SERVOSTAR 601... 620: Digital Servo Amplifier S600 Instructions Manual

SERVOSTAR 601...
620
Digital Servo Amplifier S600
Instructions Manual
Edition 12/2015
Translation of the original manual.
Valid for Hardware Revision 05.40
Keep all manuals as a product component

during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr601_e.***
Previous versions :
Edition Remarks
05/1998 First edition
08/1998 a few corrections
various minor corrections, parameter description removed, parameter setting for multi-axis systems and on/off switching be-
09/1998
havior added, Installation/setup divided into two chapters
01/1999 614 added, various minor corrections
02/1999 Interface relay for digital outputs (pages 26, 43)
06/1999 various corrections, cables and connectors removed, choke box added
08/1999 24V tolerance, encoder wiring, ventilation
11/1999 Packaging, brake resistor
12/1999 Option -AS- integrated, ground-bolt, master-slave
04/2000 various corrections, setup software on CDROM only, motors 6SM27LL and 6SM37VL added
06/2000 Wiring diagrams electr. gearing, warning and error messages, recommended torque
08/2000 Wiring diagram in chapter III.9.2 corrected
S610-30 and options -I/O-14/08- and -2CAN - incorporated, PROFIBUS and SERCOS, nameplate, motor list and connector
07/2001
assignment corrected, LED-display corrected, error messages expanded
02/2002 Dimensions BAR corrected
Frontpage new design, corrections to US English, motor table removed, order numbers added,
06/2002
last page new design and contents, new; connection to diff. mains supply networks, block diagram to ch.III
07/2003 several corrections, DeviceNet expansion card added, directives and standards page revised, cover design
09/2003 Ethernet expansion card and Single axis controller expansion card added
03/2004 new brake resistors BAR(U), several corrections
Company name updated, expansion cards updated, new sections on EtherCAT and SynqNet, chapter l restructured, new
02/2006 sections on motor chokes, Encoder power supply and encoder termination, various error corrections, new ordering codes,
Feedback section revised, BAR removed, cross section (awg )
09/2006 Hardware Revision, disposal acc. to WEEE-2002/96/EG, new structure+cover pages, Quickstart integrated
Part number scheme, servo system graphics expanded, shock-hazard protection new, BISS feedback, feedback expanded,
04/2007
enc. emulation, switch-on/off behavior and AS updated, accessories removed, DC-Bus link expanded, fuses brake resistor
07/2007 Timing diagramm motor brake, motor connector, example cat.3 to EN954-1
06/2008 Repair, deinstallation, syntax: "regen" => "brake", EMC standards, Hiperface, CE declaration
08/2008 SCCR->42kA
07/2010 Logo, Repair-Disposal, ANSI Z535 safety symbols, GOST-R, HWR 5.20, holding brake hints, WIKI links
12/2010 Company name and address, CE certificate, name plate, fax form, UL markings updated
08/2012 CE declaration of conformity
PCB redesigned, use only with firmware 8.50 or higher, CE & Gost certificate, option -AS- according to EN954-1 (not
02/2014
functional safe any more), KCM modules
12/2014 Certificates removed, HWR, export classification
02/2015 UL/cUL markings in EN+FR
12/2015 KCM wiring updated, nameplate updated, Fax form removed, safe voltage 60V->50V, LVD2014-35-EG, EMCD2014-30-EG
Hardware Revision (HWR)

Hardware Rev. Firmware Rev. Export Classification Remarks
05.10 >= 5.76 AL-3A225 Firmware >=6.68 required with BISS
>= 5.81 AL-3A225 CAN Controller neu, Standard
05.20
>= 6.86 AL-3A225 CAN Controller neu, BiSS/EtherCAT Support
>= 9.00 AL-3A225 PCB update, Standard
05.30
>= 8.50 AL-3A225 PCB update, BiSS/EtherCAT Support
>= 9.00_ND1 AL-3A225 New data structure, Standard
05.40
>= 8.50_ND1 AL-3A225 New data structure, BiSS/EtherCAT Support
>= 9.00_ND0 - New data structure, Standard
05.40
>= 8.50_ND0 - New data structure, BiSS/EtherCAT Support
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH
® ®
sercos is a registered trademark of sercos international e.V
Technical changes which improve the performance of the equipment 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 Koll-
morgen Europe GmbH.
Kollmorgen 12/2015 Contents
Page
1 General
1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.4 Maintenance/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.5 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4.6 Repair and Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Approvals
3.1 Conformance with UL and cUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 EC conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 European Directives and Standards for the machine builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Package
4.1 Package supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Part number scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Technical description
5.1 The SERVOSTAR 600 family of digital servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.1 Recommended torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.2 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.3 Environment conditions, ventilation, mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.4 Conductor cross-sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4 Control for motor holding brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5 Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6 Electrical Brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.7 Switch-on and switch-off behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.7.1 Behavior in standard operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.7.2 Behavior in the event of an error (with standard setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.8 Stop/Emergency Stop Function to EN 60204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.8.1 Stop: Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.8.2 Emergency Stop: Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.9 Shock-hazard protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.9.1 Leakage current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.9.2 Residual-current circuit breakers (FI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.9.3 Isolating transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Mechanical Installation
6.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Guide to mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SERVOSTAR 601...620 Instructions Manual 3

Contents 12/2015 Kollmorgen
Page
7 Electrical Installation
7.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Guide to electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.1 Technical data for connecting cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.3.2 Shielding connection to the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.3.3 Motor connector with shieldplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4 Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.5 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.6 Pin assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.7 Connection diagram (overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8.1 Connection to various mains supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8.2 Mains supply connection (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.8.3 24V auxiliary supply (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.9 DC bus link (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.9.1 External brake resistor (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.9.2 Capacitor Module KCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.10 Motor connection with holding brake (X9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.11 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.11.1 Resolver (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.11.2 Sine Encoder 5V with BiSS (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.11.4 Sine Encoder without data channel (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.11.5 Incremental encoder / sine encoder with Hall (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.11.6 Incremental Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.12 Electronic Gearing, Master-slave operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.12.2 Connection to encoders with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.12.3 Connection to a sine-cosine encoder (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.12.4 Connection to an SSI encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.12.5 Connection to stepper motor controllers (step and direction). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.12.5.1 Step/Direction with 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.12.5.2 Step/Direction with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.13 Encoder emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.13.1 Incremental encoder output - A quad B (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.13.2 SSI output (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.14 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.14.1 Analog inputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.14.2 Analog outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.14.3 Digital inputs (X3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.14.4 Digital outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.15 RS232 interface, PC connection (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.16 CANopen Interface (X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 SERVOSTAR 601...620 Instructions Manual

Kollmorgen 12/2015 Contents
Page
8 Setup
8.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2 Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.1.1 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.1.2 Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.1.3 Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2.1.4 Operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2.2 Installation under WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3 Quickstart Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3.2 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.3.3 Important Screen Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.3.4 Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.3.5 Motor (synchronous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.3.6 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.3.7 Save Parameters and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.8 Jogging the Motor (Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3.9 Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.3.10 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.3.11 Additional Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.4 Multi-axis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.4.1 Node address for CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.4.2 Baud rate for CAN-bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.4.3 Example of connections for multi-axis system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.5 Key operation / LED display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.5.1 Key operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.5.2 Status display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.5.3 Standard menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.5.4 Extended menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.6 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.7 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.8 Removing faults/warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9 Expansions / Accessories
9.1 Option -AS-, restart lock according to EN 954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.1.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.1.2 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.1.3 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.1.4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.1.5 Signal diagram (sequence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.1.6 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.1.7 Connection diagram (principle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.1.8 Application example category 1 according to EN954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1.8.1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1.8.2 Mains supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1.9 Application example category 3 according to EN954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.1.9.1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.1.9.2 Mains supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.1.9.3 Flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.2 Expansion Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.2.1 Guide to installation of expansion cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.2.2 Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.2.2.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.2.2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.2.2.3 Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.2.2.4 Select motion task number (Sample) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.2.2.5 Connector assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9.2.2.6 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Contents 12/2015 Kollmorgen
Page
9.2.3 Expansion cards -PROFIBUS-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.2.3.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.2.3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.2.4 Expansion card -SERCOS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.2.4.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.2.4.2 Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.2.4.5 Modifying the station address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.2.4.6 Modifying the baud rate and optical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.2.5 Expansion card -DEVICENET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.2.5.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.2.5.4 Combined module/network status-LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.2.5.5 Setting the station address (device address). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.2.5.6 Setting the transmission speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.2.5.7 Bus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9.2.6 Expansion card -EtherCAT- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2.6.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2.6.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.2.7 Expansion card -SYNQNET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.2.7.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.2.7.2 NODE ID Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.2.7.3 Node LED table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.2.7.4 SynqNet Connection, Connector X21B/C (RJ-45). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9.2.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2.7.6 Connection diagram digital inputs/outputs, connector X21A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2.8 Expansion module -2CAN-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2.8.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2.8.2 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2.8.4 Connector assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
9.3 Special Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.1 Power Supply SINCOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.2 Terminating adapter for encoder cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.3 Hall Dongle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10 Appendix
10.1 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.2 Order numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.2.1 Servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.2.2 Expansion cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.2.3 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.2.4 Special accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Kollmorgen 12/2015 General
1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR 601...620 series
(standard version, 1.5 to 20 Amps nominal current). Servoamplifiers of the SERVOSTAR 640/670
series are described in additional manuals.
A more detailed description of the expansion cards which are currently available and the digital
connection to automation systems can be found on the accompanying CD-ROM in Acrobat-Reader
format (system requirements: WINDOWS with Internet browser, Acrobat Reader) in several
language versions. Technical data and dimensional drawings of accessories such as cables, brake
resistors, mains supplies, etc., can be found in the accessories manual.
You can print this documentation on any standard printer. A printed copy of the documentation is
available from us at extra cost.
More background information can be found in the "Product WIKI", please check
www.wiki-kollmorgen.eu.
1.2 Hints for the online edition (PDF format)

Bookmark:
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 indica-
ted.
Page/chapter numbers in the text:
Page/chapter numbers with cross references are active. Click at the page/chapter number to reach
the indicated target.
1.3 Symbols used

Symbol Indication
Indicates a hazardous situation which, if not avoided, will result in death
DANGER or serious injury.
Indicates a hazardous situation which, if not avoided, could result in de-

WARNING ath or serious injury.
Indicates a hazardous situation which, if not avoided, could result in mi-

CAUTION nor 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.

General 12/2015 Kollmorgen
1.4 Standards used

Standard Content
ISO 4762 Hexagon socket head cap screws
ISO 12100 Safety of machinery: Basic concepts, general principles for design
Safety of machinery: Safety-related parts of control systems
ISO 13849
(former EN 954)
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 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 com-
IEC 61491
munications 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 - Structuring, content and presentation
UL Standard for Safety for Insulation Coordination Including Clearances and
UL 840
Creepage Distances for Electrical Equipment
UL 508C UL Standard for Safety Power Conversion Equipment
IEC International Electrotechnical Commission
ISO International Organization for Standardization
UL Underwriters Laboratories

Kollmorgen 12/2015 General
1.5 Abbreviations used

The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
AS Restart Lock, option
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Européenne (EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN German Institute for industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EN European standard
ESD Electrostatic discharge
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IEC International Electrotechnical Commission
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
NSTOP Limit-switch input for CCW rotation (left)
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input for CW rotation (right)
RAM Volatile memory
RB Brake (regen) resistor
RBext External brake resistor
RBint Internal brake resistor
RES Resolver
ROD 426 (EEO) A quad B encoder
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriters Laboratory
VAC AC voltage
VDC DC voltage
VDE Verein deutscher Elektrotechniker
XGND Ground for the 24V supply

Safety 12/2015 Kollmorgen
2 Safety
This section helps you to recognize and avoid dangers to people and objects.
2.1 You should pay attention to this

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, installa-
tion, assembly, commissioning and operation of drives and who bring their relevant minimum qualifi-
cations 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 pre-
vention regulations.
Read the documentation!

Read the available documentation before installation and commissioning. Improper handling of the
servo amplifiers can cause harm to people or damage to property. The operator must therefore
ensure that all persons entrusted to work on the SERVOSTAR 600 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 docu-
mentation). 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 damaged 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 conduc-
tive 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 assess-
ment.

Kollmorgen 12/2015 Safety
Automatic restart
The drive might restart automatically after power on, voltage dip or interruption of the supply vol-
tage, 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.
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 earthing 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 protection. Capacitors can have
dangerous voltages present up to five minutes after switching off the supply power. There is a risk
of death or severe injury from touching exposed contacts. Do not open or touch the equipment
during operation. 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 after switching off the supply power. Risk of burns and blinding.
Wait at least five 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 con-
nections. Always measure the voltage in the DC bus link and wait until the voltage is below 50 V
before handling components.
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 components with power vol-
tage, 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

l The servo amplifiers are components which are built into electrical equipment or machines,
and can only be used as integral components of such equipment.
l 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.
l The SERVOSTAR 600 family of servo amplifiers (overvoltage category III acc. to EN
61800-5-1) can be connected directly to symmetrically earthed (grounded) three-phase indu-
strial mains supply networks [TN-system, TT-system with earthed (grounded) neutral point, not
more than 42,000 rms symmetrical amperes, 480VAC maximum].
Connection to different mains supply networks (with additional isolating transformer) ð p.46.
l Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier
may not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed
2000V.
l If the servo amplifiers are used in residential areas, or in business or commercial premises,
then additional filter measures must be implemented by the user.
l The SERVOSTAR 600 family of servo amplifiers is only intended to drive specific brushless
synchronous servomotors, with closed-loop 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 of the servo amplifier.
l The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account
the ambient conditions defined on page 22 and the dimensions shown on page 34. Ventilation
or cooling may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
l Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the
NEC 60°C or 75°C column for AWG size).
l SERVOSTAR 600 does not have any safety functionality according to IEC 61800-5-2. The op-
tional restart lock function -AS- cannot be compared to the safety function STO. The described
function -AS- is proofen according to EN 954-1. This standard is not listed in the EC Machine
Directive 2006/42/EG since 31.12.2012. The requirements for a restart lock according to EN
954-1 are nevertheless fulfilled
l Consider the specifications on page 92 when you use the restart lock option -AS-.
2.3 Prohibited use

l Other use than described in chapter 2.2 is not intended and can lead to damage of persons,
equipment or things.
l 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, vapours, dusts
- directly on non-grounded supply networks or on asymmetrically grounded supplies
with a voltage >240V.
- on ships or off-shore applications
l 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
l The control of holding brakes by the SERVOSTAR 600 alone may not be used in applications,
where functional safety is to be ensured with the brake.

Kollmorgen 12/2015 Safety
2.4 Handling
2.4.1 Transport
l Only by qualified personnel in the manufacturer’s original recyclable packaging
l Avoid shocks
l Temperature –25 to +70°C, max. 20K/hr rate of change
l Humidity max. 95% relative humidity, no condensation
l If the packaging is damaged, check the unit for visible damage. In this case, inform the shipper
and the manufacturer.
The servo amplifiers contain electrostatically sensitive components which can be damaged by incor-
rect handling. Discharge yourself before touching the servo amplifier. Avoid contact with highly insu-
lating materials (artificial fabrics, plastic films etc.). Place the servo amplifier on a conductive sur-
face.
2.4.2 Packaging
l Cardboard box, can be recycled
l Dimensions: SERVOSTAR 601...610 (HxWxD) 125x415x350 mm
SERVOSTAR 614 / 620 (HxWxD) 170x415x350 mm
l Labeling : nameplate outside at the box
2.4.3 Storage
l Storage only in the manufacturer’s original recyclable packaging
l Max. stacking height 8 cartons
l Storage temperature -25 to +55°C, max. rate of change 20°C / 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 am-
plifier. 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 instruments do not require any maintenance, opening the instruments invalidates the warranty.
Cleaning : — if the casing is dirty: clean with Isopropanol or similar
Note: do not immerse or spray
— if there is dirt inside the unit it must be cleaned by the manufacturer
— dirty protective grill on fan must be cleaned with a dry brush

2.4.5 Disassembling
Observe the sequence below, if a servo amplifier has to be disassembled (e.g. for replacement).
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 five minutes
after switching off mains voltage. Risk of electric shock! Wait at least five 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 50V.
c. Remove the connectors. 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 and Disposal

Repair of the servo amplifier must be done by the manufacturer. Opening the devices means loss of
the guarantee. Disassemble the equipment as described in chapter 2.4.5.
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.
Contact Kollmorgen and clarify the logistics.

Kollmorgen 12/2015 Approvals
3 Approvals
Certificates can be found in our Product WIKI on page Approvals.
3.1 Conformance with UL and cUL

This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Cana-
dian standard (in this case UL 840 and UL 508C).
This standard describes the fulfilment by design of minimum requirements for electrically operated
power conversion equipment, such as frequency converters and servo amplifiers, 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. and Canadian standard is determined by an independent
UL (cUL) inspector through the type testing and regular check-ups.
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 (cUL)-certification of the equipment.
UL 508C: UL 508C describes the fulfilment 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 fulfilment by design of air and insulation creepage spacings for elec-
trical equipment and printed circuit boards.
Markings Marquages
l Use 60°C or 75°C copper wire only. l Utilisez un fil en cuivre 60°C ou 75 °C min..
l Use Class 1 wire only. l Utilisez seulement un fil de classe 1.
l Tightening torque for field wiring terminals. l Couples de serrage recommandée
X0A, X0B, X7, X8, X9: X0A, X0B, X7, X8, X9:
0.5 - 0.6Nm (4.43 to 5.31 lbf in). 0.5 - 0.6Nm (4.43 to 5.31 lbf in).
l Use in a pollution degree 2 environment. l Utilisation dans un environnement de polluti-
on de niveau 2.
l These devices provide solid state motor l Ces variateurs offrent une protection contre
overload protection at 130% of full load les surcharges de moteur à semi-conduc-
current. teur à 130 % du courant FLA nominal.
l Integral solid state short circuit protection l Une protection de court-circuit à semi-con-
does not provide branch circuit protection. ducteur intégrale ne fournit pas de protecti-
Branch circuit protection must be provided on de la dérivation. Il convient de garantir
in accordance with the National Electrical une protection de la dérivation conforme au
Code and any additional local codes. NEC (National Electrical Code) et aux régle-
mentations locales en vigueur, ou aux direc-
tives équivalentes applicables.
l These devices are not provided with motor l Ces variateurs n’offrent pas de capteurs de
over-temperature sensing. température excessive.
l Suitable for use on a circuit capable of deli- l Ce produit est conçu pour une utilisation sur
vering not more than 42kA rms symmetri- un circuit capable de fournir 42 000 ampè-
cal amperes for a max. voltage of 480 Vac. res symétriques (rms) maximum pour 480V.

Approvals 12/2015 Kollmorgen
3.2 EC conformance
The servo amplifiers have been tested by an authorized testing laboratory in a defined configura-
tion, 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 responsi-
ble for carrying out new measurements to ensure conformance with regulatory requirements.
Kollmorgen declares the conformity of the products SERVOSTAR 601, 603, 606, 610, 614, 620 with
the following directives
l EC EMC Directive (2014/30/EC)
l EC Low Voltage Directive (2014/35/EC)
Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental
category (industrial environment). For noise emission the amplifier meets the requirement to a pro-
duct of the category C3.
This product can cause high-frequency interferences in non industrial environments which can
require measures for interference suppression.
3.3 European Directives and Standards for the machine builder

Servo amplifiers are components that are intended to be incorporated into electrical plant and
machines for industrial use. When the servo amplifiers are built into machines or plant, the amplifier
must not be used until it has been established that the machine or equipment fulfills the require-
ments of the
l EC Machinery Directive (2006/42/EC)
l EC EMC Directive (2014/30/EC)
l EC Low Voltage Directive (2014/35/EC)
Standards to be applied for conformance with the EC Machinery Directive (2006/42/EC)

EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 12100 (Safety of Machines)
The manufacturer of the machine must generate a risk assessment for the machine, and 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(2014/35/EC)

EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 60439-1 (Low Voltage Switchgear Combinations)
Standards to be applied for conformance with the EC EMC Directive (2014/30/EC)
EN 61000-6-1 / 2 (Interference Immunity in Residential & Industrial Areas)
EN 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 (such as shielding, grounding,
treatment of connectors and cable layout) 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 12/2015 Package
4 Package
4.1 Package supplied
When you order a SERVOSTAR 600 series amplifier (order numbers ð p.117), you will receive:
— SERVOSTAR 6xx
— mating connectors X3, X4, X0A, X0B, X7, X8
The mating SubD connectors and motor connector X9 are not part of the package!
— Assembly, Installation and Setup Instructions (Instructions Manual)

— Online documentation on CD-ROM
— Setup software DRIVE.EXE on CD-ROM
Accessories: (must be ordered separately; description see accessories manual)
— AC synchronous servomotor (linear or rotary)
— motor cable (pre-assembled), or both motor connectors separately, with motor cable as a
cut-off length
— feedback cable (pre-assembled or both feedback connectors separately,
with feedback cable as length
— Power supply for encoders with a power consumption of more than 150mA (ð p. 113)
— Terminating adapter for encoders with no terminating resistors (ð p. 113)
— motor choke 3YL for cable length above 25m
— external brake resistor BAR(U)
— communications cable to the PC(ð p.69) or Y-adapter (ð p.84) for setting parameters of up
to 6 servo amplifiers from one PC
— power cable, control cables, fieldbus cables (as lengths)
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.
Servo amplifier type Serial number Comments Hardware Revision
c UL US
Kollmorgen Europe GmbH Customer Support
Pempelfurtstraße 1 Europe Tel. +49 (0)2102 / 93940 ®
E217428 LISTED
D-40880 Ratingen Italy Tel. +39 (0)362 / 594260
IND. CONT. EQ.
www.kollmorgen.com North America Tel. +1 540 633 3545 1VD4
Typenbezeichnung Model Number Ser. Nr Ser. No. Bemerkung Comment
Eingang Input Ausgang Output

Spannung / Voltage: 3x230V - 480V, 50Hz Zwischenkreisspannung/DC-Link Voltage: 260V - 675V
Spannung / Voltage: 3x208V - 480V, 60Hz Phasen / Phases: 3 Strom/Current: xxA
Nennstrom / Full load current: xxA Schaltfrequenz / Bases Frequency: 8kHz (16kHz with VDCmax=400V)
Umgebungstemp. Hardware
Ambient temp. 45°C Schutzart Encl.Rating Revision
xx.yy
RoHS
conform IP20
example Made in Austria example

Package 12/2015 Kollmorgen
4.3 Part number scheme
S 6 0 6 0 0 - S E*
Family Expansions
S6 S600 NA no expansion
DN DeviceNet
Current rating PB PROFIBUS
01 1A rms SE SERCOS
03 3A rms SN SynqNet
06 6A rms EC EtherCAT
10 10A rms IO I/O-Expansion
1P 10/30A rms
14 14A rms
20 20A rms
electr. option
Voltage rating
0 no option
0 230...480V
1 AS option
* additional coding defines customer specific specials.
Comparison (without expansion) device name -> part number
Device Name Part Number

SERVOSTAR 601 S60100-NA
SERVOSTAR 610-30 S61P00-NA

Kollmorgen 12/2015 Technical description
5 Technical description
5.1 The SERVOSTAR 600 family of digital servo amplifiers
Standard version
l 6 current ratings (1.5 A -Europe only-, 3 A , 6 A , 10 A , 14 A, 20 A)
l 3 instrument widths : 70 mm for 1.5A up to 10A rated current
100 mm for 14A rated current
120 mm for 20A rated current
l Wide range of rated voltage (3x208V –10% to 3x480V +10%)
l Overvoltage category III acc. to EN 61800-5-1
l Shield connection directly at the servo amplifier
l 2 analog setpoint inputs
l Integrated CANopen (default 500 kBaud), for integration into CAN bus systems and for
setting parameters for several amplifiers via the PC-interface of one amplifier
l Integrated RS232, electrically isolated, integrated pulse-direction interface
l Synchronous servomotors, linear motors and asynchronous motors can be used
Electrical supply
l Directly off grounded 3 phase system,
230V-10% ... 480V+10%, 50 Hz,
208V-10% ... 480V+10%, 60 Hz
TN-system or TT-system with grounded neutral point, max. 42,000 rms symmetrical amperes.
Connection to other mains supply networks only with insulating transformer ð p.46
l B6 rectifier bridge, directly off 3-phase earthed (grounded) supply system, integral power input
filter and inrush circuit
l Single-phase supply (e.g. for setup) is possible
l Fusing: (e.g. fusible cutout) provided by the user
l Shielding: All shielding connections directly on the amplifier
l Output stage: IGBT- module with isolated current measurement
l Brake circuit: with dynamic distribution of the brake power between several
amplifiers on the same DC bus link circuit. Internal brake resistor as
standard, external brake resistors if required
l DC bus link voltage 260 — 900 VDC, can be switched in parallel
l Interference suppression filter for the supply input (to category 3) is integrated
l Interference suppression filter for the 24V aux. supply (to category 3) is integrated
Integrated safety
l Safe electrical separation between the power input / motor connections and the signal electro-
nics, provided by appropriate insulation/creepage distances and complete electrical isolation
l Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
l Temperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)

Technical description 12/2015 Kollmorgen
Auxiliary supply voltage 24VDC

l Electrically isolated, internal fusing (3.15 AT), from an external 24VDC psu, e.g. with insulating
transformer
Operation and parameter setting

l With our user-friendly software for setup through the serial interface of a PC
l Direct operation by means of two keys on the servo amplifier and a 3-character LED display for
status display in case there is no PC available
l Fully programmable via RS232 interface
Completely digital control

l Digital current controller (space vector pulse-width modulation, 62.5 µs)
l digital speed controller adaptable to most different load conditions (65µs or 250 µs)
l Integral position controller with adaptation possibilities for customer needs (250 µs)
l Pulse direction interface integrated for connection of a servomotor to a stepping motor
control
l Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder
l Encoder simulation (incremental or SSI)
Auxiliary functions
l 2 analog monitor outputs
l 4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l 2 programmable digital outputs
l Freely programmable combinations of all digital signals
Options/Expansions
l Option -AS-, built-in restart lock according to EN954-1 ð p. 91
l I/O expansion card ð p. 99
l PROFIBUS DP expansion card ð p. 102
l SERCOS expansion card ð p. 103
l DeviceNet expansion card ð p. 105
l EtherCAT expansion card ð p. 108
l SynqNet expansion card ð p. 109
l -2CAN- expansion module, separated connectors for CAN bus and RS232 ð p. 111
l Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for further
information)

5.2 Technical data

SERVOSTAR
Rated data DIM 601 603 606 610 610-30 614 620
Rated supply voltage (grounded system) V~ 3 x 230V-10% ... 480V+10%, 50 Hz
(L1,L2,L3) V~ 3 x 208V-10% ... 480V+10%, 60 Hz
Rated installed load for S1 operation kVA 1 2 4 7 7 10 14
Rated DC bus link voltage V= 290 - 675
Rated output current (rms value, ± 3%) Arms 1.5 3 6 10 10 14 20
Peak output current (max. ca. 5s, ± 3%) Arms 3 6 12 20 30 (2s) 28 40
Clock frequency of the output stage kHz 8 (16 with VDCmax=400V)
Technical data for brake circuit — ð p.25
Overvoltage protection threshold V 450...900
Max. load inductance mH 150 75 40 25 24 15 12
Min. load inductance mH 25 12 7.5 4 4 2.5 2
Form factor of the output current
— 1.01
(at rated data and min. load inductance)
Bandwidth of subordinate current con-
kHz > 1.2
troller
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage dis-
W 15
abled
Dissipation at rated current (incl. power
W 30 40 60 90 90 160 200
supply losses, without brake dissipation)
Inputs
Setpoint 1/2, resolution 14bit/12bit V ±10
Common-mode voltage max. V ±10
Input resistance to AGND kW 20
Digital inputs V according to IEC 61131
Digital outputs, open collector V according to IEC 61131
V DC max. 30, AC max. 42
BTB/RTO output, relay contacts
mA 500
Aux. power supply, electrically isolated V 24 (-0% +15%)
without brake A 1 (max. 16)
Aux. power supply, electrically isolated V 24 (-0% +15%)
with brake (consider voltage loss!) A 3 (max. 16)
Min./max. output current, brake A 0,15 / 2
Connections
Control signals — Combicon 5.08 / 18 pole , 2,5mm²
Power signals — Power Combicon 7.62 / 4x4 + 1x6-pole, 4mm²
Resolver input — SubD 9pole (socket)
Sine-cosine encoder input — SubD 15pole (socket)
PC-interface, CAN — SubD 9pole (plug)
Encoder simulation, ROD (EEO) / SSI — SubD 9pole (plug)
Mechanical
Weight kg 4 5 7.5
Height without connectors mm 275
Width mm 70 100 120
Depth without connectors mm 265

5.2.1 Recommended torque
Connector Recommended torque

X3, X4 0.5 to 0.6 Nm (4.43 to 5.31 in lb)
X0A, X0B, X7, X8, X9 0.5 to 0.6 Nm (4.43 to 5.31 in lb)
Ground bolt 3.5 Nm (31 in lb)
5.2.2 Fusing
Internal Fusing
Circuit internal fuse

Auxiliary supply 24V 3.15 AT (FRx-3)
Brake resistor electronic
External fusing
Fusible cutouts or similar SERVOSTAR SERVOSTAR SERVOSTAR

(Fuse UL time delay) 601/ 603 606/ 610 614/ 620
AC supply FN1/2/3 6 AT (FRx-6) 10 AT (FRx-10) 20 AT (FRx-25)
24V supply FH1/2/3 max. 12 AF (max. FRx-12)
Brake resistor FB1/2 6 AT (FRS-6) 10 AT (FRS-10) 10 AT (FR10-10)
(x = S or S-R for 480V applications x = N or N-R for 230V applications)
5.2.3 Environment conditions, ventilation, mounting position
Storage, hints ð p.13

Transport, hints ð p.13
Supply voltage tolerances
Input power min 3x 230V-10% AC / max 3x 480V+10%, 50 Hz
min 3x 208V-10% AC / max 3x 480V+10%, 60 Hz
Aux. power supply 24 VDC (-0% +15%), check voltage drop

0 to +45°C (32 to 113°F) at rated data
Ambient temperature in operation +45 to +55°C (113 to 131°F) with power derating
2.5% / K
Humidity in operation rel. humidity 85%, no condensation
up to 1000m a.m.s.l. without restriction
Site altitude 1000 — 2500m a.m.s.l. with power derating
1.5%/100m
Pollution level Pollution level 2 to EN 60664-1
Vibrations Class 3M1 according to IEC 60721-3-3
Noise emission max. 45 dB(A)
Enclosure protection IP 20 according to EN60529
Mounting position generally vertical. ð p.34
Ventilation forced convection by built-in fan
Make sure that there is sufficient forced ventilation within the switchgear cabinet.

5.2.4 Conductor cross-sections
Technical data for connection cables ð p.40. Following EN 60204 (for AWG: table 310-16 of the
NEC 60°C or 75°C column), we recommend for single-axis systems:
SERVOSTAR 601-610: 1.5 mm² (14awg) 600V,80°C (176°F),
AC connection
SERVOSTAR 614/620: 4 mm² (12awg) twisted
600V,80°C (176°F),
SERVOSTAR 601-610: 1.5 mm² (14awg)
DC bus link shielded for
SERVOSTAR 614/620: 4 mm² (12awg)
lengths>20cm
600V,80°C (176°F),
Motor cables SERVOSTAR 601-610: 1-1.5 mm² (14awg)
shielded,
up to 25 m length* SERVOSTAR 614/620: 2.5 mm² (12awg)
capacitance <150pF/m
Motor cables 600V,80°C (176°F),
SERVOSTAR 601-606: 1 mm² (14awg)
25 to 100 m length*, shielded,
SERVOSTAR 610-620: 2.5 mm² (12awg)
with motor choke 3YL capacitance <150pF/m
Resolver, thermal control, 4x2x0.25 mm² (22awg) twisted pairs, shielded,
max.100m length* capacitance <120pF/m
Encoder, thermal control, 7x2x0,25 mm² (22 awg) twisted pairs, shielded,
max.50m length* capacitance <120pF/m
Setpoints, monitors, AGND 0.25 mm² (22awg) twisted pairs, shielded
Control signals, BTB,
0.5 mm² (20awg)
DGND
min. 0.75 mm² (18awg), 600V,80°C (176°F), shielded,
Holding brake (motor)
check voltage drop
+24 V / XGND max. 2.5 mm² (12awg), check voltage drop
For multi-axis systems, please note the special operating conditions in your installation.
To reach the max. permitted cable length, observe cable requirements ð p. 40.
* Kollmorgen North America delivers cables up to 39m length.
* Kollmorgen Europe delivers cables up to the maximum length.
5.3 LED display

A 3-character LED display shows the amplifier status after switching on the 24V supply (ð p.86).
During operation of the amplifier via the keys on the front panel, the parameter and function num-
bers (ð p.87) are displayed, as well as the numbers of any errors which occur (ð p.88).

5.4 Control for motor holding brake

A 24V / max. 2A holding brake in the motor can be controlled directly by the servo amplifier.
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.
The brake only works with sufficient voltage level (ð p.22). 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 parameter (setting: WITH BRAKE). In the
diagram below you can see the time and functional relationships between the ENABLE signal,
speed setpoint, speed and braking force.
During the internal ENABLE delay time of 100ms (DECDIS) the speed setpoint of the servo ampli-
fier is internally driven down a 10ms ramp to 0. The brake output is switched on when the speed
5rpm (VELO) is reached or after 5s (EMRGTO) the latest.
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).
A description of the interface can be found on page 50 .

5.5 Grounding system

AGND — ground for analog inputs/outputs, internal analog/µC ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder simulation, RS232, CAN, optically isolated
The potential isolation is shown in the block diagram (ð p. 43).
5.6 Electrical Brake circuit

During electrical braking with the aid of the motor, energy is fed back to the servo amplifier. This
energy is converted into heat in the brake resistor. The brake circuit (thresholds) are adjusted to the
supply voltage with the help of the setup software.
Our customer service can help you with the calculation of the brake power which is required. A
simple method is described in the "Product Wiki" which is accessible at www.wiki-kollmorgen.eu. A
description of the interface can be found on page 48.
Internal brake resistor
SERVOSTAR 601/603 66 W
SERVOSTAR 606-620 33 W
External brake resistor

SERVOSTAR 601-620 33 W
Functional description
1.- Individual amplifiers, not coupled through the DC bus link (DC+, DC-)
The circuit starts to respond at a DC bus link voltage of 400V, 720V or 840V (depending on the
supply voltage).
If the energy which is fed back from the motor, as an average over time or as a peak value, is hig-
her than the preset brake power, then the servo amplifier will output the status “brake power excee-
ded” and the brake circuit will be switched off.
At the next internal check of the DC bus link voltage (after a few ms) an overvoltage will be detected
and the servo amplifier will be switched off with the error message “Overvoltage F02" (ð p.88).
The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p.68)
2.- Several servo amplifiers coupled through the DC bus link circuit (DC+, DC-)
Thanks to the built-in brake circuit, several amplifiers (even with different current ratings) can be
operated off a common DC bus link. This is achieved by an automatic adjustment of the brake
thresholds (which vary, because of tolerances). The brake energy is distributed equally among all
the amplifiers.
The combined power of all the amplifiers is always available, as continuous or peak power. The
switch-off takes place as described under 1. (above) for the servo amplifier with the lowest
switch-off threshold (resulting from tolerances). The RTO (BTB) contact of this amplifier (terminals
X3/2,3) will be opened at the same time (ð p.68).
Technical Data
The technical data depend on the used servo amplifier type and on the mains voltage. See table on
the next page.

Brake circuit: technical data SERVOSTAR

Supply
Rated data DIM 601 - 603 606 - 620
voltage
Upper switch-on level of brake circuit V 400 - 430
Switch-off level of brake circuit V 380 - 410
Overvoltage F02 V 450
Continuous power of brake circuit (RBint) W 80 200
3 x 230 V
Continuous power of brake circuit (RBext) max. kW 0.25 0.75
Pulse power, internal (RBint max. 1s) kW 2.5 5
Pulse power, external (RBext max. 1s) kW 5
External brake resistor W 33
3 x 400 V
Pulse power, internal (RBint max. 1s) kW 8 16
3 x 480 V
Pulse power, internal (RBint max. 1s) kW 10.5 21
Suitable external brake resistors can be found in our regional accessories manual.

5.7 Switch-on and switch-off behavior

This chapter describes the switch-on and switch-off behavior of the SERVOSTAR and the steps
required to achieve operational stopping or emergency stop behavior that complies with standards.
The servo amplifier’s 24 V supply must remain constant. 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.
Behavior (see also ASCII reference in the online help of the se-
STOPMODE ACTFAULT
tup software)
0 (default) 0 Motor coasts to a standstill in an uncontrolled manner
1 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 software: 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: Warning 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 message 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 motor 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. 24). Removing the ENABLE signal triggers electrical braking. As with all
electronic circuits, the general rule applies that there is a possibility of the internal “holding brake”
module failing. Bringing a motor to a standstill using a holding brake in a way that is functional safe
also requires an electromechanical “make” contact for the holding equipment and a suppressor
device for the brake.
Behavior of the optional restart lock -AS-
With the optional restart lock –AS-, the drive can be secured on standstill using its internal electro-
nics so that even when power is being supplied, the drive shaft is protected against unintentional
restart. The chapter “Restart lock -AS-” describes how to use the restart lock -AS-. See page 91
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.
DC bus link
Motor speed
Power Stage
Enable (internal)
Devices which are equipped with a selected “Brake” function use a special sequence for
switching off the output stage (ð p.24).

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 (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help). The diagram
shows the startup procedure and the procedure that the internal control system follows in the event
of one or more electrical supply phases failing, assuming that the standard parameter settings
apply.
(F16/F19 = error messages Mains BTB /input phase, F05 = error message Undervoltage)
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 an input phase
error is detected and assuming that no changes have been made to the factory setting (ACT-
FAULT=1).

5.8 Stop/Emergency Stop Function to EN 60204

With the optional restart lock -AS- (according to EN954-1, see page 91 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.
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to implement the 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: Standards

The Stop function is used to shut down the machine in normal operation. The Stop functions are
defined by EN 60204.
Category 0: Shut-down by immediate switching-off of the energy supply to the
drive machinery (i.e. an uncontrolled shut-down);
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.
Function".

5.8.2 Emergency Stop: Standards
The emergency Stop function is used for the fastest possible shut-down of the machine in a dan-
gerous situation. The Emergency Stop function can be triggered by the actions of a single person. It
must be fully functional and available at all times. The user must not have to work out how to ope-
rate this mechanism.
The Emergency Stop function is defined by EN 60204.
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 operating situa-
tions;
l the energy supply to any drive machinery that could cause dangerous situations must be swit-
ched off as fast as possible, without causing any further hazards (e.g. by using mechanical lat-
ching devices that do not require an external supply of energy, by counter-current braking in
Stop Category 1);
l the reset must not initiate a restart.
If necessary, provision must be made for the additional connection of emergency stop devices (see
EN 60204, "Requirements for emergency stop devices").
The Emergency Stop must be effective as a stop of either Category 0 or Category 1.
The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired, electromechanical components may be used for the Category 0 Emergency Stop
function. It must not be triggered using switching logic (hardware or software), by transferring com-
mands via a communication network, or via a data link.
The drive must be shut down using an electromechanical circuit. If the connected servo motor has
an integrated brake, this must always be controlled by an electromechanical circuit as well.
Category 1
With the Category 1 Emergency Stop function, there must be absolute certainty in terms of the
power supply for the machine drives being switched off (i.e., secured) using electromechanical com-
ponents. Additional Emergency Stop equipment may be connected. Bringing the motor to a stand-
still by interrupting the mains supply and using controlled electronic braking. The 24 V supply for the
servo amplifier must remain constant. The issue of which circuit should be used is highly dependent
on the requirements of the application at hand.
Usually a brake in a servo motor only has the function of a holding brake. To ensure an emergency
stop function, the braking torque that is required must be checked. If the holding brake fulfills the
dynamic requirements, it must be taken into acount that this application will cause increased wear.
Function".

5.9 Shock-hazard protection

5.9.1 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. For this reason, the leakage
current cannot be measured using a conventional multimeter.
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 EN61800-5-1 the PE
connection must either be doubled or a connecting cable with a cross-section >10mm² must be
used. Use the PE terminals (X0A and X0B) or the PE bolt in order to fulfil this requirement.
The following measures can be used to minimise leakage currents.

— Reduce the length of the engine cable
— Use low-capacity cables (see p.40)
— Avoid mains asymmetries (with an isolating transformer)
5.9.2 Residual-current circuit breakers (FI)

In conformity with DIN IEC 60364-4-41 – Regulations for installation and EN 60204 – Electrical
equipment of machinery, residual-current circuit-breakers (called FI below) can be used provided
the requisite regulations are complied with.
The SERVOSTAR 600 is a 3-phase system with a B6 bridge. Therefore, FIs which are sensitive
to all currents must be used in order to detect any d.c. fault current. Refer to chapter 5.9.1 for the
rule of thumb for determining the leakage current.
Rated residual currents in the FI
Protection against "indirect contact" (personal fire protection) for stationary and mo-
10 -30 mA
bile equipment, as well as for "direct contact".
Protection against "indirect contact" (personal fire protection) for stationary equip-
50 -300 mA
ment
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 residual-current
circuit-breaker which is sensitive to all currents.
If you use a selective FI circuit-breaker, the more intelligent evaluation process will prevent spurious
tripping of the circuit-breakers.
5.9.3 Isolating transformers

If protection against indirect contact is absolutely essential despite a higher leakage current, or if an
alternative form of shock-hazard protection is sought, the SERVOSTAR 600 can also be operated
via an isolating transformer. A ground-leakage monitor can be used to monitor for short circuits.
We would advise you to keep the length of wiring between the transformer and the servo amplifier
as short as possible.

Kollmorgen 12/2015 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 22.
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 assist you to carry out the mechanical installation in a sensible
sequence, without overlooking anything important.
In a closed switchgear cabinet. Observe page 22 .

Site The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p. 34
Check that the ventilation of the servo amplifier is unimpeded

and keep within the permitted ambient temperature ð p. 22 .
Ventilation
Keep the required space clear above and below the servo amplifier ð p 34.
Assemble the servo amplifier and power supply, filter and choke close
Assembly
together on the conductive, grounded mounting plate in the cabinet.
EMC-compliant (EMI) shielding and grounding (ð p. 45)

Grounding
Earth (ground) the mounting plate, motor housing and CNC-GND of the controls.
Shielding
Notes on connection techniques are on page 40

Mechanical Installation 12/2015 Kollmorgen
6.3 Assembly
Material : 2 or 4 hexagon socket screws to EN 4762, M5
Tool required : 4 mm Allen key
SERVOSTAR SERVOSTAR SERVOSTAR SERVOSTAR

601-610 601-610 614 620
SERVOSTAR 600

Kollmorgen 12/2015 Mechanical Installation
6.4 Dimensions
SERVOSTAR 601/603/603/610
SERVOSTAR 614
SERVOSTAR 620

Mechanical Installation 12/2015 Kollmorgen
This page has been deliberately left blank.

Kollmorgen 12/2015 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 five 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 five 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 50 V. 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 page 39.
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.22. Hints for use of
Residual-current circuit breakers (FI) ð p.32.
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 40.
Feedback lines may not be extended, since thereby the shielding would be interrupted and the sig-
nal processing could be disturbed. Lines between amplifiers and external brake resistor must be
shielded. Install all power cables with an adequate cross-section, as per IEC 60204 (ð p.23) and
use the requested cable material (ð p. 40) 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 12/2015 Kollmorgen
7.2 Guide to electrical installation

The following notes should assist you to carry out the electrical installation in a sensible sequence,
without overlooking anything important.
Cable selec-
Select cables according to EN 60204 (ð p. 23)
tion
EMC-compliant (EMI) shielding and grounding (ð p. 45)

Grounding
Earth (ground) the mounting plate, motor housing and CNC-GND of the controls.
Shielding
Notes on connection techniques are on page 40
— Route power leads and control cables separately

Wiring — Wire the BTB/RTO contact in series into the emergency stop circuit of
the system.
— Connect the digital control inputs to the servo amplifier
— Connect up AGND (also if fieldbuses are used)
— Connect the analog setpoint, if required
— Connect up the feedback unit (resolver and/or encoder)
— Connect the encoder emulation, if required
— Connect the expansion card (see hints from page 98)
— Connect the motor cables, connect shielding to EMI connectors at both ends
— Use motor chokes (3YL) for lead lengths >25m
— Connect the external brake resistor (with fusing) if required
— Connect aux. supply (for max. permissible voltage values ð p. 22)
— Connect main power supply (for max. permissible voltage values ð p. 22)
— Connect PC (ð p. 69).
— Final check of the implementation of the wiring,

Final check
— according to the wiring diagrams which have been used.

7.3 Wiring
The installation procedure is described as an example. A different procedure may be sensible or
necessary, depending on the application of the equipment.
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 possible surface area between
the unit indicated and the mounting plate in the switchgear cabinet.
This connection is for the effective grounding of HF interference, and must not be confused with the
PE- symbol W (a protective measure to EN 60204).
Use the following connection diagrams:

Overview : page 45
Mains power : page 47
Motor : page 50
Feedback : page 51ff
Electronic Gearing / Master Slave
Master-Slave : page 58
Pulse-Direction : page 61
Encoder Emulation:
ROD (A quad B) : page 63
SSI : page 64
Digital/Analog I/Os : page 65ff
RS232 / PC : page 69
CAN Interface : page 70
Multi-axis systems, example : page 85
Restart lock option -AS- : page 94
Expansion cards:
I/O-14/08 : page 101
PROFIBUS : page 102
SERCOS : page 104
DeviceNet : page 105
EtherCAT : page 108
SynqNet : page 110
-2CAN- : page 112

7.3.1 Technical data for connecting cables

Further information on the chemical, mechanical and electrical characteristics of the cables can be
obtained from our customer service.
Observe the restrictions in the chapter "Conductor cross-sections" on page 23.

To reach the max. permitted cable length, you must use cable material that matches the
capacitance requirements listed below.
Insulation material
Sheathing PUR (polyurethane, code 11Y)
Core insulation PETP (polyesteraphtalate, code 12Y)
Capacitance
Motor cable less than 150 pF/m
RES-/Encoder-cable less than 120 pF/m
Technical data
For a detailed description of cable types and how to assemble them, please refer to the accessories
manual.
Motor cables longer than 25m with motor choke 3YL only.
7.3.2 Shielding connection to the front panel
Remove the outer covering of the cable

and the shielding braid from the cores
for the required length. Secure the cores
with a cable tie.
Remove the outer covering of the cable

over a length of about 30mm, without
damaging the shielding braid.
Pull a cable tie through the slot in the

shielding rail (front panel) of the servo
0 amplifier.
R 60
A
ST
RVO
SE
00 Use the cable tie to clamp the shielding

AR6 braid of the cable firmly to the shielding
ST rail.
RVO
SE

7.3.3 Motor connector with shieldplate

The motor is connected to the SERVOSTAR 600 by a Power Combicon connector (X9). You can
obtain the connector kit from us (connector, housing, shield plate, rubber bushes, installation mate-
rial, order codes see p.117).
The cable material depends on the motor that is used. Please refer to the instructions manual for
the corresponding motor series. Please take note that the connector can accept a maximum con-
ductor cross-section of 4mm².
First push the rubber sleeve onto the
cable, and then strip off about 70mm
of the outer covering, without dama-
ging the shielding.
Carefully separate the shielding braid

from the cores.
Twist the shielding braid into a pigtail

and tie it to the sleeve with the wire.
Shorten the brake cores to 55mm
and the power cores to 45mm.
Fold back the overhanging length of

the shielding pigtail to face forwards.
Strip off the ends of the cores for
about 10mm. This length can vary,
depending on the type of bootlace
ferrule that is used.
Apply bootlace ferrules to the con-

ductors. Place the shield plate in the
bottom half of the connector housing.
Place the cable in the strain relief, so
that the folded shielding pigtail lies on
the shield plate, but the tie-wire is not
clamped inside.
Tighten up the screws, without crus-
hing the cable.
Place the connector in the housing.

Take care that the tongue of the
shield plate sits in the PE clamp.
Wire up the connector according to
the wiring diagram on page 50, and
tighten up the clamping screws. Take
care that the insulation is not trapped
underneath. Close the housing.

7.4 Components of a servo system
PC
Control / PLC
I/O
Option -AS-
24V supply
Fuses Brake resistor

(optional)
Drive cut-out
Motor
Terminals Motor choke
(optional)
Cables drawn bold are shielded. Electrical ground is drawn with dash-dotted lines.
Optional devices are connected with dashed lines to the servo amplifier. The required accessories
are described in our accessories manual.

7.5 Block diagram

The block diagram below is just an overview.

7.6 Pin assignments

7.7 Connection diagram (overview)
Reference Safety Instructions (ð p.10)

and Use As Directed (ð p.12) ! SERVOSTAR 600
ð p.65
ð p.66
ð p.52
ð p.67
ð p.50
ð p.68
ð p.48
ð p.63
ð p.64
ð p.58
ð p.61
ð p.47
ð p.47
ð p.69
ð p.47

7.8 Power supply

7.8.1 Connection to various mains supply networks
This page illustrates all the possible connection variations for different electrical supply networks.
An isolating transformer is always required for 400...480V mains networks without earth (ground)
and for networks with asymmetrical earth (ground).
208V with 60Hz only

SERVOSTAR
230...480V with 50Hz or 60Hz
SERVOSTAR SERVOSTAR
SERVOSTAR SERVOSTAR
SERVOSTAR SERVOSTAR
SERVOSTAR SERVOSTAR
SERVOSTAR SERVOSTAR

7.8.2 Mains supply connection (X0)

— Directly to earthed (grounded) 3~ supply, integrated EMI filter
— Fusing (e.g. fusible cut-outs) provided by the user ð p.22
SERVOSTAR 600
7.8.3 24V auxiliary supply (X4)

— Electrically isolated, external 24VDC supply, e.g. with insulating transformer
— Required current rating ð p.21
— Integrated EMI filter for the 24V auxiliary supply
SERVOSTAR 600
7.9 DC bus link (X7)

Can be connected in parallel. A patented circuit distributes the brake power among all the amplifiers
connected to the same DC bus link circuit. (Connection example ð p.72).
l Only servo amplifiers with mains supply from the same mains (identical mains supply voltage)
may be connected by the DC bus link.
l The sum of the rated currents for all of the servo amplifiers connected in parallel
to an SERVOSTAR 600 must not exceed 40A.
l Use unshielded single cores (2.5mm²) with a max. length of 200 mm. Use shielded cables for
longer lengths.

7.9.1 External brake resistor (X8)

Remove the plug-in link between the terminals X8/1 (-RB) and X8/2
(+Rbint). Information for brake circuit and technical data can be found
on page 25. Use the optional Y-connector X8Y, if you want to link the
DC bus with other SERVOSTAR 600 servo amplifiers.
SERVOSTAR 600
7.9.2 Capacitor Module KCM
KCM modules (KOLLMORGEN Capacitor Modules) absorb energy generated by

the motor when it is operating in generator mode. Normally, this energy is dissipa-
ted as waste via brake resistors. SERVOSTAR 600 modules, however, feed the
energy they have stored back into the DC Bus link as and when it is required.
Dimensions (HxWxD) : 300x100x201 mm
KCM-S Saves energy: The energy stored in the capacitor module during regenerative braking is
available the next time acceleration happens. The module’s inception voltage is calcula-
ted automatically during the first load cycles.
KCM-P Power in spite of power failure: If the power supply fails, the module provides the servo
amplifier with the stored energy that is required to bring the drive to a standstill in a con-
trolled manner (this only applies to the power supply voltage; battery-back the 24 V
supply separately).
KCM-E Expansion module for both applications. Expansion modules are available in two capaci-
tance classes.
The KCM modules can be connected to S601 ... S620 devices (mains supply voltage 400/480V,
rated current max. 20A). Information for mounting, installation and setup can be found in the KCM
Instructions Manual and in the Product WIKI.
Technical Data KCM Modules
Rated
Storage Peak supply Protection Inception
supply Power Weight
capacity voltage class voltage
voltage
Typ [Ws] [V DC] [V DC] [kW] [V DC] [kg]
KCM-S200 1600 evaluated 6.9
max.
KCM-P200 2000 max. 470 VDC 6.9
950 VDC 18 IIP20
KCM-E200 2000 850 VDC - 4.1
(30s in 6min)
KCM-E400 4000 - 6.2

Wiring example KCM Modules

Maximum cable length between servo amplifier and SERVOSTAR 600 module: 500 mm.
Twist the cables +DC/-DC. Longer cable lengths require shielding. Ensure that the polarity is cor-
rect; swapping round DC+/DC- will destroy the KCM modules.
DANGER
DC Bus link terminals in servo systems carry high DC voltage of up to 900 V.
Touching the terminals while they are carrying voltage is extremely dangerous.
Switch off (disconnect) the line voltage. You must only work on the connections
when the system is disconnected.
It can take over an hour for the modules to self-discharge. Check the state of
charge with a measuring device that is suitable for a DC voltage of up to 1000V.
When measuring a voltage of over 50 V between the DC+/DC- terminals or to
ground, wait some minutes and measure again or discharge the modules as
described in the KCM instructions manual.
KCM-S: Connect the BR connection to the SERVOSTAR 600 with the most frequent regenerative
braking processes in the system. This SERVOSTAR 600 must have an active internal or external
brake resistor. For setup, enable the SERVOSTAR 600 and operate the driving profile that causes
the brake chopper to respond. The KCM-S determines the chopper threshold and begins to charge;
LED flashes. The energy stored is available the next time acceleration happens.
KCM-P: The KCM-P begins the charging process at approx. 470 V DC; the LED flashes. If the
power supply fails, the module provides the servo amplifier with the stored energy that is required to
bring the drive to a standstill in a controlled manner (this only applies to the power supply voltage;
battery-back the 24 V supply separately).
More information see Product WIKI.
KCM-P KCM-S KCM-E
SERVOSTAR

7.10 Motor connection with holding brake (X9)

Lead length £ 25m
SERVOSTAR 600
Lead length >25m

For lead lengths above 25m the choke box 3YL/3YLN (see accessories manual) must be wired into
the motor lead, close to the amplifier.
SERVOSTAR 600

7.11 Feedback
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, informa-
tion will be fed back to the servo amplifier using digital or analog means.
SERVOSTAR 600 supports the most common types of feedback device whose functions must be
assigned with the parameters
FBTYPE (screen page FEEDBACK), primary Feedback
EXTPOS (screen page POSITION), secondary Feedback
GEARMODE (screen page GEARING), secondary Feedback
in the setup software. Scaling and other settings must always be made here.
Commu- Speed Position- electr.

Configuration Location ASCII Parameter
tation control control gearing
One Feedback motor FBTYPE X X X
motor FBTYPE X X
Two Feedbacks EXTPOS X
externally
GEARMODE X
For a detailed description of the ASCII parameters, please refer to the online help of the setup soft-
ware.
The table below provides an overview of the supported feedback types, their corresponding para-
meters and a reference to the relevant connection diagram in each case. On each of these, the pin
assignment shown on the encoder side relates to the Kollmorgen motors.
Wiring
Primary feedback type Connector FBTYPE
diagram
Resolver X2 ð p.52 0, 3
SinCos Encoder BISS X1 ð p.53 20*
SinCos Encoder ENDAT X1 ð p.54 3, 4
SinCos Encoder HIPERFACE X1 ð p.54 2, 3
SinCos Encoder w/o data channel X1 ð p.55 6, 7 (16*)
SinCos Encoder + Hall X1 ð p.56 11*
RS422 5V + Hall X1 ð p.56 12*
RS422 5V X5 ð p.57 8*, 9*
Sensorless (w/o feedback) - - 10*
* Can only be set on the terminal screen of the setup software
** RS422 means “incremental encoder AquadB”.
Hints for combining primary with secondary feedback systems for position control/electr. gearing
can be found from page 58.

7.11.1 Resolver (X2)
Connection of a Resolver (2 to 36-poles) as a feedback system (primary, ð p.51). The thermal con-
trol in the motor is connected via the resolver cable to X2 and evaluated there.
If cable lengths of more than 100 meters are planned, please contact our customer service.
FBTYPE: 0, 3
SERVOSTAR 600 SubD9 12pol.round
The pin assignment shown on the encoder side relates to the Kollmorgen motors.

7.11.2 Sine Encoder 5V with BiSS (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with BiSS interface as a feedback system
(firmware revision from 6.68). During start-up of the servo amplifier the parameters stored in the
encoder eeprom are uploaded, after that phase only the sine/cosine signals are used.
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.
Encoder types with a power consumption of more than 150mA can also be connected using our
external power supply (ð p. 113). For encoders that do not have integrated terminating resistors,
we offer an optional terminating adapter (ð p. 113).
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
FBTYPE 20
SERVOSTAR 600

7.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1)

Wiring of a single-turn or multiturn sine-cosine encoder as a feedback system. Preferred types are
ECN1313 and EQN1325. The thermal control in the motor is connected via the encoder cable to the
SERVOSTAR 600 and evaluated there. All signals are connected using our pre-assembled encoder
connection cable.
If lead lengths of more than 50m are planned, please consult our customer service.
Encoder with EnDat: FBTYPE 3, 4
Encoder with HIPERFACE: FBTYPE 2, 3
SubD1 17pol.round
SERVOSTAR 600

7.11.4 Sine Encoder without data channel (X1)

Wiring of a sine-cosine encoder without data channel as standard feedback system. Every time the
24V auxiliary voltage is switched on, the amplifier needs start-up information for the position control-
ler (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.
The thermal control in the motor is connected via the encoder cable to X1 and evaluated there.
If lead lengths of more than 50m are planned, please consult our customer service.
Encoder type FBTYPE Remarks

SinCos 5V 6 MPHASE from EEPROM
SinCos 5V 7 MPHASE with wake & shake
Resolver+SinCos5V 16 Commutation with Resolver, speed&position with Encoder
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 this feedback
type with vertical load (hanging load).
SERVOSTAR 600

7.11.5 Incremental encoder / sine encoder with Hall (X1)

Encoder types (incremental or sine/cosine) that do not provide definitive information on commuta-
tion, can be used as a complete feedback system using an additional Hall dongle.
In this case, an adapter is used for interfacing and adapting the signals (Hall dongle, ð p. 90). This
adapter is also used to connect encoders known as ComCoders.
we offer an optional terminating adapter (ð p. 113)
If you plan to use a cable longer than 25m, please contact our application department.
Frequency limit (A, B): 250 kHz
RS422 with Hall: FBTYPE 12
Encoder with Hall: FBTYPE 11
SERVOSTAR 600

7.11.6 Incremental Encoder (X5)

An incremental encoder can be used as standard motor feedback.
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.
The thermal control in the motor is connected to X1 (see p.54) or X2 (see p.52).
If lead lengths of more than 50m are planned and for questions concerning the power supply of the
encoder, please consult our customer service.
AGND and DGND (connector X3) must be joined together!
Frequency limit: 1.5 MHz
Encoder type FBTYPE Remarks

RS422 5V 9 MPHASE from EEPROM
RS422 5V 8 MPHASE with wake & shake
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 this feedback
type with vertical load (hanging load).
SERVOSTAR 600 SubD 9

7.12 Electronic Gearing, Master-slave operation

In the case of the “electronic gearing” functionality (see setup software and description of GEAR-
MODE parameter), the servo amplifier is controlled by a secondary feedback device as a slave.
More information can be found in the Online Help of the setup software.
It is possible to set up master/slave systems, use an external encoder as a setpoint encoder or con-
nect the amplifier to a stepper motor control.
The amplifier is parameterized using the setup software (electronic gearing).
Primary Feedback: adjust on screen page "Feedback" (FBTYPE)
Secondary Feedback: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
Master-/Slave adjustment
Master: adjust encoder emulation on screen page "ROD/SSI/Encoder" (ENCMODE)
Slave: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
The following types of external encoder can be used:
Wiring
secondary Feedback type Connector GEARMODE
diagram
Incremental Encoder 5V X5 ð p.59 3, 5*, 13*, 15*
Incremental Encoder 24V X3 ð p.59 0, 2*, 10*, 12*
Sine/Cosine Encoder X1 ð p.60 6, 8*, 9*, 16*
SSI Encoder X5 ð p.61 7*, 17*
Pulse and Direction 5V X5 ð p.62 4, 14*
Pulse and Direction 24V X3 ð p.62 1, 11*
* adjustable via terminal screen of the setup software
The follwing table shows the allowed feedback combinations:
Secondary Feedback for Position control/Following

Sine Encoder Increment. Enco- Pulse&Direct. SSI Encoder
Primary Feedback
(X1) der5V/24V (X5/X3) 5V/24V (X5/X3) (X5)
EXTPOS = 1,2,3 EXTPOS = 1,2,3 EXTPOS = 1,2,3 EXTPOS = 1,2,3
Resolver (X2) GEARMODE = GEARMODE = GEARMODE = GEARMODE =
FBTYPE = 0 6,8,9,16 0,2,3,5,10,12,13,15 1,4,11,14 7,17
FPGA = 0 FPGA = 0 FPGA = 0 FPGA = 1
ENCMODE = 0 ENCMODE = 0 ENCMODE = 0 ENCMODE = 2
EXTPOS = 1,2,3 EXTPOS = 1,2,3 EXTPOS = 1,2,3
GEARMODE = GEARMODE = GEARMODE =
Sine Encoder (X1)
- 0,2,3,5,10,12,13,15 1,4,11,14 7,17
FBTYPE = 2,4,6,7,20
FPGA = 1 FPGA = 1 FPGA = 1
ENCMODE = 0 ENCMODE = 0 ENCMODE = 2
EXTPOS = 1,2,3 EXTPOS = 1,2,3
Encoder & Hall (X1)
GEARMODE = GEARMODE =
- 0,2,3,5,10,12,13,15 1,4,11,14 -
FBTYPE = 11,12
FPGA = 1 FPGA = 1
ENCMODE = 0 ENCMODE = 0
RS422 Encoder (X5)
- - - -
FBTYPE = 8,9
EXTPOS = 1,2,3 EXTPOS = 1,2,3 EXTPOS = 1,2,3
Sensorless GEARMODE = GEARMODE = GEARMODE =
FBTYPE = 10 - 0,2,3,5,10,12,13,15 1,4,11,14 7,17
FPGA = 0 FPGA = 0 FPGA = 1
ENCMODE = 0 ENCMODE = 0 ENCMODE = 2

7.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5)

You can link several SERVOSTAR amplifiers together in master-slave operation.
Up to 16 slave amplifiers can be controlled by the master via the encoder output. The connector X5
must be used.
Frequency limit: 1,5 MHz, slew rate tv £ 0,1 µs
SERVOSTAR 600
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together !
7.12.2 Connection to encoders with 24 V signal level (X3)

This interface can be used to operate the SERVOSTAR as a slave, mastered by an encoder with
24 V signal level (master-slave operation). The digital inputs DIGITAL-IN 1 and 2 at connector X3
must be used. Frequency limit: 250 kHz, slew rate tv £ 0,1 µs
SERVOSTAR 600

7.12.3 Connection to a sine-cosine encoder (X1)

You can operate the SERVOSTAR as a slave, mastered by a sine-cosine encoder (master-slave
operation). The connector X1 must be used.
Encoder types with a power consumption of more than 150 mA can also be connected using our
external power supply (ð p.113). For encoders that do not have integrated terminating resistors, we
offer an optional terminating adapter (ð p. 113).
Frequency limit: 250 kHz
SERVOSTAR 600

7.12.4 Connection to an SSI encoder (X5)

You can set up the SERVOSTAR 600 as a slave following a synchronous serial absolute-encoder
(master-slave operation). This application uses the SubD connector X5.
If lead lengths of more than 50 m are planned and for questions concerning the power supply of the
encoder, please consult our customer service.
Frequency limit: 1,5MHz
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together!
7.12.5 Connection to stepper motor controllers (step and direction)

This interface can be used to connect the servo amplifier to a third-party stepper-motor controller.
The parameters for the servo amplifier are set up with the aid of the setup software (electrical gea-
ring). The number of steps can be adjusted, so that the servo amplifier can be adjusted to the
pulse-direction signals of any stepper-motor controller. Various monitoring signals can be output.
The analog setpoint inputs are out of action.
Observe the frequency limit! Using an A quad B encoder provides better EMC noise immunity.
Speed profile and signal diagram

7.12.5.1 Step/Direction with 5 V signal level (X5)

Connection of the servo amplifier to a stepper-motor controller with 5 V signal level. The connector
X5 must be used.
Frequency limit: 1,5 MHz
SERVOSTAR 600
7.12.5.2 Step/Direction with 24 V signal level (X3)

Connection of a servo amplifier to a stepper-motor controller with 24 V signal level. The digital
inputs DIGITAL-IN 1 and 2 at connector X3 must be used.
Frequency limit: 250 kHz
SERVOSTAR 600

7.13 Encoder emulations

7.13.1 Incremental encoder output - A quad B (X5)
The incremental-encoder interface is part of the package supplied. Select the encoder function
ROD (screen page “Encoder”). In the servo amplifier, the position of the motor shaft is calculated
from the cyclic-absolute signals of the resolver or encoder. Incremental-encoder compatible pulses
are generated from this information. Pulses are output on the SubD-connector X5 as two signals, A
and B, with 90° phase difference and a zero pulse.
The resolution (lines before quadrature) can be changed with the RESOLUTION parameter:
Encoder function
Feedback system Resolution Zero position
(ENCMODE)
one per revolution
Resolver 256...4096
(only if A=B=1)
ROD (1)
256...524288 one per revolution
Encoder
(28 ... 219) (only if A=B=1)
22...27 analog pass through
ROD interpolation (3) Encoder
TTL lines per sine line from X1 to X5
You can also adjust and store the position of the zero pulse within one mechanical turn
(parameter NI-OFFSET).
The drivers are supplied from an internal supply voltage. PGND must always be connected to the
controls. The max. admissible cable length is 10 m.
Connections and signal description for incremental-encoder interface :

Default count direction: upwards when the motor shaft is rotating clockwise (looking at the shaft
end).
SERVOSTAR 600

7.13.2 SSI output (X5)

The SSI interface (synchronous serial absolute-encoder simulation) is part of the delivered
package. Select the encoder function SSI (screen page “Encoder”). In the servo amplifier, the posi-
tion of the motor shaft is calculated from the cyclically absolute signals from the resolver or encoder.
This information is used to create a position output in a format that is compatible with the standard
SSI-absolute-encoder format. 24 bits are transmitted.
SINGLE TURN selected: The upper 12 bits are fixed to ZERO, the lower 12 bits contain the posi-
tion information. For 2-pole resolvers, the position value refers to the position within one turn of the
motor, for 4-pole resolvers it is within half a turn, and for 6-pole resolvers it is within a third of a turn.
Exception: If an encoder with a commutation track is used as the feedback unit, then the upper 12
bits are set to 1 (data invalid!) until a homing run is performed.
MULTI TURN selected: The upper 12 bits contain the number of motor turns, the lower 12 bits con-
tain the position information.
The signal sequence can be output in Gray code (standard) or in binary code (parameter
SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with
the SSI-TAKT parameter (200 kHz or 1.5MHz and inverted).
Drivers are supplied from internal supply voltage. PGND must always be connected.
Connection and signal description for SSI interface :

Default count direction: upwards when the motor shaft is rotating clockwise (looking at the shaft
end).
SERVOSTAR 600

7.14 Digital and analog inputs and outputs

7.14.1 Analog inputs (X3)
The servo amplifier is equipped with two differential inputs for analog setpoints which are
programmable. AGND (X3/1) must always be joined to the CNC-GND of the controls as a ground
reference.
Technical characteristics
— Differential-input voltage max. ± 10 V
— Resolution 1.25 mV
— Ground reference AGND, terminal X3/1
— Input resistance 20 kW
— Common-mode voltage range for both inputs ± 10 V
— Update rate 62.5 µs
SERVOSTAR 600
Input Analog-In 1 (terminals X3/4-5)

Differential input voltage max. ± 10 V, resolution 14-bit, scalable
Standard setting : speed setpoint
Input Analog-In 2 (terminals X3/6-7)
Differential input voltage max. ± 10 V, resolution 12-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
Fixing the direction of rotation
Standard setting : clockwise rotation of the motor shaft (looking at the shaft end)
— Positive voltage between terminal X3/4 (+ ) and terminal X3/5 ( - ) or
— Positive voltage between terminal X3/6 (+ ) and terminal X3/7 ( - )
To reverse the direction of rotation, swap the connections to terminals X3/4-5 and. X3/6-7 or
change the ROT. DIRECTION parameter in the “Speed controller” screen.

7.14.2 Analog outputs (X3)
— Reference ground is analog-GND (AGND, terminal X3/1 and X3/10)
— Output resistance 2.2 kW
— Output voltage ±10 V
— Resolution 10 bit.
— Update rate 62.5 µs
SERVOSTAR 600
Programmable analog outputs Analog-Out 1 / Analog-Out 2

The terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) can have the following analog signals
assigned to them:
Standard setting :
Analog-Out 1 : Tachometer voltage nact (speed)
The output delivers ±10V at the preset limit speed.
Analog-Out 2 : Current actual value Iact (torque)
The output delivers ± 10V at the preset peak current Ipeak (effective r.m.s. value).
You can use the terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) to output converted analog
values for digital measurements which are contained in the servo amplifier.
You can find a list of pre-programmed functions on the "Analog I/O" screen of our setup software.

7.14.3 Digital inputs (X3)
All digital inputs are electrically isolated through optocouplers.

— Reference ground is digital-GND (DGND, terminal X3/18)
— Inputs at X3 meet PLC standards (IEC 61131-2 Type 1)
— High: 11...30V / 2...11mA, Low -3...+5V / <1 mA
— Update rate: 250µs
SERVOSTAR 600
ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X3/15, input 24V, active-high).
In the inhibited state (low signal) the motor which is attached does not have any torque.
Programmable digital inputs :
You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate
preprogrammed functions that are stored in the servo amplifier.
You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software.
If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the
EEPROM of the servo amplifier, and the 24V auxiliary supply of the servo amplifier must be
switched off and on again (to reset the amplifier software).
Limit-switches PSTOP / NSTOP
Terminals X3/13 and X3/14 are normally programmed for the connection of limit switches. If these
inputs are not needed for the connection of limit switches, then they are programmable for other
input functions.
Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/13 and X3/14), high level in normal
operation (fail-safe for a cable break).
A low signal (open) inhibits the corresponding direction of rotation, the ramp function remains
effective.
DIGITAL-IN 1 / DIGITAL-IN 2
The digital inputs on terminal X3/11 (DIGITAL-IN 1) or terminal X3/12 (DIGITAL-IN 2) can be logi-
cally combined in a pre-programmed function.

7.14.4 Digital outputs (X3)
— Reference ground is digital-GND (DGND, terminal X3/18)
— All digital outputs are floating
— DIGITAL-OUT1 and 2 : Open-Collector, max. 30 VDC, 10 mA
BTB/RTO : Relay output, max. 30 VDC or 42 VAC, 0.5 A
— Update rate : 250 µs
SERVOSTAR 600
Ready-to-operate contact BTB/RTO

Operational readiness (terminals X3/2 and X3/3 ) is signaled by a floating relay contact.
The contact is closed when the servo amplifier is ready for operation, 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 switch-off of the output stage (if the BTB
contact is open, the output stage is disabled -> no power).
A list of the error messages can be found on page 88.
Programmable digital outputs DIGITAL-OUT 1 / 2:

You can use the digital outputs DIGITAL-OUT1 (terminal X3/16) and DIGITAL-OUT2 (terminal
X3/17) to output messages from pre-programmed functions that are stored in the servo amplifier.
You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software.
If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the
EEPROM of the servo amplifier, and the 24V auxiliary supply of the servo amplifier must be swit-
ched off and on again (to reset the amplifier software).
Evaluate the outputs via inverting interface relays (see connection diagram), for example
Phönix DEK-REL-24/I/1 (turn-on delay 6 ms, turn-off delay 16ms).
The described logic in the online help of the setup software refers to the output of the inverting
interface relays. Consider the delay of the applied relay !

7.15 RS232 interface, PC connection (X6)

The setting of the operating, position control, and motion-block parameters can be carried out with
an ordinary commercial PC.
Connect the PC interface (X6) of the servo amplifier while the supply to the equipment is swit-
ched off via a normal commercial 3-core null-modem cable to a serial interface on the PC.
Do not use a null-modem link cable!
The interface is electrically isolated through an optocoupler, and is at the same potential as the
CANopen interface.
The interface is selected and set up in the setup software.
Further notes can be found on page 72.
With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise
use the same connector X6, are separated onto two connectors (ð p.111).
SERVOSTAR 600
Interface cable between the PC and servo amplifiers of the SERVOSTAR 600 series:
(View : looking at the face of the built-in SubD connectors, this corresponds to 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 communication profile CANopen DS301 and the drive profile DS402. The following functions are
available in connection with the integrated position controller:
Jogging with variable speed, reference traverse (zeroing), 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 electrically isolated by
optocouplers, and is at the same potential as the RS232 interface. The analog setpoint inputs can
still be used.
With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise
use the same connector X6, are separated onto two connectors ð p.111).
SERVOSTAR 600
CAN bus cable

To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120 W. 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 resistance (loop) 159.8 W/km
Cable length, depending on the transmission rate
Transmission rate (kbaud) max. cable length (m)
1000 20
500 70
250 115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance

(loop, 115 W/km) make it possible to achieve greater distances.
(Characteristic impedance 150 ± 5W Þ terminating resistor 150 ± 5W).
For EMC reasons, the SubD connector housing must fulfill the following conditions:
— metal or metallised housing
— provision for cable shielding connection in housing, large-area connection

Kollmorgen 12/2015 Setup
8 Setup
The procedure for setup is described as an example. Depending on the application,
a different procedure may be sensible or necessary. In multi-axis systems, setup each servo ampli-
fier individually.
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.
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
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 five 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 five 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 50V.
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 longer than 1 year, then the DC bus link capacitors will
have to be re-formed.
To do this, disconnect all the electrical connections.
Supply the servo amplifier for about 30 min. from single-phase 230VAC to the terminals L1 / L2.
This will re-form the capacitors.
Further information on setup :

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

Setup 12/2015 Kollmorgen
8.2 Setup software

8.2.1 General
This chapter describes the installation of the setup software DRIVE.EXE for the SERVOSTAR 600
digital servo amplifiers.
We offer training and familiarization courses on request.
8.2.1.1 Use as directed

The setup software is intended to be used for setting up and storing the operating parameters for
the SERVOSTAR 600 series of servo amplifiers. The attached servo amplifier can be setup with the
assistance of the software - during this process the drive can be controlled directly by the service
functions.
Only professional personnel who have the relevant expertise described on page 7 are permitted to
carry out online parameter setting for a drive which is running.
Sets of data which are stored on data media are not safe against unintended alteration by other
persons. After loading a set of data you must therefore check all parameters
thoroughly before enabling the servo amplifier.
8.2.1.2 Software description

The servo amplifiers must be adapted to the requirements of your installation. 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 (see p.69) .
The setup software provides the communication between SERVOSTAR 600 and the PC.
You will find the setup software on the accompanying CD-ROM and at our web site.
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.
Simultaneously, important actual values are read out from the amplifier and displayed on the PC
monitor (oscilloscope function).
Any interface modules (expansion cards) which may be built into the amplifier are automatically
recognized, and the additional parameters which are required for position control or motion-block
definition are made available.
Sets of data can be stored on data media (archived) and loaded again. Sets of data which are sto-
red on data media can be printed.
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 supports you in
each situation.

8.2.1.3 Hardware requirements

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.69).
Connect / disconnect the interface cable only when the supply is switched off for both the PC and
the servo amplifier.
The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the same
potential as the CANopen interface.
Minimum requirements for the PC:
®
Processor : Pentium I or higher
Operating system : WINDOWS
Graphics adapter : Windows compatible, color
Drives : hard disk with at least 10 MB free space
CD-ROM drive
Main memory : at least 8MB
Interface : one free serial interface (COM1...COM10)
8.2.1.4 Operating systems
WINDOWS 95(c) / 98 / 2000 / ME / NT / XP / Vista / 7

DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME / NT 4.0 / XP / Vista / 7.
The HTML help system is not available under WINDOWS 95a and 95b.
WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2 Unix, Linux
DRIVE.EXE is not executable under WINDOWS 3.xx, DOS, OS2.
In emergency, operation is possible through an ASCII terminal emulation (without user-interface).
Interface settings : 9600 bps, no parity, no handshake.
Unix, Linux
The software function has not been tested running within Unix or Linux.
WINDOWS 8
DRIVE.EXE is not tested with WINDOWS 8.
8.2.2 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 DRIVE.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 and the PC interface (X6) of the
SERVOSTAR 600 (ð p. 69).

8.3 Quickstart Guide

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 6.3
4. Wire the servo amplifier as described in chapter 7.3 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 Instructions Manual (this manual)

l CANopen Communication Profile Manual
l Accessories Manual
Depending on the installed expansion card you need one of these documents:
l PROFIBUS DP Communication Profile Manual
l DeviceNet Communication Profile Manual
l SERCOS Communication Profile Manual
l EtherCAT 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.
Motor-Feedback
ENC
RES
PC
C A N
X3 2
3
Power ON
Enable
15
18
24V ON
X4
+ 1
2
24V DC 3
-
Power
Motor
Motor-Power

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 current classe
(e.g. for 3 amps). If the power supply voltage is switched on, too, a leading P is display-
ed (e.g. for Power, 3 amps).
If a fault code ( ) or a warning ( ) or a status message (./_ / E/S) appears in the

display, you will find the description on page 88ff. If there is fault, fix the problem.
Double-Click the DRIVE.EXE icon on your Windows desktop to start the software.
You can work offline or online with .

Work ONLINE now. Select the interface where the servo am-
plifier is connected to.
The software tries to communicate with the

drive and to upload the parameters. If it's
not successful, you receive this error mes-
sage.
- wrong interface chosen

- wrong connector chosen at the servo amplifier
Frequent causes: - interface is used by another software
- 24 V auxiliary voltage for the servo amplifier not working
- interface cable broken or wrong wiring
Click OK to remove the error message. Detect and remove the error source. Restart the software.

If communication works, parameters are transmitted from the servoamplifier to the computer.
Then you see the start screen.
Make sure, that the amplifier is dis-

abled (Input HW-Enable
connector X3 pin 15 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 ? or
Starts online help with table of contents.
Online HTML Help
Tool Bar
Save to EEPROM,
required if you changed parameters.
Reset (coldstart),
required if you changed important configuration parameters.
Operation Mode, use Digital Velocity mode for drive testing.
Disable and Enable of the amplifier's output stage via software.
Status Bar

8.3.4 Basic Setup
On the start screen click "Basic Setup" button.
Regen Resistor: Change only if you use an external brake resistor. Most applications don't need
an external brake resistor
max. Mains Voltage: Select the nominal mains AC voltage
Mains Phase Missing: You can select either warning "n05" or error "F19" in case of phase loss.
The setting "F19" disables the output stage, "n05" is just a message.
Units: Acceleration, Velocity, Position
Select usable units for your application referring to the moved load.
Leave all other fields unchanged.
Click OK. On the start screen click "Motor" button.

8.3.5 Motor (synchronous)
Press function key F12 (Software Disable) before changing motor parameters.
Motor Type: Select Synchronous Motor. If you use a linear motor or an induction motor, please
contact our support department.
Number-Name: Click the list to start uploading the motor parameter table, which is stored in the
servo amplifier. Search and select the connected motor. If your motor is not listed, please contact
our support department.
Click OK.
If your motor has a built-in brake, click Yes,

otherwise "No".
If Software Enable is active, a warning appe-

ars. You can proceed, but after the amplifier is
restarted, you must check whether the holding
brake configuration is correct.
Click OK.
Parameters are uploaded to the amplifier's

RAM now (takes some seconds). When this is
done, you have to accept the changed confi-
guration with "Yes" or to discard the changes
in the appearing screen.
If you click "Yes", the parameters are saved in
the EEPROM and the amplifier makes a cold-
start (reset). This takes some seconds.
On the start screen, click "Feedback" button.

8.3.6 Feedback
Press F12 (disable) before changing feed-

back parameters.
Feedback Type:
Select the feedback type used.
If Software Enable is active, a warning appears.

The configuration change cannot be performed.
Click OK on the warnings, press F12 (SW disab-

le) and start the Feedback procedure again.
If everything was ok, the same procedure (para-

meter upload) that has been described for the
motor selection starts.
If you click "Yes", the parameters are saved in
the EEPROM and the amplifier makes a cold-
start (reset). This takes some seconds.

8.3.7 Save Parameters and Restart

You are going to finish setup and you have changed several basic parameters. Depending on the
parameters you changed, two possible reactions can occur:
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
amplifier (takes a few seconds). For example, this happens after motor or feedback selection.
Other parameters changed
No warning appears. Parameters are saved in the volatile RAM only. Save the parameters to the
EEPROM of the servo amplifier manually by clicking the symbol in the tool bar. A coldstart
of the amplifier is not necessary.
Reset the amplifier
You can reset the amplifier manually (e.g. in case of an error). Click the icon .

8.3.8 Jogging the Motor (Speed Control)

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.
l Switch on the power supply for the drive.

l Hardware-Enable: +24 VDC to Enable [connector X3 pin 15].
l Software-Enable: Click the "Enable" button on the start screen or use key
combination Shift+F12. Now, the front display shows an E and the current rating (e.g.
for Enable, 3 amps).
l Click the icon "Oscilloscope"
l Select Service-Mode "Speed F6", then click "Parameter" button
l Enter a safe speed. The sign defines the direction of movement.
Observe the "safe reduced speed" requirements for your application!
l Click OK.
l Start the service function ("Start" button or press F6).
Click OK on the warning notice.

Opmode is switched to "0" and the output stage is enabled automatically. The symbol's color
changes to green as long as the function is active.
l The function is active until you click the "Stop" button or press F9.
l The output stage can be disabled by pressing function key F12.

8.3.9 Status
Actual warnings and errors are listed on the Status screen, which can be accessed on the start
screen by clicking the "Status" button. This button monitors the current status of the amplifier and
can appear with different text.
The Reset button can be used to clear some actual error messages. A description of errors/war-
nings can be found on page 88.
Now you have setup and tested the basic functions of the drive successfully.
8.3.10 Monitor
Click the icon "Monitor"
The Monitor screen shows all

important electrical and me-
chanical actual values
8.3.11 Additional Setup Parameters

Detailed information on all setup functions can be found in the online help system and and the inte-
grated command reference.

8.4 Multi-axis systems

Using a special multilink cable, you can connect up to six servo amplifiers together and to your PC :
Cable type -SR6Y- (for 4 amplifiers) or -SR6Y6- (for 6 amplifiers).
PC Cable -SR6Y-
X6
CAN
COMx
Add.: Add.: Add.: Add.:
RS232
01 02 03 04
Baud rate identical for all amplifiers,
see table below.
With the PC connected to just one servo amplifier you can now use the setup software to select all
four / six amplifiers through the preset station addresses and set up the parameters.
8.4.1 Node address for CAN-bus

During setup it makes sense to preset the station addresses for the individual amplifiers and the
baud rate for communication by means of the keypad on the front panel (ð p.87).
8.4.2 Baud rate for CAN-bus

After changing the station address and baud rate you must turn the 24V auxiliary supply of 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
0 10 5 250
1 20 6 333
2 50 7 500
3 100 8 666
4 125 9 800
10 1000

8.4.3 Example of connections for multi-axis system
Reference Safety Instructions (ð p.10)

and Use As Directed (ð p.12) !
SERVOSTAR 600
M
SERVOSTAR 600
Power supply
SERVOSTAR 600
M

8.5 Key operation / LED display

In this chapter the two possible operation menus and the use of the keys in the front panel are
shown. Normally, the SERVOSTAR 600 only places the standard menu at your disposal. If you
want to attend the amplifier via the detailed menu, you must keep the right key pressed while swit-
ching on the 24V-supply.
8.5.1 Key operation

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

press once : go up one menu item, increase number by one
press twice in rapid succession : increase number by ten
press once : go down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
press and hold right key, then press left key as well :
enter a number, return function name
8.5.2 Status display

8.5.3 Standard menu structure
ð p.84
8.5.4 Extended menu structure

Keep the right key pressed while switching on the 24V-supply.
ð p.84
ð p.84

8.6 Error messages

Errors which occur are shown in coded form by an error number in the LED display on the front
panel. All error messages result in the BTB/RTO contact being opened, and the output stage of the
amplifier being switched off (motor loses all torque). If a motor-holding brake is installed, it will be
activated.
Number Designation Explanation
E/S/A/P Status Messages Status messages, no error, see p. 86
... Status Message Updating the startup configuration
- Status Message Programming mode
Heat sink temperature too high
F01* Heat sink temperature
limit is set by manufacturer to 80°
Overvoltage in DC bus link
F02* Overvoltage
limit depends on the electrical supply voltage
F03* Following error Message from the position controller
F04 Feedback Cable break, short-circuit, short to ground
Undervoltage in DC bus link
F05* Undervoltage
limit is set by manufacturer to 100V
Motor temperature too high or temp. sensor defect
F06 Motor temperature
limit is set by manufacturer to 145°C
F07 Internal voltage supply Internal amplifier supply voltages are out of tolerance
F08* Overspeed Motor runs away, speed is too high
F09 EEPROM Checksum error
F10 Flash-EPROM Checksum error
F11 Brake (motor) Cable break, short-circuit, short to ground
F12 Motor phase Motor phase missing (cable break or similar)
F13* Internal temperature Internal temperature too high
F14 Output stage Fault in the power output stage
F15 I²t max. I²t maximum value exceeded
F16* Supply BTB/RTO 2 or 3 phases missing in the mains supply feed
Error in the analog-digital conversion, normally caused by
F17 A/D converter
extreme electromagnetic interferences.
F18 Brake Brake circuit faulty or incorrect setting
A phase is missing in the mains supply power feed
F19* Supply phase
(can be switched off for 2-phase operation)
F20 Slot fault Slot error (hardware fault on expansion card)
F21 Handling error Software error on the expansion card
F22 Earth short circuit For 40/70 amps type only
F23 CAN-bus off Severe CAN bus communication error
F24 Warning Warning is displayed as fault
F25 Commutation error Commutation error
Homing error (machine has driven onto hardware limit
F26 Limit switch
switch)
Operational error with -AS- , input for AS-Enable and EN-
F27 AS
ABLE have been set at the same time
External position profile generator created a step, that ex-
F28 External Trajectory
ceeded the maximum value
F29 Slot Fault depends on expansion card, see online help
F30 Emergency timeout Timeout emergency stop
F31 Macro Macro program error
F32 System Error system software not responding correctly
* = These error messages can be cancelled by the ASCII command CLRFAULT, without executing a reset. If
only these errors are present, and the RESET button or the I/O-function RESET is used, the CLRFAULT com-
mand is also all that is carried out.
More information to the messages can be found in the ASCII Object Reference (online help), see
parameter ERRCODE. Hints for removal can be found in section "Trouble-Shooting" of 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.
Number Designation Explanation
E/S/A/P Status Messages Status messages, no error, see p. 86
... Status Message Updating the startup configuration
- Status Message Programming mode
n01 I²t I²t threshold exceeded
n02 Brake power Reached preset electrical 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 Underrun software limit switch 1
n07* SW limit switch 2 Overrun software limit switch 2
n08 Motion task error A faulty motion task was started
n09 No reference point No reference point (Home) set at start of motion task
n10* PSTOP PSTOP limit-switch activated
n11* NSTOP NSTOP limit-switch activated
Only for ENDAT or HIPERFACE® :
Motor default values
n12 discrepancy between motor number saved in the enco-
loaded
der and the amplifier, motor default values loaded
n13* Slot warning 24V supply of the I/O expansion board is missing
SinCos commutation (wake & shake) not completed, will
n14 SinCos feedback be canceled when amplifier is enabled and wake & sha-
ke carried out
n15 Table error Fault according to speed/current table INXMODE 35
n16 Summarized warning Summarized warning for n17 to n31
The mode synchronization SYNCSRC is selected but
n17 Fielbus Synchronization
the drive isn’t in synchronies cycle
Using Multiturn encoder feedback, an overrun over the
n18 Multiturn overrun
maximum number of resolutions was detected
Motion task ramps are li-
n19 Range overflow on motion task data
mited
n20 Wrong GMT data Wrong "Graphical Motion Task" data
n21 PLC program error For details see plc code
max. motor temperatur The user can shut down the process before the tempera-
n22
reached ture eror will interrupt the process immediately
n23...n31 reserved reserved
n32 firmware beta version Firmware is an unreleased beta version
* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)
More information to the messages can be found in the ASCII Object Reference (online help), see
parameter STATCODE. Hints for removal can be found in section "Trouble-Shooting" of the online
help.

8.8 Removing faults/warnings

Depending on the conditions in your installation, there may be a wide variety of reasons for the
fault. In multi-axis systems there may be further hidden causes of a fault.
Detailled 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.
Measures to remove the cause of
Fault possible causes
the fault
— wrong cable used — use null-modem cable
HMI message: — cable plugged into wrong position — plug cable into the correct
communication in servo amplifier or PC sockets on the servo amplifier
fault and PC
— wrong PC interface selected — select correct interface
— servo amplifier not enabled — apply enable signal
— break in setpoint cable — check setpoint cable
— motor phases swapped — correct motor phase sequence
motor does not
— brake not released — check brake control
rotate
— drive is mechanically blocked — check mechanism
— no. of motor poles set incorrectly — set no. of motor poles
— feedback set up incorrectly — set up feedback correctly
— gain too high (speed controller) — reduce Kp (speed controller)
motor oscillates — shielding in feedback cable is broken — replace feedback cable
— AGND not wired up — join AGND to CNC-GND
— Irms or Ipeak is set to low — increase Irms or Ipeak
drive reports
(keep within motor data !)
following error
— setpoint ramp is too long — shorten setpoint ramp +/-
motor overhea-
— Irms/Ipeak set too high — reduce Irms/Ipeak
ting
— 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)
— PID-T2 too high — reduce PID-T2
— T-Tacho too high — reduce T-Tacho
— 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
— PID-T2 too low — increase PID-T2
— T-Tacho too low — increase T-Tacho
— offset not correctly adjusted for — adjust setpoint-offset (analogI/O)
axis drifts at analog setpoint provision
setpoint = 0V — AGND not joined to the CNC-GND — join AGND and CNC-GND
of the controls

Kollmorgen 12/2015 Expansions / Accessories
9 Expansions / Accessories
9.1 Option -AS-, restart lock according to EN 954-1
A frequently required application task is the protection against the restarting of drives. This can not
be achieved by an electronic inhibit, but must be implemented with mechanical elements (positively
driven relay contacts).
A safety relay in the servo amplifier is activated either by the PLC or manually. Positively driven
contacts provide a safe disconnection of the servo amplifier, the setpoint input of the servo amplifier
is inhibited, and a signal is sent to the safety circuit.
The suggested circuits (ð p. 95) fulfills safety category 1 (EN 954-1) or category 3 with additional
safety relay (e.g. PNOZ of PILZ company).
Advantages of the -AS- option
— 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
Moving single axes or axis-groups in setting-up operation
In setting-up operation, people will frequently be within the danger zone of the machinery. Axes will
normally be moved under the control of permission switches. An additional switch-off of the unused
axes, by means of the restart lock, increases the safety margin and avoids the repeated switching
of main contactors or motor contactors.
Switching off grouped axes with separate working areas
Even when several SERVOSTAR 600 are operating off a common mains supply and DC bus link, it
is possible to set up groups for separate working areas. These groups can then be switched off
separately.
SERVOSTAR 600 does not have any safety functionality according to IEC 61800-5-2. The optional
restart lock function -AS- cannot be compared to the safety function STO. The described function
-AS- is proofen according to EN 954-1. This standard is not listed in the EC Machine Directive
2006/42/EG since 31.12.2012. The requirements for a restart lock according to EN 954-1 are never-
theless fulfilled.
9.1.1 Important notes

l Observe "Use as directed" on page 92.
l The monitoring contacts (KSO1/2) for each amplifier with an -AS- option must be looped into
the control circuit. This is vital, so that a malfunction of the internal safety relay or a cable bre-
ak can be recognized.
l If the -AS- option is automatically activated by a control system (KSI1/2), then make sure that
the output of the control is monitored for possible malfunction. Can be used to prevent a faulty
output from activating the -AS- option while the motor is running.
l It is vital to keep to the following functional sequence when the -AS- option 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, apply an additional mechanical block to the drive
4. Activate the -AS- option

Expansions / Accessories 12/2015 Kollmorgen
9.1.2 Use as directed
The -AS- restart lock is exclusively intended to prevent the restart of a system. The wiring of the
safety circuits must meet the safety requirements of EN60204, EN12100 and EN 954-1.
The -AS- restart lock must only be activated,
— when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).
— when the monitoring contacts (KSO1/2) for all servo amplifiers are wired into the control
signal loop.
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons :
1.- cleaning, maintenance and repair operations or 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-stop situation, the main contactor is switched off
(by the emergency-stop button).
9.1.3 Block diagram

9.1.4 Functional description

An additional connector (X10) is mounted on the front panel of the SERVOSTAR 600. The coil con-
nections and a make (n.o.) contact of a safety relay are made available through 4 terminals on this
connector.
The 24VDC safety relay in the servo amplifier is controlled externally. All the relay contacts have
positive action.
Two contacts switch off the driver supply of the output stage in the servo amplifier, and short the
internal setpoint signal to AGND (0 V).
The make (n.o.) contact used for monitoring is looped into the control circuit.
If the safety relay is not energized, then the monitoring contact is open and the servo amplifier is
ready for operation.
If the drive is electronically braked, the servo amplifier is disabled and the motor-holding brake is
on, then the safety relay is energized (manually or by the controls).
The supply voltage for the driver circuit of the output stage is switched off in a safe manner, the
internal setpoint is shorted to 0V, and the monitoring contact bridges the safety logic in the control
circuit of the system (monitoring of protective doors etc.)
Even if the output stage or driver is destroyed, it is impossible to start the motor.
If the safety relay itself is faulty, then the monitoring contact cannot bridge the safety logic of the
system. Opening the protective devices will then switch off the system.
9.1.5 Signal diagram (sequence)

9.1.6 Functional test

The functioning of the restart lock must be tested during setup, after every alteration in the wiring of
the system, or after exchanging one or more components of the system.
1. Stop all drives, with setpoint 0V, disable drives, mechanically block any suspended loads
2. Activate the -AS- option.
3. Open protective screens (but do not enter hazardous area)
4. Pull off the X10 connector from an amplifier: the mains contactor must drop out
5. Reconnect X10. Switch on mains contactor again.
6. Repeat steps 4 and 5 for each individual servo amplifier.
9.1.7 Connection diagram (principle)
SERVOSTAR 600
Application examples for category 1 see chapter 9.1.8.

9.1.8 Application example category 1 according to EN954-1

Flowchart for stop and emergency stop category 0.
9.1.8.1 Control circuit
9.1.8.2 Mains supply circuit

9.1.9 Application example category 3 according to EN954-1

Flowchart for stop and emergency stop category 1.
9.1.9.1 Control circuit
9.1.9.2 Mains supply circuit

9.1.9.3 Flow chart
t(K30t) t(K10t) / t(K20t)
24V
AS Relais
ON
OFF
K1
K10t / K20t
K30t / Enable
Speed
t(K30t) ³ 500ms
t(K10t) and t(K20t) ensure that the drive remains active until the axis has come to a standstill. This
time depends on the application and must exceed the deceleration ramp.
The drive must have been braked to a safe standstill by the time t(K10t) and t(K20t) have elapsed.
After this point, active braking with the servo amplifier is no longer possible.

9.2 Expansion Cards

Information about availability and order numbers can be found on p. 117
9.2.1 Guide to installation of expansion cards
l Use a suitable screwdriver to lever off the cover of the option slot.
l Take care that no small items (such as screws) fall into the open option slot.
l Push the expansion card carefully into the provided guide rails of the slot, without twi-
sting it.
l Press the expansion card firmly into the slot, until the front cover touches the fixing
lugs. This ensures that the connectors make good contact.
l Screw the screws on the front cover into the threads in the fixing lugs.

9.2.2 Expansion card -I/O-14/08-

This chapter describes the I/O-expansion card -I/O-14/08-. It only describes the additional features
that the expansion card makes available for the SERVOSTAR 600.
The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The functions of
the inputs and outputs are fixed. They 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.
The functions of the inputs and signal outputs correspond exactly to the functions that can be assig-
ned to the digital-I/O on connector X3 of the SERVOSTAR 600.
The 24VDC supply for the expansion card is taken from the controller. All inputs and outputs are
electrically isolated from the servo amplifier by optocoupler.
9.2.2.1 Front view
9.2.2.2 Technical data
Control inputs 24 V / 7 mA, PLC-compatible

Signal outputs 24 V / max. 500 mA, PLC-compatible
24 V (18 ... 36 V) / 100 mA plus total current of the out-
puts (depends on the input wiring of the controls).
Supply inputs, to IEC 61131 The 24 VDC voltage has to be supplied by an elec-
trically isolated power supply, e.g. with insulating
transformer.
Fusing (external) 4 AT
MiniCombicon, 12-pole, coded on PIN1 and 12 respec-
Connectors
tively
Data – up to 50m long : 22 x 0.5mm², unshielded,
Cables
Supply – 2 x 1mm², check voltage drop
Waiting time between 2 motion tasks depends on the response time of the control system
Addressing time (min.) 4 ms
Starting delay (max.) 2 ms
Response time of digital outputs max. 10 ms
9.2.2.3 Light emitting diodes (LEDs)

Two LEDs are mounted next to the terminals on the expansion card. The green LED signals that
the 24 V auxiliary supply is available for the expansion card. The red LED signals faults in the out-
puts from the expansion card (overload, short-circuit).
9.2.2.4 Select motion task number (Sample)
Motion task no. 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 -

9.2.2.5 Connector assignments
Connector X11A
Pin Dir Function Description
1 In A0 Motion task no., LSB
2 In A1 Motion task no., 21
8 In A7 Motion task no., MSB
Polls the reference switch. If a digital input on the basic unit is
9 In Reference used as a reference input, then the input on the I/O expansion
card will not be evaluated.
Clear the warning of a following error (no3) or the response
10 In FError_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 task
11 In Start_MT Next 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 basic unit.
Start of the setup mode "Jog Mode" with a defined speed. After
selecting the function, you can enter the speed in the auxiliary
12 In Start_Jog v=x variable “x”. The sign of the auxiliary variable defines the directi-
on. A rising edge starts the motion, a falling edge cancels the
motion.
Connector X11B
Continues the motion task that was previously interrupted.
1 In MT_Restart The motion task can also be continued by an appropriately confi-
gured digital input on the basic unit.
Start of the motion task that has the number that is presented,
bit-coded, at the digital inputs (A0 to A7).
2 In Start_MT I/O The digital function with the same name, in the basic unit, starts
the motion task with the address from the digital inputs on the
basic unit.
When the target position for a motion task has been reached (the
InPosition window), this is signaled by the output of a HIGH-sig-
3 Out InPos
nal.
A cable break will not be detected
The start of each motion task in an automatically executed se-
quence of motion tasks is signaled by an inversion of the output
signal. The output produces a Low signal at the start of the first
Next-InPos
4 Out motion task of the motion task sequence.
The form of the message can be varied by using ASCII com-
mands.
PosReg0 Can only be adjusted by ASCII commands.
A LOW signal indicates that the position has gone outside the
5 Out FError
acceptable following error window.
6 Out PosReg1
7 Out PosReg2 The preset function of the corresponding position register is indi-
8 Out PosReg3 cated by a HIGH-signal.
9 Out PosReg4
10 Out PosReg5 Can only be adjusted by ASCII commands.
11 Supply 24VDC auxiliary supply voltage
12 Supply I/O-GND Digital-GND for the controls

9.2.2.6 Connection diagram
SERVOSTAR 600

9.2.3 Expansion cards -PROFIBUS-

This chapter describes the PROFIBUS expansion card for the SERVOSTAR 600.
Information on the range of functions and the software protocol can be found in the manual
"Communication profile PROFIBUS DP". The PROFIBUS expansion card has two 9-pin Sub-D
sockets wired in parallel.
The supply voltage for the expansion card is provided by the servo amplifier.
9.2.3.1 Front view
9.2.3.2 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are
described in the “Installation guidelines for PROFIBUS-DP/FMS” from PNO, the PROFIBUS User
Organization.
SERVOSTAR 600

9.2.4 Expansion card -SERCOS-

®
This chapter describes the sercos expansion card for SERVOSTAR 600.
Information on the range of functions and the software protocol can be found in the manual
®
"IDN Reference Guide sercos ".
9.2.4.1 Front view
9.2.4.2 Light emitting diodes (LEDs)
indicates whether sercos® telegrams are being correctly received. In the final Communica-
RT
tion 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 stations 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 (BAUDRATE) and the fibre-optic connection.
ERR
If this LED flickers, this indicates a low level of interference for sercos® communication,
or the optical transmitting power is not correctly adjusted to suit 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
DRIVE.EXE on the sercos® screen page, by altering the parameter for the cable length.

® ®
For the fiber optic cable connection, only use sercos components to the sercos Standard 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 with an F-SMA connector.


®
Layout of the sercos bus system in ring topology, with optical fibre cables (schematic).
9.2.4.5 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. There are various ways to set the station address:
Keys on the front of the servo amplifier
®
The sercos address can also be modified using the keys on the front (p. 87).
Setup software
The address can also be modified in the setup software. For additional information, 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.
9.2.4.6 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 opti-
cal range for a standard 1 mm² glass fibre cable, where # is the length of the cable in metres.
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. For additional informa-
tion, please refer to the “Setup software” online help. Alternatively, the commands SBAUD # and
SLEN # can be entered in the “Terminal” screen.

9.2.5 Expansion card -DEVICENET-

This section describes the DeviceNet expansion card for SERVOSTAR 600.
Information on the range of functions and the software protocol can be found in our manual “Device-
Net Communication Profile”.
9.2.5.1 Front view

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are
all described in the “DeviceNet Specification, Volume I, II”, published by ODVA.
SERVOSTAR 600

9.2.5.4 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 establis-
green
hed. The device has been assigned to a master.
The device is operating as normal, is online, but the connections have not been estab-
lished.
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 state.
red
- 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).
9.2.5.5 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, COLD-
START, 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 para-
meters in non-volatile memory (Class 0x25, Attribute 0x65) and then restart the drive after set-
ting/altering the address.
9.2.5.6 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, COLD-
START, 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 se-
tup tool. You must save the parameters in non-volatile memory (Class 0x25, Attribute 0x65)
and then restart the drive after altering the baud rate.

9.2.5.7 Bus cable
To meet ISO 898, a bus cable with a characteristic impedance of 120 W should be used. The maxi-
mum 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 impe- Shunt C = 5pF
dance (recessive state) Shunt R = 25KW (power on)
Min. differential input impe- Shunt C = 24pF + 36 pF/m of the permanently 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 of the
Absolute max.
transceiver. The voltage is higher than that on the V-terminal by
voltage range
the amount of the forward voltage drop of the Schottky diode. This
voltage drop must be < 0.6 V.
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: 120 W, 1% metal-film, 1/4 W

9.2.6 Expansion card -EtherCAT-

This section describes the EtherCAT expansion card for SERVOSTAR 600. Information on the
range of functions and the software protocol can be found in the EtherCAT documentation. This
expansion card enables the servo amplifier to be connected to the EtherCAT network via RJ-45
connectors (IN and OUT ports).
9.2.6.1 Front view
9.2.6.2 LEDs
LED Function
flickering = Booting Error
blinking = Invalid Configuration
ERROR single flash = Unsolicited State Change
double flash = Watchdog Timeout
off = No Error
on = Device is in state OPERATIONAL
blinking = Device is in state PRE-OPERATIONAL
RUN
single flash = Device is in state SAFE-OPERATIONAL
off = Device is in state INIT
on = linked, but not active at X20A (in)
ACT IN flickering = linked and active at X20A (in)
off = not linked at X20A (in)
on = linked, but not active at X20B (out)
ACT OUT flickering = linked and active at X20B (out)
off = not linked at X20B (out)

9.2.7 Expansion card -SYNQNET-

This section describes the SynqNet expansion card for SERVOSTAR 600. Information on the range
of functions and the software protocol can be found in the SynqNet documentation.
9.2.7.1 Front view
LED2 LED1 LED4 LED3
9.2.7.2 NODE ID Switch

With these hexadecimal switches you can set the main and low significant bytes of the Node ID
seperately. SynqNet does not require an address for correct operation in the network, however in
some machines this can be a convenient way of identifying build options to the application program.
9.2.7.3 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
9.2.7.4 SynqNet Connection, Connector X21B/C (RJ-45)

Connection to the SynqNet network via RJ-45 connectors (IN and OUT ports) with integrated LEDs.

9.2.7.5 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
1 In +24V power supply
2 Out NODEALARM indicates a problem with the node
3 Out OUT_01 digital output
4 In IN_00 (fast) capture input (fast)
5 In IN_04 digital input
7 In HOME reference switch
8 In POSLIM limit switch, positive direction
9 In GND power supply
14 In NEGLIM limit switch, negative direction
15 In NODEDISABLE disables Node
9.2.7.6 Connection diagram digital inputs/outputs, connector X21A

9.2.8 Expansion module -2CAN-

Connector X6 of the SERVOSTAR 6xx 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 swit-
ched into circuit if the SERVOSTAR 6xx is at the end of the bus.
9.2.8.1 Installation
The modul must be placed onto the option slot after levering off the cover of the option slot:
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 SERVOSTAR 600
9.2.8.2 Front View

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).

9.2.8.4 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

9.3 Special Accessories

9.3.1 Power Supply SINCOS
The extended power supply enables the
to servo amplifier operation of encoder systems at con-
(max. 2 m) nector X1 with a power consumption of
up to 400 mA DC. This power supply is
switched between X1 and the encoder
and supplied by SERVOSTAR 600.
The connection between the amplifier
and the power supply requires a 1:1 pro-
tected data cable with a maximum
length of 2 m (see ordering information,
p. 117ff).
The encoder is connected to the power
supply using the normal encoder con-
nection cable (max. 50 m).
to feedback
(max. 50 m)
Technical Data
Output voltage 5 V DC (-5%…+5%)
Output current max. 400 mA DC
Protection type IP20
Ambient temperature 0…+55°C
Type of mounting Mounting rail
Cable length (amplifier -> mains supply) max. 2 m
Cable length (mains supply -> encoder) max. 50 m
9.3.2 Terminating adapter for encoder cables

Encoders that do not have integrated terminating resistors can be connected to X1 with our stan-
dard cables using this adapter (see ordering information p.117ff).
The terminating resistors increase noise immunity. The adapter (approx. 200 mm long) is connec-
ted to the servo amplifier (X1).

9.3.3 Hall Dongle

Encoder types that do not provide definitive information on commutation, can be used as a com-
plete feedback system using an additional Hall dongle.
Encoders with analog signals are connected to the dongle, digital encoders are connected to con-
nector X5 on the servo amplifier. Refer to the connection diagram on p. 56.
The connection between the amplifier and the dongle requires a 1:1 protected data cable with a
maximum length of 2 m (see ordering information, p. 117ff).
Encoders that require a supply current of more than 150 mA can be operated using the extended
power supply "Power Supply SINCOS" (see p.113).
X1.2
X1.3 to Encoder
to Hall feedback (analog signals)
X1.1
to SERVOSTAR, X1

Kollmorgen 12/2015 Appendix
10 Appendix
10.1 Glossary
B Brake circuit Converts superfluous energy, which is fed back
during braking, into heat in the brake resistor
C Clock Clock signal
Common-mode voltage The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
Continuous power of brake circuit Mean power which can be dissipated in the brake circuit
Counts Internal count pulses, 1 pulse = 1/220 turn-1
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 (0V or open)
E Enable Enable signal for the servo amplifier (+24V)
F Final speed Maximum value for speed normalization at ±10V
Fieldbus interface CANopen, PROFIBUS, SERCOS etc.
G GRAY-code Special method of representing binary numbers
H Holding brake Brake in the motor, which can only be used when the
motor is at a standstill
I I²t threshold Monitoring of the actually required r.m.s. current
Input drift Temperature and age-dependent alteration of an analog
input
Incremental encoder interface Position signaling by 2 signals with 90° phase
difference, 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-switch Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact
M Machine The complete assembly of all connected parts or
devices, of which at least one is movable
Monitor output Output of an analog measurement
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

Appendix 12/2015 Kollmorgen
P P-controller Control loop with purely proportional behavior

Phase shift Compensation for the lag between the electromagnetic
and magnetic fields in the motor
PID-controller Control loop with proportional, integral and
differential behavior
PID-T2 Filter time constant for the speed controller output
Position controller Regulates the difference between the position setpoint
and the actual position to 0
Output : speed setpoint
Potential isolation Electrically decoupled
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 Regen circuit see Brake Circuit
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 position of a
servomotor
Setpoint ramps Limits for the rate of change of the speed setpoint
Short to ground Electrically conductive connection between a
phase and PE (protective earth (ground))
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 Cyclic-absolute, serial position output
Supply filter Device to divert interference on the power supply
cables to PE
T T-tacho, tachometer time constant Filter time constant in the speed feedback
of the control loop
Tachometer voltage Voltage proportional to the actual speed
Thermal control Temperature-sensitive device built into the
motor winding (usually a PTC)
Tn, I-integration time Integral section of a control loop
Z Zero pulse Output once per turn from incremental encoders,
used to zero the machine

10.2 Order numbers

The order numbers of accessories such as cables, brake resistors, mains supplies, etc., can be
found in the accessories manual.
10.2.1 Servo amplifiers
Article EU order code US order code

SERVOSTAR 601 DE-89700 -
SERVOSTAR 603 DE-89701 S60300-NA
SERVOSTAR 610-30 DE-102192 S610-3000-NA
SERVOSTAR 601-AS DE-90350 -
SERVOSTAR 603-AS DE-90351 S60301-NA
SERVOSTAR 610-30-AS DE-102897 S610-3001-NA
*= NA means without built-in expansion card
10.2.2 Expansion cards

Expansion card DeviceNet DE-103571 OPT-DN
Expansion card PROFIBUS DP DE-90056 OPT-PB
Expansion card SERCOS DE-90879 OPT-SE
Expansion card -I/0-14/08- DE-90057 OPT-EI
Expansion card EtherCAT DE-108350 OPT-EC
Expansion card SynqNet DE-200073 OPT-SN
Expansion module 2CAN DE-101174 -
10.2.3 Connectors

Connector X3 (I/O) DE-90061 CON-S6X3
Connector X4 (24V) DE-90062 CON-S6X4
Connector X0A (Mains) DE-92258 CON-S6X0A
Connector X0B (Mains) DE-92259 CON-S6X0B
Connector X7 (DC bus link) DE-90064 CON-S6X7
Connector X8 (Brake-R) DE-90065 CON-S6X8
Connector X9 (Motor) DE-90066 CON-S6X9
Connector X10 (AS) DE-101696 CON-S6X10
Connector X15 (DeviceNet) DE-106368 CON-S6X15
10.2.4 Special accessories

Power supply SINCOS DE-107712 -
HALL Dongle DE-107351 -
Connection Cable, 1m
for X1-Hall Dongle or DE-107730 -
for X1-Power Supply SINCOS
Termination Adapter SINCOS DE-103692 -

Appendix 12/2015 Kollmorgen
This page has been deliberately left blank.

10.3 Index
! 24Vaux. supply, interface . . . . . . . . . . . 47 N Nameplate . . . . . . . . . . . . . . . . . . . 17
Node address . . . . . . . . . . . . . . . . . 84
A AS-Option . . . . . . . . . . . . . . . . . . . 91 Noise emission . . . . . . . . . . . . . . . . . 22
Abbreviations . . . . . . . . . . . . . . . . . . 9 O Operating systems . . . . . . . . . . . . . . . 73
Ambient conditions . . . . . . . . . . . . . . . 22
Analog outputs . . . . . . . . . . . . . . . . . 66 Optical power . . . . . . . . . . . . . . . . . 104
Assembly. . . . . . . . . . . . . . . . . . . . 34 Options . . . . . . . . . . . . . . . . . . . . . 20
Order numbers . . . . . . . . . . . . . . . . 117
B BISS Interface . . . . . . . . . . . . . . . . . 53 Outputs
BTB/RTO. . . . . . . . . . . . . . . . . . . . 68 Analog 1/2 . . . . . . . . . . . . . . . . . 66
Baudrate . . . . . . . . . . . . . . . . . . . . 84 BTB/RTO . . . . . . . . . . . . . . . . . . 68
Block diagram (overview) . . . . . . . . . . . 43 DIGI-OUT 1/2 . . . . . . . . . . . . . . . 68
Brake. . . . . . . . . . . . . . . . . . . . . . 24 P PC connection . . . . . . . . . . . . . . . . . 69
Brake circuit . . . . . . . . . . . . . . . . . . 25
Brake resistor, interface . . . . . . . . . . . . 48 Package supplied . . . . . . . . . . . . . . . 17
Packaging . . . . . . . . . . . . . . . . . . . 13
C CANopen-Interface. . . . . . . . . . . . . . . 70 Part number scheme . . . . . . . . . . . . . . 18
CE conformance . . . . . . . . . . . . . . . . 16 Pin assignments . . . . . . . . . . . . . . . . 44
Capacitor Module . . . . . . . . . . . . . . . 48 Pollution level . . . . . . . . . . . . . . . . . 22
ComCoder interface . . . . . . . . . . . . . . 56 Protection . . . . . . . . . . . . . . . . . . . 22
Conductor cross-sections . . . . . . . . . . . 23 Pulse-direction, interface . . . . . . . . . . . . 61
Connection diagram . . . . . . . . . . . . . . 45 Q Quickstart Guide . . . . . . . . . . . . . . . . 74
D DC-link interface . . . . . . . . . . . . . . . . 47
R ROD interface . . . . . . . . . . . . . . . . . 63
Dimensions. . . . . . . . . . . . . . . . . . . 35
Disassembling . . . . . . . . . . . . . . . . . 14 RS232/PC, interface . . . . . . . . . . . . . . 69
Disposal . . . . . . . . . . . . . . . . . . . . 14 Repair . . . . . . . . . . . . . . . . . . . . . 14
Resolver, interface . . . . . . . . . . . . . . . 52
E Enclosure protection . . . . . . . . . . . . . . 22
S SSI, interface. . . . . . . . . . . . . . . . . . 64
Encoder emulations . . . . . . . . . . . . . . 63
Error messages . . . . . . . . . . . . . . . . 88 Safety instructions . . . . . . . . . . . . . . . 10
Expansion card Setpoint inputs . . . . . . . . . . . . . . . . . 65
-2CAN- . . . . . . . . . . . . . . . . . . 111 Setup. . . . . . . . . . . . . . . . . . . . . . 71
-DeviceNet- . . . . . . . . . . . . . . . . 105 Shielding
-EtherCat- . . . . . . . . . . . . . . . . . 108 Connection diagram . . . . . . . . . . . . 45
-I/O-14/08- . . . . . . . . . . . . . . . . . 99 Installation . . . . . . . . . . . . . . . . . 38
-PROFIBUS- . . . . . . . . . . . . . . . 102 Shock-hazard protection . . . . . . . . . . . . 32
-SERCOS- . . . . . . . . . . . . . . . . 103 Sine-cosine encoder, interface . . . . . . . . . 55
-SynqNet- . . . . . . . . . . . . . . . . . 109 Site . . . . . . . . . . . . . . . . . . . . . . . 33
Guide to installation . . . . . . . . . . . . 98 Site altitude. . . . . . . . . . . . . . . . . . . 22
External fusing . . . . . . . . . . . . . . . . . 22 Standards . . . . . . . . . . . . . . . . . . . . 8
Storage. . . . . . . . . . . . . . . . . . . . . 13
F Forming . . . . . . . . . . . . . . . . . . . . 71 Supply voltage . . . . . . . . . . . . . . . . . 22
G Glossary . . . . . . . . . . . . . . . . . . . 115 Surrounding temperature. . . . . . . . . . . . 22
Ground symbol . . . . . . . . . . . . . . . . . 39 Switch-on and switch-off behavior . . . . . . . 27
Grounding Symboles . . . . . . . . . . . . . . . . . . . . 7
Connection diagram . . . . . . . . . . . . 45 System components, overview. . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . 38 T Target group . . . . . . . . . . . . . . . . . . 10
H Hall Dongle . . . . . . . . . . . . . . . . . . 114 Technical data . . . . . . . . . . . . . . . . . 21
Hardware requirements . . . . . . . . . . . . 73 Torque, connectors . . . . . . . . . . . . . . 22
Holding brake . . . . . . . . . . . . . . . . . 24 Transport . . . . . . . . . . . . . . . . . . . . 13
Trouble shooting . . . . . . . . . . . . . . . . 90
I Incremental encoder, interface . . . . . . . . . 57
U Use as directed
Inputs
Analog setpoints . . . . . . . . . . . . . . 65 Option AS . . . . . . . . . . . . . . . . . 92
DIGITAL-IN 1/2 . . . . . . . . . . . . . . . 67 Servo amplifier . . . . . . . . . . . . . . . 12
Enable . . . . . . . . . . . . . . . . . . . 67 Setup software . . . . . . . . . . . . . . . 72
NSTOP . . . . . . . . . . . . . . . . . . . 67 V Ventilation
PSTOP . . . . . . . . . . . . . . . . . . . 67 Installation . . . . . . . . . . . . . . . . . 33
Installation Tech.Data . . . . . . . . . . . . . . . . . 22
Expansion cards . . . . . . . . . . . . . . 98 Vibrations . . . . . . . . . . . . . . . . . . . 22
Hardware . . . . . . . . . . . . . . . . . . 38 W Warning messages. . . . . . . . . . . . . . . 89
Software . . . . . . . . . . . . . . . . . . 73
Wiring . . . . . . . . . . . . . . . . . . . . . 38
K Key operation . . . . . . . . . . . . . . . . . 86
L LC-Display . . . . . . . . . . . . . . . . . . . 86
LED display . . . . . . . . . . . . . . . . . . 23
Leakage current . . . . . . . . . . . . . . . . 32
Limit Switch Inputs . . . . . . . . . . . . . . . 67
M Mains supply connection, interface. . . . . . . 46
Maintenance . . . . . . . . . . . . . . . . . . 13
Master-slave . . . . . . . . . . . . . . . . . . 58
Motor connector . . . . . . . . . . . . . . . . 41
Motor holding brake . . . . . . . . . . . . . . 24
Motor, interface . . . . . . . . . . . . . . . . 50
Mounting position . . . . . . . . . . . . . . . 22
Multi-axis systems . . . . . . . . . . . . . . . 84

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 - 400 661 2802
Fax: +86 - 21 6071 0665
KOLLMORGEN
CN Website

SERVOSTAR 601... 620: Digital Servo Amplifier S600 Instructions Manual

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SERVOSTAR 601... 620: Digital Servo Amplifier S600 Instructions Manual

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SERVOSTAR 601...

Keep all manuals as a product component

Hardware Revision (HWR)

SERVOSTAR 601...620 Instructions Manual 3

4 SERVOSTAR 601...620 Instructions Manual

SERVOSTAR 601...620 Instructions Manual 5

6 SERVOSTAR 601...620 Instructions Manual

1.2 Hints for the online edition (PDF format)

1.3 Symbols used

Indicates a hazardous situation which, if not avoided, could result in de-

Indicates a hazardous situation which, if not avoided, could result in mi-

Warning of danger from electricity and its effects.

Warning of hot surfaces.

Warning of suspended loads.

SERVOSTAR 601...620 Instructions Manual 7

1.4 Standards used

8 SERVOSTAR 601...620 Instructions Manual

1.5 Abbreviations used

SERVOSTAR 601...620 Instructions Manual 9

2.1 You should pay attention to this

Read the documentation!

Check the Hardware Revision!

Pay attention to the technical data!

Observe electrostatically sensitive components!

Perform a risk assessment!

10 SERVOSTAR 601...620 Instructions Manual

Never modify the servo amplifiers!

SERVOSTAR 601...620 Instructions Manual 11

2.2 Use as directed

2.3 Prohibited use

12 SERVOSTAR 601...620 Instructions Manual

SERVOSTAR 601...620 Instructions Manual 13

2.4.6 Repair and Disposal

14 SERVOSTAR 601...620 Instructions Manual

3.1 Conformance with UL and cUL

SERVOSTAR 601...620 Instructions Manual 15

3.3 European Directives and Standards for the machine builder

Standards to be applied for conformance with the EC Machinery Directive (2006/42/EC)

Standards to be applied for conformance with the EC Low Voltage Directive(2014/35/EC)

16 SERVOSTAR 601...620 Instructions Manual

— Assembly, Installation and Setup Instructions (Instructions Manual)

Servo amplifier type Serial number Comments Hardware Revision

Eingang Input Ausgang Output

SERVOSTAR 601...620 Instructions Manual 17

4.3 Part number scheme

* additional coding defines customer specific specials.

Comparison (without expansion) device name -> part number

Device Name Part Number

18 SERVOSTAR 601...620 Instructions Manual

SERVOSTAR 601...620 Instructions Manual 19

Auxiliary supply voltage 24VDC

Operation and parameter setting

Completely digital control

20 SERVOSTAR 601...620 Instructions Manual

5.2 Technical data

SERVOSTAR 601...620 Instructions Manual 21

5.2.1 Recommended torque

Connector Recommended torque

Circuit internal fuse