
Motion task ramps are
n19 Range overflow on motion task data
limited
n20 Invalid motion task Invalid motion task
n21 PLC program error For details see PLC code
Max.motor temperature The user can shut down the process before the tem-
n22
reached perature error will interrupt the process immediately
n23 Sin Cos feedback Warning level reached
n24 Digital I/O Configuration is not logical
n25-n31 Reserve Reserve
n32 Firmware beta version Firmware is an unreleased beta version
More information to the messages can be found in the ASCII Object Reference and in
the Online Help).

8.8 Trouble Shooting

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

Kollmorgen 12/2014 Expansions
9 Expansions
You can find information about availability and order numbers on page 151.
9.1 Expansion cards for slot 1

9.1.1 Guide to installation of expansion cards in slot 1
2 - Detach the film (at the per- 3 - Tear off the film (as far
1 - Boundary of SLOT1
forations) as the mark)
4 - Break the top rib 5 - Break the bottom rib 6 - Pull out the top plate
7 - Pull out the bottom plate 8 - Push in the card 9 - Fasten the screws

Expansions 12/2014 Kollmorgen
9.1.2 Expansion card -I/O-14/08-
This section describes the additional features that the expansion card -I/O-14/08- provi-
des for the S748/772. If you ordered the expansion card together with the servo amplifier,
then it will be delivered already inserted into the expansion slot of the servo amplifier and
screwed in place.
The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The
functions of the inputs and outputs are adjustable with the setup software.
The 24V DC voltage must be supplied by an electrically isolated power supply (e.g. with
isolating transformer).
The I/Os are used to initiate the motion tasks that are stored in the servo amplifier and to
evaluate signals from the integrated position control in the higher-level control system.
The functions of the inputs and signal outputs correspond to the functions that can be
assigned to the digital I/Os on connector X3. All inputs and outputs are electrically isola-
ted from the servo amplifier by optocouplers.
9.1.2.1 Technical data
Control inputs 24V / 7mA , PLC-compatible, IEC 61131

Signal output 24V / max. 500mA , PLC-compatible, IEC 61131
24V (18 … 36V) / 100mA plus total current of the out-
Supply inputs, to IEC 61131
puts (depends on the input wiring of the controls)
Fusing (external) 4 AT
Connectors MiniCombicon, 12-pin, coded on PIN1 and 12
Data – up to 50m long : 22 x 0.5 mm², unshielded,
Cables
Supply – 2 x 1mm², check voltage drop
Waiting time between
depends on the response time of the control system
2 motion tasks
Addressing time (minimum) 4ms
Starting delay (maximum) 2ms
Response time of digital
max. 10ms
outputs
9.1.2.2 LEDs
Two LEDs are mounted next to the terminals on the expansion card. The green LED sig-
nals that the 24V auxiliary supply is available for the expansion card. The red LED signals
faults in the outputs from the expansion card (overload of switching components,
short-circuit).
9.1.2.3 Entering a motion block number (example)
Motion block number A7 A6 A5 A4 A3 A2 A1 A0

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

9.1.2.4 Connector assignments
The functions are adjustable with the setup software. In the table below the default values
are described.
Connector X11A
Default
Pin Dir Description
function
1 In A0 Motion block number, LSB
2 In A1 Motion block number, 21
8 In A7 Motion block number, MSB
Polls the home switch. If a digital input on the base unit is
9 In Reference used as a home input, then the input on the expansion card
will not be evaluated.
Clears the warning of a following error (n03) or the response
10 In F_error_clear
monitoring (n04)
The following task, that is defined in the motion task by “Start
with I/O” is started. The target position of the present motion
11 In Start_MT_Next task must be reached before the following task can be started.
The next motion block can also be started by an appropriately
configured digital input on the base unit.
Starts the "Jog Mode" with a defined speed. “x” is the speed
12 In Start_Jog v= x saved in the servo amplifier for the function "Jog Mode". A ri-
sing edge starts the motion, a falling edge cancels the motion.
Connector X11B
1 In MT_Restart Continues the motion task that was previously interrupted.
Starts the motion task that is addressed by A0-A7 (connector
2 In Start_MT I/O X11A/1...8). If no motion task is addressed, then a
homing task is started.
When the target position for a motion task has been reached
3 Out InPos (the InPosition window), this is signaled by the output of a
HIGH signal. A cable break will not be detected.
The start of each motion task in an automatically executed
sequence of motion tasks is signaled by an inversion of the
Next-InPos output signal. The output produces a LOW signal at the start
4 Out
of the first motion task of the sequence. The form of the mes-
sage can be varied by using ASCII commands.
PosReg 0 Can only be adjusted by ASCII commands/setup software.
A LOW signal indicates that the position has gone outside the
5 Out F_error
acceptable following error window.
6 Out PosReg1 default: SW limit 1, indicated by a HIGH signal
7 Out PosReg2 default: SW limit 2, indicated by a HIGH signal
8 Out PosReg3 Can only be adjusted by ASCII commands/setup software.
11 - 24V DC Supply voltage for output signals.
12 - I/O-GND Digital GND for the control system.

9.1.2.5 Connection diagram (default)
S748/772

9.1.3 Expansion card -PROFIBUS-
This section describes the PROFIBUS expansion card for the S748/772.
Information on the range of functions and the software protocol can be found in our
manual “Communication Profile PROFIBUS DP”.
The PROFIBUS expansion card has two 9-pin SubD sockets wired in parallel.
The supply voltage for the expansion card is provided by the servo amplifier.
9.1.3.1 Connection technology
Cable selection, cable routing, shielding, bus connector, bus termination and transmis-
sion times are all described in the “Installation Guidelines for PROFIBUS-DP/FMS” from
PNO, the PROFIBUS User Organization.
9.1.3.2 Connection diagram
S748/772

9.1.4 Expansion card -SERCOS-
This section describes the sercos® II expansion card for S748/772. Information on the
range of functions and the software protocol can be found in our manual “IDN Reference
Guide sercos® ”.
9.1.4.1 LEDs
Indicates whether sercos® telegrams are being correctly received. In the final
RT Communication Phase 4 this LED should flicker, since cyclical telegrams are being
received.
Indicates that sercos® telegrams are being transmitted. In the final Communication
Phase 4 this LED should flicker, since cyclical telegrams are being transmitted.
TT Check the station addresses for the controls and the servo amplifier if:
- the LED never lights up in sercos® Phase 1 or
- the axis cannot be operated, although the RT LED is lighting up cyclically.
Indicates that sercos® communication is faulty or suffering from interference.
If this LED is very bright, then communication is suffering strong interference, or is

non-existent. Check the sercos® transmission speed for the controls and the servo
amplifier (BAUD RATE) and the fiber-optic connection.
ERR
If this LED fades or flickers, this indicates a low level of interference for sercos®
communication, or the optical transmitting power is not correctly matched to the
length of cable. Check the transmitting power of the (physically) previous sercos®
station. The transmitting power of the servo amplifier can be adjusted in the setup
software DRIVEGUI.EXE on the sercos® screen page, by altering the length para-
meter for the cable length.
For the fiber optic cable connection, only use sercos® components to the sercos® Stan-
dard IEC 61491.
Receive data
The fiber optic cable carrying receive data for the drive in the ring structure is connected
to X13 with an F-SMA connector.
Transmit data
Connect the fiber optic cable for the data output to X14 by F-SMA connector.

9.1.4.3 Connection diagram
The sercos® II bus system has ring topology, with fiber optical cables.
9.1.4.4 Setup
Modifying the station address

The drive address can be set to a value between 0 and 63. With address 0, the drive is
assigned as an amplifier in the sercos® ring.
Keys on the front of the servo amplifier
The sercos® address can be modified using the keys on the front of the amplifier
(see p. 110).
Setup software
The address can also be modified in the setup software, “CAN/Fieldbus” screen (please
refer to the setup software online help). Alternatively, enter the command ADDR # in the
“Terminal” screen, where # is the new address of the drive.
Modifying the baud rate and optical power
If the baud rate is not set correctly, communication is not possible.
The SBAUD # parameter can be used to set the baud rate, where # is the baud rate. If
the optical power is not set correctly, errors occur in telegram transmission and the red
LED on the drive lights up. During normal communication, the green send and receive
LEDs flash, giving the impression that the relevant LED is on.
The SLEN # parameter can be used to specify the optical range for a standard 1 mm²
glass fibre cable, where # is the length of the cable in meters.
SBAUD SLEN
2 2 Mbaud 0 Very short connection
4 4 Mbaud 1…< 15 Length of the connection with a 1 mm² plastic cable
8 8 Mbaud 15…< 30 Length of the connection with a 1 mm² plastic cable
16 16 Mbaud ³ 30 Length of the connection with a 1 mm² plastic cable
Setup software
The parameters can be modified in the setup software, “SERCOS” screen (please refer to
the setup software the online help). Alternatively, the commands SBAUD # and SLEN #
can be entered in the “Terminal” screen.

9.1.5 Expansion card - DEVICENET -
This section describes the DeviceNet expansion card for S748/772.

Information on the range of functions and the software protocol can be found in our
manual “DeviceNet Communication Profile”.
9.1.5.1 Connection technology, Connection diagram
Cable selection, cable routing, shielding, bus connector, bus termination and transmis-
sion times are all described in the “DeviceNet Specification, Volume I, II”, published by
ODVA.
S748/772

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

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

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

9.1.5.4 Bus cable
To meet ISO 11898, a bus cable with a characteristic impedance of 120 W should be
used. The maximum usable cable length for reliable communication decreases with
increasing transmission speed. As a guide, you can use the following values which we
have measured, but they are not to be taken as assured limits.
General characteristic Specification

Bit rates 125 kbit, 250 kbit, 500 kbit
500 meters at 125 kBaud
Distance with larger
bus connections
Number of nodes 64
Signal environment CAN
Modulation Basic bandwidth
Coupling medium DC-coupled differential transmit/receive operation
Isolation 500 V (option: optocoupler on the transceiver's node side)
Typical differential input im- Shunt C = 5pF
pedance (recessive state) Shunt R = 25KW (power on)
Shunt C = 24pF + 36 pF/m of the permanently
Min. differential input impe-
attached stub cable
dance (recessive state)
Shunt R = 20KW
-25 V to +18 V (CAN_H, CAN_L)
The voltages for CAN_H and CAN_L refer to the ground pin
Absolute max.
of the transceiver. The voltage is higher than that on the
voltage range
V-terminal by the amount of the forward voltage drop of the
Schottky diode. This voltage drop must be < 0.6V.
Grounding:
The DeviceNet network must only be grounded at one point, to avoid ground loops. The
circuitry for the physical layer in all devices are referenced to the V-bus signal. The
ground connection is made via the power supply for the bus system. The current flowing
between V- and ground must not flow through any device other than the power supply.
Bus topology:
The DeviceNet medium utilizes a linear bus topology. Termination resistors are required
at each end of the connecting cable. Stub cables are permitted up to a length of 6 meters,
so that at least one node can be connected.
Termination resistors:
DeviceNet requires a termination at each end of the connecting cable.
These resistors must meet the following requirements: 120W, 1% metal-film, ¼ W

9.1.6 Expansion card -SYNQNET-
This section describes the SynqNet expansion card for S748/772. Information on the
range of functions and the software protocol can be found in the SynqNet documentation.
LED2 LED1 LED4 LED3
9.1.6.1 NODE ID Switch
With these hexadecimal switches you can set the main and low significant bytes of the
Node ID separately. SynqNet does not require an address for correct operation in the net-
work, however in some machines this can be a convenient way of identifying build options
to the application program.
9.1.6.2 Node LED table
LED# Name Function

ON = receive valid (IN port)
LED1, green LINK_IN
OFF= not valid, power off, or reset.
ON = network cyclic
LED2, yellow CYCLIC BLINK = network not cyclic
OFF = power off, or reset
ON = receive valid (OUT port)
LED3, green LINK_OUT
OFF = not valid, power off, or reset
ON = repeater on, network cyclic
LED4, yellow REPEATER BLINK = repeater on, network not cyclic
OFF = repeater off, power off, or reset
9.1.6.3 SynqNet Connection, Connector X21B/C (RJ-45)
Connection to the SynqNet network via RJ-45 connectors (IN and OUT ports) with inte-
grated LEDs.

9.1.6.4 Digital inputs/outputs, connector X21A (SubD 15-pin, socket)
Inputs (In): 24V (20...28V), opto-isolated, one high-speed input (Pin 4)

Outputs (Out): 24V, opto-isolated, Darlington driver
Pinout connector X21A (SubD 15 pin)

Pin Type Description Pin Type Description
1 In +24V power supply 9 In GND power supply
NODE- indicates a problem
2 Out 10 Out OUT_00 digital output
ALARM with the node
3 Out OUT_01 digital output 11 Out OUT_02 digital output
4 In IN_00 capture input (fast) 12 In IN_02 digital input
5 In IN_04 digital input 13 In IN_03 digital input
limit switch, negati-
6 In IN_01 digital input 14 In NEGLIM
ve direction
NODE-
7 In HOME reference switch 15 In disables Node
DISABLE
limit switch, positive
8 In POSLIM
direction
9.1.6.5 Connection diagram digital inputs/outputs, connector X21A
S748/772

9.1.7 Expansion card - FB-2to1 -
This chapter describes the Feedback extension card FB-2to1 for the S748/772. The card
enables simultaneous connection of a digital primary and of an analog secondary feed-
back to the connector X1. The supply of 24V DC auxiliary voltage to X33 is converted on
the extension card into a precise 5V DC encoder supply for the secondary feedback.
9.1.7.1 Pinout
X33 Pinout Combicon Connector

+ +24V DC (20...30V), approx. 500mA
- GND
Pinout SubD 9 poles Pinout SubD 15 poles
X32 (secondary Feedback) X1B (primary Feedback)
SinCos (1V p-p) EnDat 2.2, BiSS digital, SSI absolute
1 B- (Cosine) 1 n.c.
2 SENSE+ 2 0V
3 A- (Sine) 3 n.c.
4 n.c. 4 +5V DC
5 +5V DC (300mA) 5 DATA
6 B+ (Cosine) 6 n.c.
7 SENSE- 7 Temperatur Sensor Motor
8 A+ (Sine) 8 CLOCK
9 0V 9 n.c.
- - 10 Sense 0V
- - 11 n.c.
- - 12 Sense +5V
- - 13 DATA
- - 14 Temperatur Sensor Motor
- - 15 CLOCK

9.1.7.2 Wiring example with BiSS digital (primary) and SinCos (secondary)

9.1.8 Expansion module -2CAN-
Connector X6 of the S748/772 is assigned to the signals for the RS232 interface and the
CAN interface. It is therefore not the standard pin assignment for these interfaces, and a
special cable is required to be able to use both interfaces simultaneously.
The -2CAN- expansion module provides the interfaces on separate Sub-D connectors.
The two CAN connectors are wired in parallel. A termination resistor (120 W) for the CAN
bus can be switched into circuit if the S748/772 is at the end of the bus.
9.1.8.1 Installation
The modul must be placed onto the option slot after levering off the cover of the option
slot 1 (see p. 115):
l Screw the distance pieces into the fixing lugs of the option slot.
l Place the expansion module onto the option slot.
l Screw the screws into the threads of the distance pieces.
l Plug the Sub-D9 socket into connector X6 on the S748/772
Standard shielded cables can be used for the RS232 and CAN interfaces.
If the servo amplifier is the last device on the CAN bus, then the switch for the bus
termination must be set to ON.
Otherwise, the switch must be set to OFF (condition as delivered).

9.1.8.3 Connector assignments
RS232 CAN1=CAN2
X6A Pin Signal X6B=X6C Pin Signal
1 Vcc 1
2 RxD 2 CAN-Low
3 TxD 3 CAN-GND
4 4
5 GND 5
6 6
7 7 CAN-High
8 8
9 9
9.1.8.4 Setup of Station Address and Baud Rate
During setup it makes sense to use the keypad on the front panel to preset the station
addresses for the individual amplifiers and the Baud rate for communication.
After changing the station address and baud rate you must turn the 24V auxiliary supply
for the servo amplifier off and on again.
Possible ways for setup:
l keypad on the front panel of the servo amplifier
l setup software: screen page “CAN / Fieldbus”
l serial interface with a sequence of ASCII commands:
ADDR nn Þ SAVE Þ COLDSTART (with nn = address)
CBAUD bb Þ SAVE Þ COLDSTART (with bb = baud rate in kBaud)
Coding of the Baud rate in LED display:

Baud rate in
Coding Baud rate in kBit/s Coding
kBit/s
1 10 25 250
2 20 33 333
5 50 50 500
10 100 66 666
12 125 80 800
100 1000


The method of installing the expansion card in slot 2 is the same

as that described for slot 1 (see p.115).
l Remove the lower crosshatched area of the front film (labe-
led slot 2).
l Lever out the cover plates under the film.
l Push the expansion card into the slot.
l Use the screws provided to fasten the front plate of the ex-
pansion card in place.
Boundary of SLOT 2
9.2.2 Option "F2", controlled Fan
To reduce noise emission the servo amplifiers can be ordered with the built-in option card
F2. This option cannot be built-in later. The F2 option card fits to slot2 or 3 (see part num-
ber scheme on p.20).
Option card F2 can be used combined with a card in slot 1 even if it is plugged to slot 2!
Function
The fan is switched on and off or runs with 50% rated speed depending on temperature
values. That reduces the average noise emission.
Switching temperature
Monitoring Fan off Fan ~50% Fan on
Internal temperature < 55°C ~ 58°C >65°C
Heat sink temperature < 58°C ~ 68°C > 80°C

9.2.3 Expansion card "PosI/O" and "PosI/O-Monitor"
The “PosI/O”and "PosI/O-Monitor" expansion cards can be pushed into slot2 or 3. The
expansion cards cannot be combined and the use of only one slot in time is allowed.
PosI/O
This expansion card provides an extra SubD connector (X5) with high-speed, bidirectio-
nal digital 5 V inputs/outputs. The setup software can be used to preset various input and
output functions, e.g.:
l Position encoder emulation (ROD- or SSI-compatible)
l Input for high-speed 5 V RS485 signals (electronic gearing, master-slave operation)
PosI/O-Monitor
This expansion card provides the features of the PosI/O card plus an extra connector
X3C with analog +/-10V Inputs and Outputs (see page 140, chapter "Analog I/O").
Functionality can be set with the setup software or with macro functions.

9.2.3.1 Feedback
9.2.3.1.1 ROD (AquadB) 5V (X5, X1)
A 5V incremental encoder (AquadB) can be used as standard motor feedback (primary

and secondary, ð p.66).Every time the 24V auxiliary voltage is switched on, the amplifier
need start-up information for the position controller (parameter value MPHASE). Depen-
ding on the feedback type either wake&shake is executed or the value for MPHASE is
read out of the amplifier's EEPROM.
WARNING
The power supply for the encoder and thermal control in the motor is connected to X1.
If lead lengths of more than 50m are planned please consult our customer service.
Frequency limit (A, B, N): 1.5 MHz
Type FBTYPE EXTPOS GEARMODE Bemerkung
SubD 9
S748/772

9.2.3.1.2 ROD (AquadB) 5V with Hall (X5, X1)
Wiring of a 5V incremental encoder (ROD, AquadB) with Hall sensors as a feedback unit
(primary, ð p.66). For the commutation hall sensors are used and for the resolution an
incremental encoder.
The power supply for the encoder and thermal control in the motor is connected to X1
and evaluated there.
Frequency limit X5: 1.5 MHz, X1: 350 kHz
Tyoe FBTYPE EXTPOS GEARMODE

AquadB 5V with Hall 18 - -
S748/772

9.2.3.1.3 SSI Encoder (X5, X1)
Wiring of a synchronous serial absolute-encoder as a feedback system (primary or

secondary, ð p.66). The signal sequence can be read in Gray code or in Binary (stan-
dard) code.
The power supply for the encoder and thermal control in the motor is connected to X1
and evaluated there.

SSI 9 5 5
S748/772

9.2.3.1.4 Sine Encoder with SSI (X5, X1)
Wiring of sine-cosine encoder with SSI interface as a linear feedback system

(primary, ð p.66).

SinCos SSI 5V linear 28 - -
S748/772

9.2.3.2 Electronic gearing, Master-Slave operation (X5)
9.2.3.2.1 Connection to S748/772 master, 5V signal level (X5)
You can link several S748/772 amplifiers together in master-slave operation.

Master: position output to X5 (screen page "Encoder emulation")
Slave: screen page "Electronic gearing" (GEARMODE)
Up to 16 slave amplifiers can be controlled by the master, via the encoder output. The
SubD connector X5 is used for this purpose.
Example for Master-Slave operation with two S748/772 amplifiers, ROD emulation is
used:
Slave GEARMODE: 3 Master ENCMODE:1
S748/772 S748/772
If SSI emulation is used, the master ENCMODE must be set to 2 and the slave GEAR-
MODE to 5.
9.2.3.2.2 Connection to stepper motor controllers with 5 V signal level (X5)
Wiring of the servo amplifier (SubD connector X5) to a stepper-motor controller with a 5 V
signal level.

Step/Direction 5V - - 4
S748/772

9.2.3.3 Encoder-Emulation (X5)
9.2.3.3.1 Incremental encoder output - A quad B (X5)
Fast incremental encoder interface. Select encoder function ROD (A Quad B) Encoder
(“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft posi-
tion from the cyclic- absolute signals of the resolver or encoder, generating incremen-
tal-encoder compatible pulses from this information. Pulse outputs on the SubD connec-
tor X5 are 2 signals, A and B, with 90° phase difference (i.e. in quadrature, hence the
alternative term “A quad B” output), with a zero pulse.
The resolution (before multiplication) can be set by the RESOLUTION function:
Encoder function Feedback system Resolution

Zero pulse (NI)
(ENCMODE) (FBTYPE) (ENCOUT)
once per turn
0, Resolver 32...4096
(only at A=B=1)
1, ROD
256...524288 once per turn
>0, Encoder
(28 … 219) (only at A=B=1)
24...27 (multiplication) encoder signal pas-
3, ROD interpolation Encoder TTL line x encoder re- sed through from X1
solution to X5
With built in safety card only binary resolutions up to 212 are possible.
Use the NI-OFFSET parameter to adjust + save the zero pulse position within one
mechanical turn. The drivers operate off an internal supply voltage. The maximum per-
missible cable length is 100 meters.
Connections and signals for the incremental encoder interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the
shaft's end)
S748/772

9.2.3.3.2 SSI encoder output (X5)
SSI interface (synchronous serial absolute-encoder emulation). Select encoder function

SSI (“Encoder Emulation” screen page, ENCMODE 2). The servo amplifier calculates the
motor shaft position from the cyclic-absolute signals of the resolver or encoder. From this
information a SSI date (Stegmann patent specification DE 3445617C2) is provided. Max
32 bits are transferred. The leading data bit contains the number of revolutions and are
selectable from 12 to 16 bits. The following max. 16 bits contain the resolution and are
not variable.
The following table shows the allocation of the SSI date depending upon selected number
of revolutions:
Revolution Resolution (variable)
SSIREVOL
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit
13 12 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
12 11 10 9 8 7 6 5 4 3 2 1 0
11 10 9 8 7 6 5 4 3 2 1 0
The signal sequence can be output in Gray code or in Binary (standard) code.
The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the
setup software.
The drivers operate off an internal supply voltage.
Connection and signals for the SSI interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the end
of the motor shaft)
S748/772

9.2.3.4 Analog Inputs and Outputs
The expansion card "PosI/O-Monitor" adds analog inputs and outputs to the servo ampli-
fier were pre-programmed signals can be assigned to. A listing of these pre-programmed
functions can be found on the screen page "Analog I/O" of the setup software.
9.2.3.4.1 Analog Outputs ANALOG-OUT 1 and 2
You can use terminals X3C/17 (Analog-Out 1) respectively X3C/19 (Analog-Out 2) to deli-
ver analog values converted from internal digital values (e.g. tachometer voltage).
— Reference ground is Analog-GND (AGND, terminal X3C/18 and X3C/20)
— Specification according to EN 61131-2 table 11
— Output voltage ±10 V
— Resolution: 0.38 mV, 16 Bit, Update rate 250 µs
S748/772
9.2.3.4.2 Analog Inputs ANALOG-IN 3 and 4
You can use terminals X3C/21-22 (Analog-In 3) respectively terminal X3C/24-25 (Ana-
log-In 4) with several pre-programmed functions.
— Differential input voltage max. ± 10 V

— Resolution 1.25 mV, 16 bits, scalable
— Ground reference AGND, terminal X3C/23
— Input resistance 20 kW
— Common-mode voltage range for both inputs ± 10 V
— Update rate 62.5 µs
S748/772


The method of installing the expansion card in slot 3 is the

same as that described for slot 1 (see p.115).
l Remove the area of the front film colored yellow (labe-
led slot 3).
l Lever out the cover plates under the film.
l Remove the small PCB (STO Bridge) which is plugged
into slot. Use suitable pliers.
l Push the expansion card into the slot.
l Use the screws provided to fasten the front plate of the
expansion card in place.
9.3.2 Option "F2", controlled Fan
To reduce noise emission the servo amplifiers can be ordered with the built-in option card
F2. This option cannot be built-in later. The F2 option card fits to slot2 or 3 (see part num-
ber scheme on p.20).
Function
The fan is switched on and off or runs with 50% rated speed depending on temperature.
That reduces the average noise emission.
Switching temperature
Monitoring Fan off Fan ~50% Fan on
Internal temperature < 55°C ~ 58°C > 65°C
Heat sink temperature < 58°C ~ 68°C > 80°C
9.3.3 Expansion cards "PosI/O" & "PosI/O-Monitor"
The “PosI/O” and "PosI/O-Monitor" expansion cards can be pushed into slot 2 or 3. The
expansion cards cannot be combined and the use of only one slot in time is allowed.
A detailed description of the interfaces can be found from page 132.

9.3.4 Expansion card "Safety 2-2" (S4)
This expansion card (Basic version) includes various safety functions for the safe opera-
tion of drive shafts. Rotatory synchronous motors are allowed when using this safety
card. All functions fulfill the safety requirements SIL CL2 according to IEC 62061 respec-
tively performance level PLd according to ISO 13849-1.
The safety card restricts feedback capability of the drive (refer to Safety Card Operation
Manual or to the Product WIKI).
9.3.4.1 Safe drive functions S2-2
The safety functions are selected/activated using the digital inputs on the expansion card.
The following functions are available:
Safe Torque Off (STO)
With the STO function, the power supply to the motor is interrupted safely directly in the
drive. This corresponds to an uncontrolled braking in accordance with IEC 60204-1, cate-
gory 0.
Safe Stop 1 (SS1)
With the SS1 function, the drive is stopped by controlled braking and then the power
supply to the motor is interrupted safely. This corresponds to an uncontrolled braking in
accordance with IEC 60204-1, category 1.
Safe Stop 2 (SS2)
With the SS2 function, the drive is stopped by controlled braking and then remains at a
controlled standstill (SOS). This corresponds to a controlled braking in accordance with
IEC 60204-1, category 2.
Safe Operating Stop (SOS)
The SOS function monitors the stop position reached and prevents any deviation outside
a defined range.
Safely Limited Speed (SLS)
The SLS function monitors the drive to ensure that it maintains a defined speed.
Safe Limited Increments (SLI)
The SLI function monitors that the drive maintains a relative position.
Safe Speed Range (SSR)
The SSR function checks the current speed of the drive against maximum and minimum
limiting values.
Safe Direction (SDI)
The SDI function ensures that the drive can only move in one (defined) direction.
9.3.4.2 Safety Notes S2-2
Comply with the operating instructions for the safety card. You can find the operating
instructions on the CD-ROM provided with the product or on the website.

9.3.4.3 Wiring supply voltage S2-2
Input X4/5 "STO2-Enable" must be connected to +24V DC and must not be used as
additional STO input! Input STO1-Enable [X4/7] must not be connected.
9.3.4.4 Safe inputs/outputs S2-2
Inputs X30/1 SS1_Activate and X30/20 Reset must always be connected. In the case of
all inputs, only tested outputs from a safety control system may be connected.
X30 Pin E/A Description

SS1 Activate 1 I Activates function SS1
I0 2 I Programmable, activate safety function X
STO Acknowledge 5 O Status: STO activated
O0 6 O Programmable, status: safety function X activated
24V Supply 10 - 24V supply of digital outputs
n.c. 11 - n.c.
Ready 16 O Message "Safety card is ready to operate"
n.c. 17 O n.c.
n.c. 18 O n.c.
n.c. 19 O n.c.
Reset 20 I Input for Reset

9.3.4.5 Wiring inputs S2-2
9.3.4.6 Wiring outputs S2-2

9.3.5 Expansion card "Safety 1-2" (S3)
This expansion card includes all available safety functions. Rotatory synchronous motors
are allowed when using this safety card. All functions fulfill the safety requirements SIL
CL3 according to IEC 62061 respectively performance level PLe acc. to ISO 13849-1.
The safety card restricts feedback capability of the drive (refer to Safety Card Operation
Manual or to the Product WIKI).
9.3.5.1 Safe drive functions S1-2
The safety functions are selected/activated using the digital inputs on the expansion card.
The following functions are available:
Safe Torque Off (STO)
With the STO function, the power supply to the motor is interrupted safely directly in the
drive. This corresponds to an uncontrolled braking in accordance with IEC 60204-1, cate-
gory 0.
Safe Stop 1 (SS1)
With the SS1 function, the drive is stopped by controlled braking and then the power
supply to the motor is interrupted safely. This corresponds to an uncontrolled braking in
accordance with IEC 60204-1, category 1.
Safe Stop 2 (SS2)
With the SS2 function, the drive is stopped by controlled braking and then remains at a
controlled standstill (SOS). This corresponds to a controlled braking in accordance with
IEC 60204-1, category 2.
Safe Operating Stop (SOS)
The SOS function monitors the stop position reached and prevents any deviation outside
a defined range.
Safely Limited Speed (SLS)
The SLS function monitors the drive to ensure that it maintains a defined speed.
Safe Limited Increments (SLI)
The SLI function monitors that the drive maintains a relative position.
Safe Limited Position (SLP)
The SLP function monitors that the drive maintains an absolute position.
Safe Speed Range (SSR)
The SSR function checks the current speed of the drive against maximum and minimum
limiting values.
Safe Direction (SDI)
The SDI function ensures that the drive can only move in one (defined) direction.
Safe Brake Control (SBC)
An external mechanical brake can be controlled by the 2 poles output "SBC+/SBC" of the
safety card. SBC will become active with STO.
Safe Brake Test (SBT)
The safety function SBT can be used for testing the external mechanical brake and the
internal motor holding brake.
9.3.5.2 Safety Notes S1-2
Comply with the operating instructions for the safety card. You can find the operating
instructions on the CD-ROM provided with the product or on the website.

9.3.5.3 External encoder S1-2
Incremental encoder (TTL) or encoder with SSI signals can be connected to X31.
X31 Pin Incremental encoder SSI Encoder (in process)
1 Channel A+ Clock +
2 Channel B+ Data +
3 Reference Z+ n.c.
4 Supply U+ Supply U+
5 Shield n.c.
6 Channel A- Clock-
7 Channel B- Data-
8 Reference Z- n.c.
9 Supply 0 V Supply 0 V
9.3.5.4 Wiring supply voltage S1-2
Input STO1-Enable [X4/7] must not be connected.
9.3.5.5 Safe inputs/outputs S1-2
Inputs X30/1 SS1_Activate and X30/20 SS1_SIL3/Reset must always be connected. In

the case of all inputs, only tested outputs from a safety control system may be connected.
X30 Pin E/A Description
SS1 Activate 1 I Activates function SS1
STO Acknowledge 5 O Status: STO activated
Encoder Supply 11 - Power supply for external encoder
Ready 16 O Message "Safety card is ready to operate"
SBC+ 17 O Control external brake +
SBC- 18 O Control external brake -
STO SIL CL3 19 O Output single
SS1 SIL CL3/Reset 20 I Input for SIL CL3 and Reset

9.3.5.6 Wiring inputs S1-2
9.3.5.7 Wiring outputs S1-2


Kollmorgen 12/2014 Appendix
10 Appendix
10.1 Glossary
B Brake circuit Converts generative energy fed back by the motor
during braking (generated energy) to heat.
C Clock Clock signal
Common-mode voltage The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
Counts Internal count pulses, 1 pulse = ½20 turn-1
Continuous power of brake circuit Mean power that can be dissipated in the brake
circuit
Current controller Regulates the difference between the current
setpoint and the actual value to 0
Output : power output voltage
D DC bus link Rectified and smoothed power voltage
Disable Removal of the ENABLE signal
E Earth short electrical connection between a phase and
the protective earth (PE)
Enable Enable signal for the servo amplifier,
Hardware-Enable with 24V signal to X3,
Software-Enable command by setup Software,
fieldbus or permanently set.
Both are required for enabling the amplifier.
ENABLE Enable signal for the servo amplifier (+24 V)
F Fieldbus interface CANopen, PROFIBUS, SERCOS etc.
Final speed (limit speed) Maximum value for the speed normalization at
±10 V
G GRAY-code Special format for representing binary numbers
H Holding brake Brake in the motor, that can only be used when the
motor is at standstill
I I²t threshold Monitoring of the r.m.s. current that is actually
required
Input drift Temperature and age-dependent alteration of an
analog input
Incremental encoder interface Position signaling by 2 signals with 90° phase
difference (i.e. in quadrature), is not an absolute
position output
Ipeak, peak current The effective value of the peak current
Irms, effective current The r.m.s. value of the continuous current
K Kp, P-gain Proportional gain of a control loop
L Limit speed (final speed) Maximum value for speed normalization at ±10 V
Limit switch Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact

Appendix 12/2014 Kollmorgen
M Machine The complete assembly of all connected parts or

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

10.2 Order codes

The order numbers of accessories such as cables, brake resistors, mains supplies, etc.,
can be found in the accessories manual (CDROM or website).
10.2.1 Servo amplifiers
Article (standard version)* EU order code US order code

Servo amplifier S74802 S74802-NANANA
Servo amplifier S77202 S77202-NANANA
*= Standard: CANopen and EtherCAT onboard, no expansion card. See "Part number
scheme" on p. 20.
Article (standard version with F2 opti-

EU order code US order code
on built Slot 2)
Servo amplifier S74802-NAF2NA S74802-NAF2NA
Servo amplifier S77202-NAF2NA S74802-NAF2NA
Article (standard version with F2 opti-

EU order code US order code
on built Slot 3)
Servo amplifier S74802-NANAF2 S74802-NANAF2
Servo amplifier S77202-NANAF2 S77202-NANAF2
10.2.2 Memory Card
Article EU order code US order code

Industrial Memory Card
DE-201257 in process
(can remain in the drive)

10.2.3 Expansion cards
10.2.3.1 Covers for Option Slots

Slot covers
DE-201295 in process
(1 for Slot 1 & 1 for Slot 2 or Slot 3)
10.2.3.2 Slot 1

Expansion card DeviceNet DE-103571 OPT-DN
Expansion card PROFIBUS DP DE-106712 OPT-PB3
Expansion card SERCOS DE-90879 OPT-SE
Expansion card I/0-14/08 DE-90057 OPT-EI
Expansion card SynqNet DE-200073 OPT-SN
Expansion card FB-2to1 DE-201664 in process
Expansion module 2CAN DE-201076 in process
10.2.3.3 Slot 2

Expansion card PosI/O DE-200881 in process
Expansion card PosI/O-Monitor DE-201294 in process
10.2.3.4 Slot 3

Expansion card PosI/O DE-200881 in process
Expansion card PosI/O-Monitor DE-201294 in process
Expansion card Safety 1-2, SIL CL3 DE-201873 in process
Expansion card Safety 2-2, SIL CL2 DE-201874 in process
STO Bridge (instead of Safety Card) DE-200566 in process
10.2.4 Mating connectors

Mating connector X3A DE-200447 CON-S7X3A
Mating connector X3B DE-200448 CON-S7X3B
Mating connector X3C DE-200957 CON-S7X3C
Mating connector X4 DE-201241 CON-S7X4
Mating connector X9A DE-201194 CON-S7X9A
Mating connector X9B DE-201193 CON-S7X9B

10.3 Repair-/Disposal request Telefax form
To
Kollmorgen Europe GmbH
Pempelfurtstrasse 1
D-40880 Ratingen
Germany
Fax: +49 (0) 2102 9394 3444
Please advice dispatch information for (please select)
¡ Repair
¡ Disposal
of these products:
Product Serial number Reason ("fault", "return" or similar)
to this address:
Company
Street
Zip / City
Country
Specialist Name
Telephone
Telefax
E-Mail
City, Date Signature

10.4 Index
! 24V aux. supply, interface . . . . . . . . 61 G Glossary . . . . . . . . . . . . . . . . 149
Grounding
A Abbreviations used . . . . . . . . . . . . 9
Connection diagram . . . . . . . . . 59
Ambient temperature. . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . 52
Analog inputs. . . . . . . . . . . . . . . 88
H Hall sensor interface . . . . . . . . . . . 82
Assembly. . . . . . . . . . . . . . . . . 49
Hardware requirements . . . . . . . . . 99
B BTB/RTO. . . . . . . . . . . . . . . . . 92 Hiperface encoder interface . . . . . . . 72
Baud rate . . . . . . . . . . . . . . . . 109 Humidity . . . . . . . . . . . . . . . . . 26
BiSS encoder analog. . . . . . . . . . . 68 Storage . . . . . . . . . . . . . . . . 14
BiSS encoder digital . . . . . . . . . . . 69 in operation . . . . . . . . . . . . . . 26
Block diagram, overview . . . . . . . . . 57 I Inputs
Brake resistor Analog, optional . . . . . . . . . . . 140
Interface, ext. . . . . . . . . . . . . . 63 Analog, standard . . . . . . . . . . . 88
Technical data . . . . . . . . . . . . 29 Digital, standard . . . . . . . . . . . 89
Brake, see also motor-holding brake. . . 28 Enable . . . . . . . . . . . . . . . . 89
C CAN bus cable . . . . . . . . . . . . . . 94 STO-Enable . . . . . . . . . . . . . 90
CANopen interface . . . . . . . . . . . . 94 Installation
CE conformance . . . . . . . . . . . . . 18 Electrical . . . . . . . . . . . . . . . 51
Comcoder interface . . . . . . . . . . . 78 Expansion card Slot1 . . . . . . . . 115
Conductor cross-sections . . . . . . . . 27 Expansion card Slot2 . . . . . . . . 131
Expansion card Slot3 . . . . . . . . 141
Connection Diagram, overview. . . . . . 59
Mechanical . . . . . . . . . . . . . . 47
Connector assignments . . . . . . . . . 58 Software . . . . . . . . . . . . . . . 99
Connectors . . . . . . . . . . . . . . . . 25
K Keypad operation . . . . . . . . . . . . 109
D DC bus link, interface . . . . . . . . . . 62
L LED display . . . . . . . . . . . . . . . 109
Devicenet bus cable . . . . . . . . . . 124
Leakage current . . . . . . . . . . . . . 45
Dimensions. . . . . . . . . . . . . . . . 48
Disassembling . . . . . . . . . . . . . . 14 M Maintenance . . . . . . . . . . . . . . . 14
Disposal . . . . . . . . . . . . . . . . . 15 Master-Slave X5 . . . . . . . . . . . . 137
Dynamic braking . . . . . . . . . . . . . 29 Master-slave X1 . . . . . . . . . . . . . 85
Memory Card. . . . . . . . . . . . . . . 96
E Electronic gearing X1 . . . . . . . . . . 83
Motor holding brake . . . . . . . . . . . 28
Electronic gearing X5 . . . . . . . . . . 137
Motor interface . . . . . . . . . . . . . . 64
Emergency Off . . . . . . . . . . . . . . 34
Mounting position . . . . . . . . . . . . 26
Emergency Stop . . . . . . . . . . . . . 34
EnDat 2.1 Encoder Interface . . . . . . . 70 N Nameplate . . . . . . . . . . . . . . . . 19
EnDat 2.2 Encoder Interface . . . . . . . 71 Noise emission . . . . . . . . . . . . . . 24
Enclosure protection . . . . . . . . . . . 26 O Operating systems . . . . . . . . . . . . 99
Encoder emulation X1 . . . . . . . . . . 86 Optical power . . . . . . . . . . . . . . 121
Encoder-Emulation X5 . . . . . . . . . 138 Option F2 . . . . . . . . . . . . . . . . 131
Error messages . . . . . . . . . . . . . 112 Order codes. . . . . . . . . . . . . . . 151
EtherNet Outputs
EtherCat Protocol . . . . . . . . . . 95 Analog, optional . . . . . . . . . . . 140
Expansion card BTB/RTO . . . . . . . . . . . . . . . 92
-2CAN- . . . . . . . . . . . . . . . 129 Digital, standard . . . . . . . . . . . 91
-DeviceNet- . . . . . . . . . . . . . 122 STO1/2-Status . . . . . . . . . . . . 92
-FB-2to1- . . . . . . . . . . . . . . 127 P PC cable . . . . . . . . . . . . . . . . . 93
-I/O-14/08- . . . . . . . . . . . . . 116 PC connection . . . . . . . . . . . . . . 93
-PROFIBUS- . . . . . . . . . . . . 119
Package supplied . . . . . . . . . . . . 19
-PosI/O- . . . . . . . . . . . . . . . 132
-PosI/O-Monitor- . . . . . . . . . . 132 Packaging . . . . . . . . . . . . . . . . 13
-SERCOS- . . . . . . . . . . . . . 120 Part number scheme . . . . . . . . . . . 20
-Safety S3- . . . . . . . . . . . . . 145 Pollution level . . . . . . . . . . . . . . 26
-Safety S4- . . . . . . . . . . . . . 142 Q Quickstart . . . . . . . . . . . . . . . . 100
-SynqNet- . . . . . . . . . . . . . . 125
F Feedback systems . . . . . . . . . . . . 66
Fusing . . . . . . . . . . . . . . . . . . 26

R RCD . . . . . . . . . . . . . . . . . . . 45 T Target group . . . . . . . . . . . . . . . 11

ROD 24V interface . . . . . . . . . . . . 79 Technical data . . . . . . . . . . . . . . 24
ROD 24V with Hall interface . . . . . . . 80 Tightening torques, connectors . . . . . 25
ROD 5V 350kHz . . . . . . . . . . . . . 77 Transport . . . . . . . . . . . . . . . . . 13
ROD 5V with Hall interface. . . . . . . . 78 Trouble shooting . . . . . . . . . . . . 114
ROD 5V, 1.5MHz. . . . . . . . . . . . . 76 U Use as directed
ROD emulation X1 . . . . . . . . . . . . 86 Safety Function STO . . . . . . . . . 36
ROD emulation X5 . . . . . . . . . . . 138 Servo amplifiers . . . . . . . . . . . 12
RS232/PC, interface . . . . . . . . . . . 93 Setup Software . . . . . . . . . . . . 98
Repair . . . . . . . . . . . . . . . . . . 15 V Ventilation
Repair request . . . . . . . . . . . . . 153 Installation . . . . . . . . . . . . . . 47
Resolver interface . . . . . . . . . . . . 67 Technical data . . . . . . . . . . . . 26
S SSI Emulation X1 . . . . . . . . . . . . 87 Vibrations . . . . . . . . . . . . . . . . 26
SSI Encoder 5V at X1 . . . . . . . . . . 81 W Warnings . . . . . . . . . . . . . . . . 113
SSI Encoder 5V at X5. . . . . . . . . . 135 Wiring . . . . . . . . . . . . . . . . . . 52
SSI emulation X5 . . . . . . . . . . . . 139
STO . . . . . . . . . . . . . . . . . . . 35
Safe drive functions
S3 card . . . . . . . . . . . . . . . 145
S4 card . . . . . . . . . . . . . . . 142
Safety Function STO . . . . . . . . . . . 35
Safety characteristic data . . . . . . . . 35
Safety instructions . . . . . . . . . . . . 10
Setup software . . . . . . . . . . . . . . 98
Shielding . . . . . . . . . . . . . . . . . 52
Shielding connection . . . . . . . . . . . 54
Shielding plate . . . . . . . . . . . . . . 49
Shock-hazard protection . . . . . . . . . 45
SinCos encoder w/o data channel . . . . 74
SinCos encoder with Hall . . . . . . . . 75
SinCos+SSI at X1 . . . . . . . . . . . . 73
SinCos+SSI at X5. . . . . . . . . . . . 136
Site . . . . . . . . . . . . . . . . . . . . 47
Site altitude. . . . . . . . . . . . . . . . 26
Stacking height. . . . . . . . . . . . . . 14
Standards . . . . . . . . . . . . . . . . 18
Standards used . . . . . . . . . . . . . . 8
Station address
CAN bus . . . . . . . . . . . . . . 109
DeviceNet . . . . . . . . . . . . . . 123
SERCOS . . . . . . . . . . . . . . 121
SynqNet . . . . . . . . . . . . . . . 125
Step/Direction 24V . . . . . . . . . . . . 84
Step/Direction 5V at X1 . . . . . . . . . 84
Step/Direction 5V at X5 . . . . . . . . . 137
Stop . . . . . . . . . . . . . . . . . . . 33
Storage. . . . . . . . . . . . . . . . . . 14
Supply connection, interface . . . . . . . 61
Supply networks . . . . . . . . . . . . . 60
Supply voltage . . . . . . . . . . . . . . 26
Switch-on/switch-off behavior . . . . . . 30
Symbols used . . . . . . . . . . . . . . . 8
System components, overview. . . . . . 56

Service
We are committed to quality customer service. In order to serve in the most effective way,
please contact your local sales representative for assistance.
If you are unaware of your local sales representative, please contact the Customer Support.
Europe
KOLLMORGEN Customer Support Europe
Internet www.kollmorgen.com
E-Mail [email protected]
Tel.: +49 (0)2102 - 9394 - 0
Fax: +49 (0)2102 - 9394 - 3155
KOLLMORGEN European
UK Website Product WIKI
North America
KOLLMORGEN Customer Support North America
Tel.: +1 - 540 - 633 - 3545
Fax: +1 - 540 - 639 - 4162
KOLLMORGEN
US Website
Asia
KOLLMORGEN
Tel: +86 - 400 666 1802
Fax: +86 - 10 65 15 0263
KOLLMORGEN
CN Website

Kollmorgen S700 Servo Drive S748... S772 Instruction Manual

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Kollmorgen S700 Servo Drive S748... S772 Instruction Manual

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S700

Digital Servo Amplifier S748…S772

Keep all manuals as a product component

Hardware Revision (HR)

WINDOWS is a registered trademark of Microsoft Corporation

S748-S772 Instructions Manual 3

4 S748-S772 Instructions Manual

S748-S772 Instructions Manual 5

6 S748-S772 Instructions Manual

1.2 Hints for the online edition (PDF format)

S748-S772 Instructions Manual 7

1.3 Symbols used

Warning of danger from electricity and its effects.

Warning of hot surfaces.

Warning of suspended loads.

1.4 Standards used

8 S748-S772 Instructions Manual

1.5 Abbreviations used

S748-S772 Instructions Manual 9

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Specialist staff required!

S748-S772 Instructions Manual 11

2.2 Use as directed

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2.3 Prohibited use

S748-S772 Instructions Manual 13

2.4.4 Maintenance, Cleaning

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In accordance to the WEEE-2002/96/EC-Guidelines we take old devices and accessories

S748-S772 Instructions Manual 15

This page has been deliberately left blank.

16 S748-S772 Instructions Manual

l For use on a solidly grounded wye source only.

S748-S772 Instructions Manual 17

3.3 European Directives and Standards for the machine builder

18 S748-S772 Instructions Manual

Electrical supply Enclosure max. ambient Hardware Software

S748-S772 Instructions Manual 19

4.3 Part number scheme

Family Firmware Options

Expansion Cards Slot 1 Expansion Cards Slot 2

1 is void with standard

20 S748-S772 Instructions Manual

S748-S772 Instructions Manual 21

Auxiliary supply voltage 24V DC

Operation and parameter setting

Completely digital control

22 S748-S772 Instructions Manual

S748-S772 Instructions Manual 23

5.2 Technical data

Electrical data DIM S748 S772

24 S748-S772 Instructions Manual

5.2.2 Inputs / outputs, aux. voltage supply

Interface electr. data

max. cross permiss. permiss.

5.2.4 Recommended tightening torques

Connection Tightening torque

S748-S772 Instructions Manual 25

Internal fusing, wire fuse or electronic