Kollmorgen S600 Servo Drive

SERVOSTAR 600
Safety Guide
Edition: April 2016

Valid for SERVOSTAR 601...620 HWR 05.40
Valid for SERVOSTAR 640...670 HWR 02.20
Deutsch English Français Italiano Español
Original Language is German. All other content is translated from the genuine German content.
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pendant toute la durée de vie du produit. Remettez le manuel au manual a posteriores usuarios o propietarios del producto.
futur utilisateur ou propriétaire du produit.
S600 Safety Guide | 2 English
2 English
2.1 General 38
2.1.1 Using the PDF Format 38
2.1.2 Symbols Used 39
2.1.3 Abbreviations Used 40
2.2 Safety 41
2.2.1 You should pay attention to this 41
2.2.2 Warning notes placed on the product 43
2.2.3 Use as Directed 44
2.2.4 Prohibited Use 44
2.3 Handling 45
2.3.1 Transport 45
2.3.2 Packaging 45
2.3.3 Storage 45
2.3.4 Decommissioning 45
2.3.5 Maintenance and cleaning 46
2.3.6 Disassemble 46
2.3.7 System Repair 47
2.3.8 Disposal 47
2.4 Technical description and data 48
2.4.1 The SERVOSTAR 600 Family of digital servo amplifiers 48
2.4.2 Motion system with SERVOSTAR 601...620 49
2.4.3 Motion system with SERVOSTAR 640/670 50
2.4.4 Package Supplied 51
2.4.5 Ambient Conditions, Ventilation, and Mounting Position 51
2.4.6 Technical Data SERVOSTAR 601...620 52
2.4.7 Technical Data SERVOSTAR 640/670 53
2.4.8 Fusing 54
2.4.9 Recommended Tightening Torques 54
2.4.10 Option -AS-, restart lock according to EN 954-1 54
2.5 Mechanical Installation 56
2.5.1 Important Notes 56
2.5.2 Guide to Mechanical Installation 56
2.6 Electrical Installation 57
2.6.2 Guide to electrical installation 58
2.7 Setup 59
2.7.2 Key operation / LED display 60
2.7.3 Initial Drive Test 61
2.8 Trouble shooting 69
Kollmorgen | wiki-kollmorgen.eu | April 2016 37

2.1 General
This manual describes the digital servo amplifiers of the SERVOSTAR 600 series (standard
version, 1.5 to 70 Amps nominal current).
For full information refer to the Instructions Manual and additional Kollmorgen documents:
Instructions Manual (PDF format):
This manual provides instructions for installation and servo amplifier setup.
Accessories Manual (PDF format):
It provides information for accessories like cables, filters, chokes and brake resistors.
CAN-BUS Communication (PDF format):
Describes how to use your servo amplifier in CANopen applications.
DeviceNET Communication (PDF format):
Describes how to use your servo amplifier in DeviceNET applications.
EtherCAT Communication (PDF format):
Describes how to use your servo amplifier in EtherCAT applications.
PROFIBUS DP Communication (PDF format):
Describes how to use your servo amplifier in PROFIBUS DP applications.
sercos® 2 Communication (PDF format):
Describes how to use your servo amplifier in sercos® applications.
DRIVE.EXE Online help (CHMs format):
The online help includes the ASCII Object Reference which provides information for the
parameters and commands used to setup the SERVOSTAR 600.
Detailed description of the expansion cards which are currently available and the digital con-
nection to automation systems can be found on the accompanying CD-ROM in PDF format
(system requirements: WINDOWS with Internet browser, PDF Reader) in several language
versions.
You can print this documentation on any standard printer.
More background information can be found in the "Product WIKI", please check www.wiki-
kollmorgen.eu.
2.1.1 Using the PDF Format

This document includes several features for ease of navigation
Cross References Table of contents and index include active cross references.
Table of contents and Lines are active cross references. Click on the line and the appro-
index priate page is accessed.
Page/chapter numbers Page/chapter numbers with cross references are active links.
in the text
38 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.1.2 Symbols Used

Symbol Indication
Indicates a hazardous situation which, if not avoided, will res-
DANGER ult in death or serious injury.
Indicates a hazardous situation which, if not avoided, could
WARNING result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could
CAUTION result in minor or moderate injury.
Indicates situations which, if not avoided, could result in prop-
erty damage.
This symbol indicates important notes.
Warning of a danger (general). The type of danger is specified

by the text next to the symbol.
Warning of danger from electricity and its effects.
Warning of danger from hot surface.
Warning of suspended loads.
Warning of danger from automatic start.

2.1.3 Abbreviations Used

Abbrev. Meaning
(➜ # xx) See page xx. Example (➜ # 53): see page 53.
AGND Analog ground
AS Restart Lock
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

2.2 Safety
This section helps you to recognize and avoid dangers to people and objects.
2.2.1 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, installation, assembly, commissioning and operation of drives and who
bring their relevant minimum qualifications to bear on their duties:
Transport: only by personnel with knowledge of handling electrostatic sensitive com-
ponents.
Unpacking: only by electrically qualified personnel.
Installation: only by electrically qualified personnel.
Basic tests / Setup: only by qualified personnel with knowledge of electrical engineering
and drive technology
The qualified personnel must know and observe ISO 12100 / IEC 60364 / IEC 60664 and
national accident prevention 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 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 num-
ber must match the Hardware Revision Number on the cover page of the manual. If the num-
bers do not match up, visit the Tech-WIKI (http://www.wiki-kollmorgen.eu). The 'Download'
section contains the various manual versions based on the hardware version number.
Pay attention to the technical data!
Adhere to the technical data and the specifications on connection conditions (rating plate and
documentation). If permissible voltage values or current values are exceeded, the servo amp-
lifiers can be damaged. Unsuitable motor or wrong wiring will damage the system com-
ponents. Check the combination of drive and motor. Compare the rated voltage and current
of the units.
Observe electrostatic sensitive components!
The servo amplifiers contain electrostatic 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 conductive surface.
Perform a risk assessment!
The manufacturer of the machine must generate a risk assessment for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or dam-
age to any person or property. Additional requirements on specialist staff may also result
from the risk assessment.

Automatic Restart!
The drive might restart automatically after power on, voltage dip or interruption of the supply
voltage, depending on the parameter setting. Risk of death or serious injury for humans work-
ing 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 pos-
sible, while humans are in a dangerous zone of the machine. In case of using an under-
voltage protection device, you must observe EN 60204-1.
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 amplifier is safely earthed to the PE (protective earth)
busbar in the switch cabinet. Risk of electric shock. Without low-resistance earthing no per-
sonal protection can be guaranteed.
Leakage Current!
Since the leakage current to PE is more than 3.5 mA, in compliance with IEC61800-5-1 the
PE connection must either be doubled or a connecting cable with a cross-section >10 mm²
must be used. Deviating measures according to regional standards might be possible.
High voltages!
The equipment produces high electric voltages up to 900V. Do not open or touch the equip-
ment during operation. Keep all covers closed.
During operation, SERVOSTAR 600-C may have uncovered live sections, according to their
level of enclosure protection.
Lethal danger exists at live parts of the device. Built-in protection measures such as insu-
lation or shielding may not be removed. Work on the electrical installation may only be per-
formed by trained and qualified personnel, in compliance with the regulations for safety at
work, and only with switched off mains supply, and secured against restart.
Never undo any electrical connections to the SERVOSTAR 600-C while it is live. There is a
danger of electrical arcing with damage to contacts and personal injury. Wait at least 5
minutes after disconnecting the product from the supply voltages (mains supply and 24V sup-
ply) before touching potentially live sections of the equipment (such as contacts) or removing
any connections.
Always measure the voltage in the DC bus link and wait until the voltage is below 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 voltage, according to the required application test voltage. All Kollmorgen com-
ponents meet these requirements.
Never modify the servo amplifiers!
It is permissible to use the setup software to alter the settings of the servo amplifier. Any
other alterations will invalidate the warranty.
Opening the housing causes loss of warranty and all certificates become unvalid.

2.2.2 Warning notes placed on the product
Wait 5 minutes
after removing power
before servicing.
If these signs are damaged, they must be replaced immediately.

2.2.3 Use as Directed

The servo amplifiers are components which are built into electrical equipment or
machines, and can only be used as integral components of such equipment.
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
industrial 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 see Instructions Manual.
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amp-
lifier 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.
SERVOSTAR 601...620: If the servo amplifiers are used in residential areas, or in busi-
ness or commercial premises, then additional filter measures must be implemented by
the user.
SERVOSTAR 640/670: The use of external mains chokes and mains filters is required.
The SERVOSTAR 600 family of servo amplifiers is only intended to drive specific brush-
less 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.
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into
account the ambient conditions (➜ # 51) and the dimensions (➜ # 174). Ventilation or
cooling may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
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).
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 proven 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.
Consider the specifications (➜ # 54) when you use the restart lock option -AS-.
2.2.4 Prohibited Use

Other use than that described in chapter “Use as directed” is not intended and can lead to per-
sonnel injuries and equipment damage. The servo amplifier may not be used with a machine
that does not comply with appropriate national directives or standards. The use of the servo
amplifier in the following environments is also prohibited:
potentially explosive areas
environments with corrosive and/or electrically conductive acids, alkaline solutions, oils,
vapors, dusts
ships or offshore applications

2.3 Handling
2.3.1 Transport
Transport the SERVOSTAR 600 in accordance with IEC 61800-2 as follows:
Only by qualified personnel in the manufacturer’s original recyclable packaging
Avoid shocks
Temperature: –25 to +70°C, max. 20K/hr rate of change
Humidity: max. 95% relative humidity, no condensation
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 incorrect handling. Discharge yourself before touching the servo amplifier. Avoid contact
with highly insulating materials (artificial fabrics, plastic films etc.). Place the servo amplifier
on a conductive surface.
2.3.2 Packaging
The SERVOSTAR 600 packaging consists of recyclable cardboard with inserts.
Dimensions:
SERVOSTAR 601-610(HxWxD): 125x415x350 mm
SERVOSTAR 614/620(HxWxD): 170x415x350 mm
SERVOSTAR 640/670(HxWxD): 410x470x490 mm
Labeling : nameplate outside at the box
2.3.3 Storage
Store the SERVOSTAR 600 in accordance with IEC 61800-2 as follows:
Storage only in the manufacturer’s original recyclable packaging
Max. stacking height SERVOSTAR 601-620: 8 cartons
Max. stacking height SERVOSTAR 640-670: 3 cartons
Storage temperature: -25 to +55°C, max. rate of change 20°C / hour
Storage humidity: 5 ... 95% relative humidity, no condensation
Storage duration: Less than 1 year without restriction.
More than 1 year: capacitors must be re-formed before setting up and operating the servo
amplifier. To do this, remove all electrical connections and apply single-phase 230V AC
for about 30 minutes to the terminals L1 / L2.
2.3.4 Decommissioning
Only professional staff who are qualified in electrical engineering are allowed to decom-
mission parts of the drive system.
DANGER: Lethal voltages!
There is a danger of serious personal injury or death by electrical shock or electrical arcing.
Switch off the main switch of the switchgear cabinet.
Secure the system against restarting.
Block the main switch.
Wait at least 5 minutes after disconnecting.

2.3.5 Maintenance and cleaning

The device does not require maintenance. Opening the device voids the warranty. The inside
of the unit can only be cleaned by the manufacturer.
Do not immerse or spray the device. Avoid that liquid enters the device.
To clean the device exterior:
1. Decommission the device (see chapter 2.3.4 "Decommissioning").
2. Casing: Clean with isopropanol or similar cleaning solution.
Caution : Highly Flammable! Risk injury by explosion and fire.
Observe the safety notes given on the cleaning liquid package.
Wait at least 30 minutes after cleaning before putting the device back into oper-
ation.
3. Protective grill on fan: Clean with a dry brush.
2.3.6 Disassemble
Only professional staff who are qualified in electrical engineering are allowed to disassemble
parts of the drive system.
2. Check temperature.
CAUTION: During operation, the heat sink of the drive 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 below 40 °C (104 °F).
3. Remove the connectors. Disconnect the potential earth connection last.
4. Demount: loosen the fastening screws. Remove the device.

2.3.7 System Repair

Only professional staff who are qualified in electrical engineering are allowed to exchange
parts of the drive system.
CAUTION: Automatic Start! During replacement work a combination of hazards and
multiple episodes may occur.
Work on the electrical installation may only be performed by trained and qualified per-
sonnel, in compliance with the regulations for safety at work, and only with use of pre-
scribed personal safety equipment.
Exchange of SERVOSTAR 600
Only the manufacturer can repair the device. Opening the device voids the warranty.
2. Demount the device (see chapter 2.3.6 "Disassemble").
3. Send the device to the manufacturer.
4. Install a new device as described in this manual.
5. Setup the system as described in this manual.
Exchange of other drive system parts
If parts of the drive system ( for example cables) must be replaced, proceed as follows:
2. Exchange the parts.
3. Check all connections for correct fastening.
4. Setup the system as described in this manual.
2.3.8 Disposal
To dispose the unit properly, contact a certified electronic scrap disposal merchant.
In accordance with the WEEE-2002/96/EC-Guidelines and similar, the manufacturer
accepts returns of old devices and accessories for professional disposal. Transport costs
are the responsibility of the sender.
Contact Kollmorgen and clarify the logistics.

2.4 Technical description and data
2.4.1 The SERVOSTAR 600 Family of digital servo amplifiers

Part Number Scheme
Use the part number scheme for product identification only, not for the order process,
because not all combinations of features are possible, always.
Standard version
8 current ratings (1.5 A , 3 A , 6 A , 10 A , 14 A, 20 A, 40 A, 70 A).
4 instrument widths referring to current ratings.
Wide range of rated voltage (3x208V –10% to 3x480V +10%).
Overvoltage category III acc. to EN 61800-5-1.
Shield connection directly at the servo amplifier.
2 analog setpoint inputs.
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.
Integrated RS232, electrically isolated, integrated pulse-direction interface.
Synchronous servomotors, linear motors and asynchronous motors can be used.
Options/Expansions
SERVOSTAR 601...620: -AS- Option, built-in restart lock according to EN 954-1,
SERVOSTAR 640/670: -AS- standard.
Expansion Card -I/O-14/08-.
Expansion Card -PROFIBUS-.
Expansion Card -SERCOS-.
Expansion Card -DEVICENET-.
Expansion Card -EtherCAT-.
Expansion Card -SYNQNET-.
Expansion Card -2CAN-.
Details about functionality and connectivity are available in the Instruction manual.

2.4.2 Motion system with SERVOSTAR 601...620

2.4.3 Motion system with SERVOSTAR 640/670

2.4.4 Package Supplied

When you order a SERVOSTAR 600 series amplifier, you will receive:
SERVOSTAR 6xx
Several mating connectors (no mating SubD)
Printed SERVOSTAR 600 Safety Guide
All documentation in PDF format on CD-ROM
Setup software DRIVE.EXE on CD-ROM
Accessories: (must be ordered separately; description see accessories manual)
SERVOSTAR 601...620: motor choke 3YL required for cable length above 25m
SERVOSTAR 640/670: mains filter 3EF and mains choke 3L always required
Motor cable and feedback cable
External brake resistor
Communications cable to the PC or Y-adapter for setting parameters of up to 6 servo amp-
lifiers from one PC
AC synchronous servomotor (linear or rotary), see specific motor manual
2.4.5 Ambient Conditions, Ventilation, and Mounting Position

Storage, hints (➜ # 45)
Transport, hints (➜ # 45)
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
Ambient temperature in 0 to +45°C (32 to 113°F) at rated data
operation +45 to +55°C (113 to 131°F) with power derating 2.5% / K
Humidity in operation rel. humidity 85%, no condensation
Site altitude up to 1000m a.m.s.l. without restriction
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.
Ventilation forced convection by built-in fan
Make sure that there is sufficient forced ventilation within
the switchgear cabinet.

2.4.6 Technical Data SERVOSTAR 601...620

SERVOSTAR
Rated data DIM 601 603 606 610 610-30 614 620
V~ 3 x 230V-10% ... 480V+10%, 50 Hz
Rated supply voltage (grounded system)
V~ 3 x 208V-10% ... 480V+10%, 60 Hz
Rated installed load for continuous operation
kVA 1 2 4 7 7 10 14
@480V
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)
Brake circuit
- max. continuous power @480V kW 0.5 0.5 1.5 1.5 1.5 1.5 1.5
- external brake resistor Ohm 33 33 33 33 33 33 33
Overvoltage protection threshold V 450...900
Quiescent dissipation, output stage disabled W 15
Dissipation at rated current (incl. power
W 30 40 60 90 90 160 200
supply losses, without brake dissipation)
Inputs/Outputs
Setpoint 1/2, resolution 14bit/12bit V ±10
- Common-mode voltage max. V ±10
- Input resistance to AGND kOhm 20
Digital inputs according to IEC 61131
Digital outputs, open collector according to IEC 61131
V DC max. 30, AC max. 42
BTB/RTO output, relay contacts
mA 500
Aux. power supply, electrically isolated without V 24 (-0% +15%)
brake A 1 (max. 16)
Aux. power supply, electrically isolated with V 24 (-0% +15%)
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 9 pole (socket)
Sine-cosine encoder input — SubD 15 pole (socket)
PC-interface, CAN, Encoder emulation,
— SubD 9 pole (plug)
ROD/SSI
Mechanical
Weight kg 4 5 7.5
Height without connectors mm 275
Width mm 70 100 120
Depth without connectors mm 265
More technical data see Instructions Manual.

2.4.7 Technical Data SERVOSTAR 640/670

Rated data DIM SERVOSTAR 640 SERVOSTAR 670
Rated-supply voltage (grounded system) V~ 3 x 230V-10% ... 480V+10%, 50 Hz
V~ 3 x 208V-10% ... 480V+10%, 60 Hz
Rated installed load for continuous operation @480V kVA 30 50
Rated DC bus link voltage V= 290...675
Rated output current (rms value, ± 3%) Arms 40/40/40 85/80/70
@ 230V/400V/480V
Peak output current (max. ca. 5s, ± 3%) Arms 80/80/80 160/160/140
@ 230V/400V/480V
Clock frequency of the output stage kHz 8
Brake circuit
- max. continuous power @480V kW 6 6
- external brake resistor Ohm 15 10
Overvoltage protection threshold V 450...900
Quiescent dissipation, output stage disabled W 40
Dissipation at rated current (incl. power supply W 400 700
losses, without brake dissipation)
Inputs/Outputs
Setpoint 1/2, resolution 14bit/12bit V ±10
Common-mode voltage max. V ±10
Input resistance to AGND kOhm 20
Digital inputs according to IEC 61131
Digital outputs, open collector according to IEC 61131
BTB/RTO output, relay contacts V DC max. 30, AC max. 42
mA 500
Aux. power supply, electrically isolated without brake V 24 (-0% +15%)
A 2 (max. 16)
Aux. power supply, electrically isolated with brake V 24 (-0% +15%)
(consider voltage loss!) A 5 (max. 16)
Min/max. output current, brake A 0.75 / 3
Connections
Control signals — Combicon 5,08 / 18 pole , 2,5mm²
Power signals — Terminals 10mm² — 50mm²
Resolver input — SubD 9 pole (socket)
Sine-cosine encoder input — SubD 15 pole (socket)
PC-interface, CAN, Encoder emulation, ROD/SSI — SubD 9 pole (plug)
Thermal control, Motor — min. 15 VDC, 5mA
Mechanical
Weight kg 19.5 21
Height without shield sheet, w/o eyes (w. eyes) mm 345 (375)
Width mm 250
Depth without connectors mm 300
More technical data see Instructions Manual.

2.4.8 Fusing
Internal Fusing
Circuit internal fuse internal fuse
SERVOSTAR 601...620 SERVOSTAR 640/670
Auxiliary supply 24V 3.15 A 4A
Brake resistor electronic electronic
External fusing
SERVOSTAR
Fusible cutouts or similar 601 / 603 606 / 610 614 / 620 640 670
AC supply FN1/2/3 6A 10 A 20 A 50 A 80 A
24V supply FH1/2/3 max. 12 A
Brake resistor FB1/2 6A 10 A 10 A 16 A 20 A
2.4.9 Recommended Tightening Torques

Connector Recommended torque Recommended torque
X3, X4 0.5 to 0.6 Nm (4.43 to 5.31 in lbf) 0.3 Nm (2.25 in lbf)
X0A, X0B, X7, X8, X9 0.5 to 0.6 Nm (4.43 to 5.31 in lbf) -
X10 - 0,3 Nm (2.25 in lbf)
X0 - 6...8 Nm (45... 60 in lbf)
Ground bolt 3.5 Nm (31 in lbf) 3.5 Nm (31 in lbf)
2.4.10 Option -AS-, restart lock according to EN 954-1

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 proven 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 accord-
ing to EN 954-1 are nevertheless fulfilled.
-AS- is available as an option for SERVOSTAR 601...620.
-AS- is standard with SERVOSTAR 640/670 servo amplifiers.
2.4.10.1 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.
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.

2.4.10.2 Prohibited use

The -AS- restart lock must not be used if the drive is to be made inactive for the following
reasons :
cleaning, maintenance and repair operations or long inoperative periods
In such cases, the entire system should be disconnected from the supply by the per-
sonnel, and secured (main switch).
emergency-stop situations
In an emergency-stop situation, the main contactor is switched off (by the emergency-
stop button).
2.4.10.3 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, mechanically block any suspended loads, disable drives
2. Activate the -AS-.
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.
2.4.10.4 Connection diagram (principle)

2.5 Mechanical Installation

Dimensions and mounting see (➜ # 174).
2.5.1 Important Notes
CAUTION
High EMC Voltage Level!
Risk of electrical shock, 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 com-
ponents become bent or any insulation distances altered during transport and handling. Avoid
contact with electronic components and contacts.
The servo amplifier will switch itself off 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.
Do not mount devices that produce magnetic fields directly beside the servo amplifier. Strong
magnetic fields can directly affect internal components. Mount devices which produce mag-
netic field with distance to the servo amplifier and/or shield the magnetic fields.
2.5.2 Guide to Mechanical Installation

Material 2 or 4 hexagon socket screws to 4 hexagon socket screws to EN 4762,
EN 4762, M5 M6
Tool required 4 mm Allen key 5 mm Allen key
The following notes should assist you to carry out the mechanical installation in a sensible
sequence, without overlooking anything important.
Site Mount in a closed switchgear cabinet.
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet refer to (➜ # 174).
Ventilation Check that the ventilation of the servo amplifier is unimpeded and keep
within the permitted ambient temperature (➜ # 51).
Keep the required space clear above and below the servo amplifier (➜ #
174).
Assembly Assemble the servo amplifier and power supply, filter and choke close
together on the conductive, grounded mounting plate in the cabinet.
Grounding EMC-compliant (EMI) shielding and grounding see Instructions Manual.
Shielding Earth (ground) the mounting plate, motor housing and CNC-GND of the con-
trols.

2.6 Electrical Installation

For connector overview (➜ # 178). For more interface pinout refer to the Instructions Manual.

Only professional staff who are qualified in electrical engineering are allowed to install the
drive. Wires with color green with one or more yellow stripes must not be used other than for
protective earth (PE) wiring.
WARNING
High Voltage up to 900 V!
There is a danger of electrical arcing with damage to contacts and serious
personal injury. Capacitors can still have dangerous voltages present up
to 5 minutes after switching off the supply power. Control and power con-
nections can still be live, even if the motor is not rotating.
Only install and wire the equipment when it is not live.
Make sure that the cabinet is safely disconnected (for instance, with a
lock-out and warning signs).
Never remove electrical connections to the drive while it is live.
Wait at least 5 minutes after disconnecting the drive from the main sup-
ply 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.
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 (➜ # 178). 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).
With SERVOSTAR 640/670 external mains chokes and mains filters are required.
Excessively high external fusing will endanger cables and devices. The fusing of the voltage
supply must be installed by the user, best values (➜ # 54). Hints for use of Residual-current
circuit breakers (FI) see Instructions Manual.
Route power and control cables separately. We recommend a distance of at least 200 mm. 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.
Feedback lines may not be extended, since thereby the shielding would be interrupted and
the signal processing could be disturbed. Lines between servo amplifiers and filter or external
brake resistor must be shielded. Install all power cables with an adequate cross-section, as
per IEC 60204.
The servo amplifier's status must be monitored by the PLC to acknowledge critical situ-
ations. Wire the BTB/RTO contact in series into the emergency stop circuit of the install-
ation. The emergency stop circuit must operate the supply contactor.

2.6.2 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 Select cables according to EN 60204
selection
Grounding EMC-compliant (EMI) shielding and grounding see Instructions Manual
Shielding Earth (ground) the mounting plate, motor housing and CNC-GND of the
controls.
Wiring Route power leads and control cables separately
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
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 mains choke and mains filter if required (shielded lines between
filter and servo amplifier)
Connect aux. supply (for max. permissible voltage values (➜ # 51))
Connect main power supply (for max. permissible voltage values (➜ #
51))
Connect PC.
Final check Final check of the implementation of the wiring, according to the wiring dia-
grams which have been used.

2.7 Setup
For step-by-step setup guidance refer to the Instructions Manual.

Only professional personnel with extensive knowledge in the fields of electrical engineering
and drive technology are allowed to test and set up the drive.
DANGER
Lethal Voltage!
There is a danger of serious personal injury or death by electrical shock-
Lethal danger exists at live parts of the device.
Built-in protection measures such as insulation or shielding may not be
removed.
Work on the electrical installation may only be performed by trained
and qualified personnel, in compliance with the regulations for safety
at work, and only with switched off mains supply, and secured against
restart.
WARNING
Automatic Restart!
Risk of death or serious injury for humans working in the machine. The
servo amplifier might restart automatically after power on, voltage dip or
interruption of the supply voltage, depending on the parameter setting. If
parameter AENA is set to 1,
then place a warning sign (Warning: Automatic Restart at Power On) to
the machine.
Ensure, that power on is not possible, while humans are in a dan-
gerous 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 minutes from single-phase 230VAC to the terminals
L1 / L2. This will re-form the capacitors.
The adaptation of parameters and the effects on the control loop behavior are described in
the Online Help of the setup software.

2.7.2 Key operation / LED display

The description of the available menu structures can be found in the Instructions Manual.
2.7.2.1 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
2.7.2.2 Status display

2.7.3 Initial Drive Test
2.7.3.1 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 (➜ # 56).
4. Wire the servo amplifier as described in the Instructions Manual or apply the minimum wir-
ing for drive testing as described later in this chapter.
5. Install the software as described below.
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):
Instructions Manual.
CANopen Communication Profile Manual.
Accessories Manual.
Depending on the installed expansion card you need one of these documents:
PROFIBUS DP Communication Profile Manual.
DeviceNet Communication Profile Manual.
SERCOS Communication Profile Manual.
EtherCAT Communication Profile Manual.
You need a PDF Reader to read the PDFs, an installation link is on every screen of the
product CD-ROM.
2.7.3.2 Installation of DRIVE.EXE

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 pro-
gram 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 (➜ # 178).

2.7.3.3 Minimum Wiring for Drive Test SERVOSTAR 601...620 without load
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.

2.7.3.4 Minimum Wiring for Drive Test SERVOSTAR 640...670 without load
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.

2.7.3.5 Connect
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.
Switch on the 24 V power supply for the servo amplifier.
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 displayed (e.g. for Power, 3 amps).
If a fault code ( ) or a warning ( ) or a status message (./_ / E/S)

appears in the display, see (➜ # 182). If there is fault, fix the problem.
Double-Click the icon on your Windows
desktop to start the software.
You can work offline or online with
DRIVE.EXE.
Work ONLINE now. Select the interface
where the servo amplifier 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
message.
Frequent causes: wrong interface chosen

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

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

is disabled (Input HW-Enable
connector X3 pin 15 must be
0 V or open)!
2.7.3.6 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 para-
meters.
Operation Mode, use Digital Velocity mode for drive test-
ing.
Disable and Enable of the amplifier's output stage via

software.
Status Bar

2.7.3.7 Basic Setup

On the start screen click "Basic Setup" button.
Regen Resistor: Also called brake resistor.Change only if you use an external brake res-
istor.
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.

2.7.3.8 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 warn-

ing appears. 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 amp-

lifier's RAM now (takes some
seconds). When this is done, you
have to accept the changed con-
figuration 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 coldstart (reset).
This takes some seconds.
On the start screen, click "Feedback" button.

2.7.3.9 Feedback
Press F12 (disable) before changing
feedback parameters.
Feedback Type:
Select the feedback type used.
If Software Enable is active, a warn-

ing appears. The configuration
change cannot be performed.
Click OK on the warnings, press
F12 (SW disable) and start the Feed-
back procedure again.
If everything was ok, the same pro-

cedure (parameter upload) that has
been described for the motor selec-
tion starts.
If you click "Yes", the parameters
are saved in the EEPROM and the
amplifier makes a coldstart (reset).
This takes some seconds.
2.7.3.10 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 com-
mand 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 .

2.8 Trouble shooting

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.
Eliminate errors and faults in compliance with work safety rules. Troubleshooting only by
qualified and trained staff.
Detailled hints for removal of faults can be found in the online help chapter "Trouble-Shoot-
ing". Our customer service can give you further assistance with problems.
Fault Possible causes Measures to remove the cause of
the fault
HMI message: wrong cable used use null-modem cable
communication cable plugged into wrong position in plug cable into the correct sockets on the
fault servo amplifier or PC servo amplifier and PC
wrong PC interface selected select correct interface
motor does not servo amplifier not enabled apply enable signal
rotate break in setpoint cable check setpoint cable
motor phases swapped correct motor phase sequence
brake not released check brake control
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
motor oscil- gain too high (speed controller) reduce Kp (speed controller)
lates shielding in feedback cable is broken replace feedback cable
AGND not wired up join AGND to CNC-GND
drive reports Irms or Ipeak is set to low increase Irms or Ipeak (keep within motor lim-
following error its!)
setpoint ramp is too long shorten setpoint ramp +/-
motor over- Irms/Ipeak set too high reduce Irms/Ipeak
heating
drive too soft Kp (speed controller) too low increase Kp (speed controller)
Tn (speed controller) too high use motor default value for Tn (speed con-
PID-T2 too high troller)
T-Tacho too high reduce PID-T2
reduce T-Tacho
drive runs Kp (speed controller) too high reduce Kp (speed controller)
roughly Tn (speed controller) too low use motor default value for Tn (speed con-
PID-T2 too low troller)
T-Tacho too low increase PID-T2
increase T-Tacho
axis drifts at offset not correctly adjusted for analog adjust setpoint-offset (analog I/O)
setpoint = 0V setpoint provision join AGND and CNC-GND
AGND not joined to the CNC-GND of
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SERVOSTAR 600

Edition: April 2016

Deutsch English Français Italiano Español

Kollmorgen | wiki-kollmorgen.eu | April 2016 37

2.1.1 Using the PDF Format

38 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.1.2 Symbols Used

This symbol indicates important notes.

Warning of a danger (general). The type of danger is specified

Warning of danger from electricity and its effects.

Warning of danger from hot surface.

Warning of suspended loads.

Warning of danger from automatic start.

Kollmorgen | wiki-kollmorgen.eu | April 2016 39

2.1.3 Abbreviations Used

40 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.2.1 You should pay attention to this

Kollmorgen | wiki-kollmorgen.eu | April 2016 41

42 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.2.2 Warning notes placed on the product

Kollmorgen | wiki-kollmorgen.eu | April 2016 43

2.2.3 Use as Directed

2.2.4 Prohibited Use

44 Kollmorgen | wiki-kollmorgen.eu | April 2016

Kollmorgen | wiki-kollmorgen.eu | April 2016 45

2.3.5 Maintenance and cleaning

46 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.3.7 System Repair

Kollmorgen | wiki-kollmorgen.eu | April 2016 47

2.4 Technical description and data

2.4.1 The SERVOSTAR 600 Family of digital servo amplifiers

48 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.4.2 Motion system with SERVOSTAR 601...620

Kollmorgen | wiki-kollmorgen.eu | April 2016 49

2.4.3 Motion system with SERVOSTAR 640/670

50 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.4.4 Package Supplied

2.4.5 Ambient Conditions, Ventilation, and Mounting Position

Kollmorgen | wiki-kollmorgen.eu | April 2016 51

2.4.6 Technical Data SERVOSTAR 601...620

52 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.4.7 Technical Data SERVOSTAR 640/670

Kollmorgen | wiki-kollmorgen.eu | April 2016 53

2.4.9 Recommended Tightening Torques

2.4.10 Option -AS-, restart lock according to EN 954-1

2.4.10.1 Use as directed

54 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.4.10.2 Prohibited use

2.4.10.3 Functional test

2.4.10.4 Connection diagram (principle)

Kollmorgen | wiki-kollmorgen.eu | April 2016 55

2.5 Mechanical Installation

2.5.1 Important Notes

2.5.2 Guide to Mechanical Installation

56 Kollmorgen | wiki-kollmorgen.eu | April 2016

2.6 Electrical Installation

2.6.1 Important Notes

Kollmorgen | wiki-kollmorgen.eu | April 2016 57

2.6.2 Guide to electrical installation

58 Kollmorgen | wiki-kollmorgen.eu | April 2016