Kollmorgen SERVOSTAR600 (601~620) servo drive

Kollmorgen SERVOSTAR600 (601~620) servo drive

Basic Information and Security Standards

1. Version and Qualification

Software and hardware matching: 05.40 Hardware requires firmware ≥ 9.00-ND0/ND1, supporting BiSS and EtherCAT encoders;

Certification: CE, UL/cUL, CSA, meet EN, IEC, ANSI related mechanical/electrical safety standards, comply with EMC high and low frequency anti-interference specifications;

Applicable personnel: Only certified electrical and mechanical engineers are allowed to carry out disassembly, wiring, and debugging.

2. Core Security Terms

High voltage warning: The maximum DC bus of the main circuit is 900V. After power failure, the capacitor will store electricity for ≥ 5 minutes. The machine must wait for DC<50V before dismantling;

Leakage current>3.5mA, PE ground wire is either double wire parallel or wire diameter>10mm ²;

Shutdown classification: Following EN60204, Class 0 emergency shutdown (direct power-off), Class 1 controlled deceleration power-off, Class 2 non-stop power supply only controlled shutdown;

Optional - AS locking option: According to EN954-1, it can prevent accidental power on and start, and is connected in Cat1/Cat3 safety circuits. However, this driver does not have the IEC61800 STO safety torque shutdown function, and additional mechanical brakes are required for vertical heavy loads;

Prohibited for use in explosion-proof, corrosive, and ungrounded power grid environments.

3. Storage, transportation, and scrapping standards

Transportation/Storage: Environment -25~+70 ℃, humidity 95%, no condensation; Store for over 1 year, power on single-phase 230V/30min to empower the bus capacitor;

Dismantling and maintenance: The power must be cut off, locked, and tagged. The high temperature of the heat sink needs to be cooled down to below 40 ℃;

Scrap shall comply with the WEEE environmental directive and be handled by manufacturers or compliant recyclers.

Product hardware parameters and cabinet structure

1. Power and size

Model Rated output Body width Whole machine weight

601/603/606/610 1.5~10A 70mm, approximately 6.13kg

614 14A 100mm, approximately 6.8kg

620 20A 120mm, approximately 13.1kg

Power supply: three-phase 208~480VAC (± 10%) 50/60Hz; 24VDC isolated auxiliary power supply for independent power supply;

Working environment: 0~45 ℃ full load, 45~55 ℃ power reduction, altitude>1000m reduced capacity use, protection IP20.

2 Hardware Architecture

Standard interface:

X0: Three phase main power supply; X4:24V control power supply; X7: DC bus parallel terminal; X8: Braking resistor;

X9: Motor power+motor brake; X1: Main encoder; X2: Rotation; X3: Analog/Digital IO;

X5: Encoder simulation/second feedback; X6：RS232+CANopen； X10: AS safety option terminal;

Standard features: Built in braking circuit (internal resistance of 66 Ω for 601/603, remaining 33 Ω), can be connected with external braking resistor; Support multi machine DC bus sharing DC, automatic energy sharing;

Control: High speed closed-loop with current loop of 62.5 μ s, speed loop of 65/250 μ s, and position loop of 250 μ s.

3 Standard/Optional Accessories

Standard configuration: Two digital tubes on the panel+dual operation buttons CANopen（DS301/DS402）、 2-channel ± 10V analog input/2-channel analog output, multi-channel DI/DO;

Optional expansion boards: I/O-14/08, PROFIBUS-DP, SERCOS, DeviceNet, EtherCAT, Synq, 2CAN;

Peripherals: External braking resistor, KCM energy storage capacitor module, SINCOS encoder power supply, encoder terminal adapter, FAN temperature control fan.

Mechanical installation specifications

Installation environment: Vertical installation on galvanized conductive mounting plate, painting of the bottom plate is prohibited; Reserve ventilation space above and below the cabinet, and reserve fixed gaps for different models;

Fixed: M5 hexagonal screws are tightened, and the cabinet is kept away from strong magnetic equipment;

Optional FAN board for air cooling: start and stop the fan based on the cooling temperature (start at>58 ℃, stop at<55 ℃).

Electrical Installation and Wiring Guidelines

1. General requirements for wiring

The distance between power cables and control cables should be ≥ 200mm, and the shielding layer should be grounded over a large area of 360 °; Motor wires greater than 25m must be equipped with 3YL inlet choke coils;

Cable capacitance limit: power<150pF/m, encoder wire<120pF.

2 Key wiring points for each port

Power circuit: TN/TT grounded power grid can be directly connected, and isolated/asymmetric power grids must be equipped with isolation transformers; X7 can have multiple drivers connected in parallel on the DC bus, and only those with the same voltage level can be connected in parallel;

Braking circuit: Disconnect the X8 short-circuit connector before connecting an external braking resistor to distinguish between short-term peak power and continuous power consumption;

Motor X9: Integrated power U/VW+24V motor brake wiring, internal control of brake timing in the driver (delayed brake when the speed is below 5rpm);

Feedback interface (X1/X2/X5)

X2: Rotary transformer wiring;

X1：EnDat、Hiperface、BiSS、 Sine cosine encoder, Hall encoder (5V);

X5: Incremental, SSI encoder, supports encoder simulation (A/B/Z, SSI output, can be used as slave electronic gear input);

IO terminal X3:

Simulation: 2-channel differential ± 10V input (speed/torque given), 2-channel ± 10V output (speed/current monitoring);

Numbers: ENABLE enable, PSTOP forward limit, NSTOP reverse limit, universal DI/DO, BTB ready relay (disconnected in case of fault, series emergency stop circuit);

Communication X6: RS232 (PC debugging)+CANopen, interface separation after installing 2CAN board.

Three master-slave applications

Supporting electronic gears and master-slave tracking, the slave driver can follow the spindle through encoder pulses (5V/24V, SSI, sine and cosine), and can interface with stepper controller pulse direction signals.

Debugging (Setup) section

Debugging software DRIVE. EXE

Operating environment: Windows full series (excluding official testing of Win8/10), PC directly connected to X6 driver via RS232;

Function: Parameter reading and writing, oscilloscope waveform, parameter archiving, one click motor/feedback configuration, built-in motor database;

Simple and fast debugging steps: Wiring → Power on 24V → PC online → Basic settings (voltage, braking) → Select motor model → Configure encoder → Save parameters → Enable jog test run.

2 panel operation

Digital tube+up and down buttons, normal menu/long press power on to enter extended menu, can modify CAN address and baud rate;

Display: power supply, enable, fault code, model current, communication status.

3 Multi Axis Networking

Debugging up to 6 drivers on a single PC using SR6Y networking cable, with optional CAN baud rates ranging from 10k to 1M.

Detailed description of optional expansion card

I/O-14/08: Added 14 input and 8 output digital terminals, binary encoding triggers point motion tasks;

PROFIBUS DP: DP slave communication, hardware dial-up address;

SERCOS: Fiber optic ring network, RX/TX/ERR status lights, configurable fiber length and baud rate;

DeviceNet: dip code to set address/rate, terminal resistance of 120 Ω at both ends of the bus;

EtherCAT: Dual RJ45 IN/OUT interface, RUN/ACT/ERR status indicator light;

SynqNet: RJ45 bus+15 pin I/O terminal;

2CAN: Separate RS232/CAN interfaces, CAN bus terminals can be loaded with terminal resistors.

Fault alarm and maintenance

1. Fault classification

Class F faults (shutdown, BT contact disconnection, power cut-off): F01 overheating, F02 overvoltage, F05 undervoltage, F04 feedback disconnection, F08 overspeed, F16 phase loss;

Type n warning (no shutdown, only alarm): n05 phase loss, n10 limit trigger, I ² t overload, etc. Some warnings reach the threshold for controlled shutdown.

2 Common troubleshooting

Optimization of corresponding parameters such as motor non rotation, oscillation, excessive tracking error, and excessive temperature rise (gain, slope, current limit);

3 Daily maintenance

Regularly check the wiring fastening and cooling air ducts, and conduct annual checks on the brake circuit.

AS Safety Options (Key)

-The AS terminal X10 relies on a safety relay to cut off the drive output, and can only be locked when the motor is stationary. It is divided into two wiring diagrams: Cat1 (single safety circuit) and Cat3 (redundant safety circuit), which are used for equipment maintenance and anti misoperation. It cannot replace STO safety shutdown, and mechanical brake bottom protection is still required for vertical lifting equipment.