Connecting Kollmorgen ADKH Motors to SINAMICS S120

1. System Overview

Connecting third-party servomotors such as the Kollmorgen ADKH series to a SINAMICS S120 drive line-up requires a structured evaluation of the motor's encoder interface, the line voltage, and the appropriate Sensor Module Cabinet (SMC) mounted in the S120 Active Line Module / Motor Module stack. The same approach applies to Siemens 1FK7 servomotors (e.g., 1FK7060-2AF71-1RB0, 1FK7032-2AK71-1RA0) that are paired with third-party feedback. The drive line-up shown in the source data consists of:

• Smart Line Module: 6SL3130-6AE15-0AB1 (5 kW, 380–480 V 3-ph input, internal air cooling, booksize)
• Single Motor Module (Compact): 6SL3120-2TE13-0AA4 (3 A rated, internal air cooling, C/D type booksize)
• Control Unit: CU320-2 DP or CU320-2 PN with optional D425-2 extension (SINUMERIK)

The sensor module you select is driven entirely by the encoder interface on the motor (resolver, EnDat, SSI, incremental) — not by the drive firmware version. The MLFB (order number) of the SMC determines which protocols are decoded by hardware; the firmware then parameterises the correct EnDat command set automatically once the encoder type is recognised.

2. Hardware Identification and MLFB Cross-Reference

Use the table below to map the motor and encoder to the correct SMC. The MLFB string carries protocol information — for instance 6SL3055-0AA00-5BA2 is the SMC20 base unit while 6SL3055-0AA00-5BA3 adds extended functionality. Always cross-check against the SINAMICS S120/S150 List Manual before ordering.

3. Sensor Module Selection — SMC10, SMC20, SMC30

The SMC family decodes position feedback from the motor and converts it to DRIVE-CLiQ for the Control Unit. Selection rules:

1. SMC10 (6SL3055-0AA00-5AAx) — Resolver. Two-pole and multi-pole resolvers are supported. Internal excitation oscillator (8 kHz / 4 kHz) and resolver-to-digital conversion (RDC). Maximum cable length 130 m. Inputs are differential (SIN/COS, REF, EXC).
2. SMC20 (6SL3055-0AA00-5BAx) — Absolute encoder. Supports EnDat 2.1, EnDat 2.2, SSI with incremental sin/cos 1 Vpp tracks. Maximum 100 m cable. Used for HEIDENHAIN ECN/EQN, Hengstler, and any third-party EnDat encoder.
3. SMC30 (6SL3055-0AA00-5CAx) — Incremental encoder. TTL (RS422), HTL, sin/cos 1 Vpp without serial protocol. For TTL/HTL signals with marker pulse only.

For a Kollmorgen ADKH with EnDat feedback, the answer is unambiguous: use SMC20. For the resolver-equipped variant, use SMC10.

4. Voltage and Power Considerations (240 V Operation)

The Kollmorgen ADKH family is commonly available in 240 V, 400 V, and 480 V winding variants. The 240 V variant is a low-voltage servo commonly used in North American 240 V Delta or 230 V single-phase derived systems. To use 240 V with an S120 drive, the topology must match the SLM/SLM input rating.

The supplied SLM 6SL3130-6AE15-0AB1 is rated 380–480 V 3-ph. Driving a 240 V motor from a 540 V DC bus will damage the winding insulation within seconds. Solutions:

1. Add an autotransformer (480 → 240 V step-down) on the line side. The SLM is then fed with 240 V 3-ph and produces ~340 V DC, safe for the 240 V class motor.
2. Substitute a BLM with 200–240 V input. The S120 Equipment Manual lists the BLM 5 kW as 6SL3130-1TE22-0AA0.
3. Use a 400 V ADKH variant if the mechanical envelope is acceptable.

Verify the motor insulation class (typically B = 130 °C or F = 155 °C) and peak DC bus voltage (Vdc_max = 1.35 × Vline_rms × √2). For 480 V line, Vdc_max ≈ 917 V — far above 240 V insulation ratings. The S120 List Manual provides the matching procedure in section "Motor selection / third-party motors".

5. Encoder Protocol — EnDat 2.1 vs 2.2 and EnDat01 vs EnDat02

EnDat is a bidirectional synchronous serial protocol from HEIDENHAIN. The version is a property of the encoder, not the SMC. The SMC20 hardware supports both.

The HEIDENHAIN EQN1125 is a multiturn absolute encoder with 8192 steps/rev × 4096 turns = 25 bits. It speaks EnDat 2.1 and uses the EnDat01 command set. It is fully supported by SMC20. The "8192 × 4096" in the source refers to the singleturn resolution (13 bits) × multiturn turns (12 bits).

6. Control Unit D425-2 Compatibility with SMC20

The D425-2 is a SINUMERIK NC module that extends a CU320-2 with high-performance interpolation. It is plugged into the S120 booksize rack like any other DRIVE-CLiQ device. The D425-2 has no direct role in encoder evaluation; the SMC20 connected to the motor evaluates the EnDat signal and forwards the position via DRIVE-CLiQ to both the D425-2 and the CU320-2.

There is no SMC20 version-A restriction for the D425-2. The SMC20 MLFB does not change with Control Unit; the SMC is independent of whether you are using STARTER, SCOUT, TIA Portal, or the SINUMERIK HMI. The SMC20's firmware is part of the S120 firmware release (e.g., V5.2 SP3, V5.3) and is loaded automatically by the CU on first power-up.

7. Configuration in SCOUT / TIA Portal (Startdrive)

Configuration differs between SINUMERIK engineering (SCOUT) and SINAMICS-only engineering (STARTER / Startdrive). The underlying parameters are the same.

7.1 SCOUT (SINUMERIK) Procedure

1. Open the project → click the drive (e.g., SERVO_3.3:1:2) → Commissioning → Drive wizard.
2. Select Configure drive → Standard motor with third-party motor if Kollmorgen ADKH is not in the motor list. Enter the MLFBs of motor, encoder, and SMC20.
3. In Encoder selection, if EQN1125 (8192 × 4096) is not in the list, choose "Enter encoder data manually". Set:
   • p0400[0] = 9999 (user-defined encoder type)
   • p0404[0].0 = 1 (activate configuration)
   • p0408[0] = 8192 (incremental resolution)
   • p0421[0] = 4096 (multiturn resolution)
   • p0405.0 = 0001 bin (EnDat protocol)
4. Power cycle the drive. The SMC20 reads the encoder type at first power-up and stores the result in r0459[0] (encoder diagnostics). Verify with r0459[0].22 = 1 (EnDat active) and r0459[0].24 = 1 (EnDat 2.1 selected).
5. Run Optimize the speed controller from the SCOUT drive wizard.

7.2 STARTER / Startdrive Procedure

1. Open the project and connect to the target device.
2. Configure → Drive → Configuration → Motor selection. If the Kollmorgen ADKH is not in the list, use "Enter motor data" and enter the equivalent circuit parameters (stator resistance, Lq, Ld, flux, moment of inertia) from the Kollmorgen datasheet.
3. Configure → Encoder → choose EnDat encoder 2.1 singleturn/multiturn or 2.2 depending on encoder label. Set the resolution and code sequence.
4. Save to ROM and power-cycle.

8. Parameter Reference

For EnDat 2.2 with the ECN1325/EQN1325, additionally verify:

• p0437[0] = 1 (extended EnDat functions enable)
• p0438[0] = 0x... (encoder OEM data, populated automatically)

9. SMC20 vs SMC40 — Functional Comparison

The SMC40 cannot be used in an S120 drive line-up. The SIMATIC family uses different backplane signalling and is not addressable by STARTER/SCOUT.

10. Wiring and Commissioning Sequence

1. Wire the Kollmorgen ADKH power leads to the Motor Module 6SL3120-2TE13-0AA4 (U2/V2/W2 terminals, chassis ground on PE).
2. Wire the encoder cable from the encoder to the SMC20 D-sub connector. Pinout: pin 1 = +5 V, pin 2 = 0 V, pin 3 = DATA, pin 4 = /DATA, pin 5 = CLOCK, pin 6 = /CLOCK, pin 7 = SIN+, pin 8 = SIN−, pin 9 = COS+, pin 10 = COS−, pin 11 = inner shield, pin 12 = not used, shell = outer shield.
3. Connect the SMC20 to the DRIVE-CLiQ network. Use the standard RJ45 patch cable supplied with the S120.
4. Power up the SLM, wait for "Ready" LED on the CU.
5. Run Topology → Configure in STARTER. The SMC20 will appear as a downstream DRIVE-CLiQ device. Assign it to the drive (SERVO_3.3:1:2 in this example).
6. Configure encoder per section 7.
7. Run a measurement without movement (encoder alignment) followed by measurement with movement (motor identification). The S120 will automatically determine the commutation offset, the stator resistance, and the Lq/Ld values.
8. Save the project to ROM, then to the CF card of the CU.

11. Verification and Diagnostics

1. Check r0459[0] for EnDat status. Bits 22, 24, and 25 should be set if EnDat 2.1 is active and the encoder is communicating.
2. Check r0462[0] (encoder increments per revolution). For EQN1125 this should be 33,554,432 (2²⁵ = 8192 × 4096 = 33,554,432 increments after SMC20 interpolation).
3. Check r0463[0] (calculation time) — should be < 100 µs.
4. Check r0947 for fault codes. Common EnDat faults:
   • F31117 (30905) = EnDat inversion error (A/B tracks reversed)
   • F31118 (30906) = EnDat amplitude error (signal too low, cable fault, or shield break)
   • F31119 (30907) = EnDat internal error (encoder RAM/ROM defective)
   • F31120 (30908) = EnDat communication error (clock/data shorted, cable length exceeded)
5. Use Control Unit diagnostics → Buffer in SCOUT to read the fault time stamp and clear after the root cause is fixed.

12. Troubleshooting Matrix

13. Commissioning Checklist

• ✓ Motor and encoder MLFB verified against Kollmorgen delivery note
• ✓ SMC20 mounted and DRIVE-CLiQ LED green
• ✓ Encoder cable shielded at both ends, drain wire bonded at SMC20 D-sub shell
• ✓ SLM input voltage matches motor class (240 V motor ⇒ 240 V line OR BLM)
• ✓ DC bus voltage under load < motor insulation rating (e.g., 240 V motor ⇒ Vdc < 400 V)
• ✓ p0400[0] matches encoder type (2021 / 2022 / 9999)
• ✓ p0408[0] matches encoder resolution (8192 for EQN1125)
• ✓ p0421[0] matches multiturn range (4096 for EQN1125)
• ✓ r0459[0] shows EnDat 2.1 or 2.2 active
• ✓ Motor identification with movement completed
• ✓ Commutation offset stored in p0431[0]
• ✓ Project saved to ROM and CF card
• ✓ F07901 / F311xx faults cleared

FAQ