Kollmorgen Seidel SERVOSTAR 600 Series Installation and operation manual

Digital servo amplifier
SERVOSTAR™ 600
Assembly, Installation and Commissioning Instructions
Edition 02/99

Previous versions :
Edition Remarks
05/98 First edition
08/98 a few corrections
09/98 various minor corrections, parameter description removed, parameter setting for multi-axis systems and on/off swit-
ching behaviour added, Installation/Commissioning divided into two chapters
01/99 614 added, various minor corrections
02/99 Interface relay for digital outputs (pages 26, 43)
VGA is a registered trademark of International Business Machines Corp.
PC-AT is a registered trademark of International Business Machines Corp.
MS-DOS is a registered trademark of Microsoft Corp.
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
SERVOSTAR is a registered trademark of Kollmorgen Corporation.
Technical changes which improve the performance of the equipment may be made without prior notice !
Printed in the Federal republic of Germany BRD 02/99 Mat.Nr.: 90162
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method) or stored,
processed, copied or distributed by electroninc means without the written permission of Seidel Corporation.

Contents
SERVOSTAR™ 600 Installation-manual 3
Kollmorgen 02.99 Contents
I General
I.1 About this manual .................................................................................9
I.2 Prescribed use (“Use as directed”) of the servo amplifier ...................................................9
I.3 Nameplate ......................................................................................10
I.4 Instrument description .............................................................................10
I.4.1 Package supplied............................................................................10
- A.4.028.6/10
I.4.2 The digital servo amplifiers of the SERVOSTAR™ 600 family .......................................11
I.4.3 Operation directly from supply.................................................................11
I.4.4 Digital servo amplifier concept.................................................................12
I.5 Block diagram ...................................................................................13
- A.4.031.1/28
I.6 Components of a servo system.......................................................................14
I.7 Technical data of the SERVOSTAR™ 600 series........................................................15
I.7.1 External fusing .............................................................................15
I.7.2 Permissible ambient conditions, ventilation, mounting position .......................................16
I.7.3 Conductor cross-sections .....................................................................16
I.7.4 LED display ...............................................................................16
I.8 Grounding system ................................................................................17
I.9 Control for motor-holding brake .....................................................................17
- A.4.031.3/01, 1/35
I.10 Regen circuit ....................................................................................18
I.11 Switch-on and switch-off behaviour ..................................................................19
I.11.1 Stop function to EN 60204 (VDE 0113) .........................................................19
- A.4.031.3/6
I.11.2 Emergency Stop strategies ....................................................................20
II Installation
II.1 Important instructions .............................................................................21
II.2 Assembly .......................................................................................22
- A.4.031.4/15
II.2.1 Dimensions of SERVOSTAR™ 600 ............................................................23
- A.4.031.4/14
II.3 Wiring .........................................................................................24
II.3.1 Connection diagram for SERVOSTAR™ 600.....................................................26
- A.4.031.1/2
II.3.2 Example of connections for multi-axis system ....................................................27
- A.4.031.1/19
II.3.3 Pin assignments for SERVOSTAR™ 600 ........................................................28
- A.4.031.4/21
II.3.4 Notes on connection techniques ................................................................29
II.3.4.1 Tool list ...............................................................................29
II.3.4.2 Shielding connection to the front panel.......................................................29
- A.4.029.4/25
II.3.4.3 Wiring up a SubD-connector with shielding...................................................30
- A.4.029.4/2
II.3.4.4 Assembling the resolver connector (motor end) ................................................31
- A.4.029.4/6
II.3.4.5 Wiring up the motor power connector (amplifier end) ...........................................32
- A.4.029.4/24
II.3.4.6 Wiring up the motor power connector (motor end) .............................................33
- A.4029.4/9
II.3.5 Technical data for connecting cables ............................................................34
II.4 Operator software.................................................................................35
II.4.1 General ...................................................................................35
II.4.1.1 Use as directed .........................................................................35
II.4.1.2 Software description .....................................................................35
II.4.1.3 Hardware requirements ...................................................................36
II.4.1.4 Operating systems .......................................................................36
II.4.2 Installation under WINDOWS 95 /98 / NT .......................................................36
Drawing Page
Contents ...............................................3
Safety instructions ........................................6
European directives and standards .............................7
- / UL- conformance ......................................7
Abbreviations and symbols...................................8

Contents
4 SERVOSTAR™ 600 Installation-manual
Contents 02.99 Kollmorgen
III Interfaces
III.1 Power supply ....................................................................................37
III.1.1 Mains supply connection (X0) .................................................................37
III.1.2 24V auxiliary supply (X4) ....................................................................37
III.1.3 DC-link (X7)...............................................................................37
- A.4.031.1/21,25
III.2 Motor connection with brake (X9)....................................................................38
III.3 External regen resistor (X8) .........................................................................38
- A.4.031.1/17,18
III.4 Feedback .......................................................................................39
III.4.1 Resolver connection (X2) .....................................................................39
- A.4.031.1/26
III.4.2 Encoder (X1)...............................................................................40
- A.4.031.1/27
III.5 Control signals, monitor signals......................................................................41
III.5.1 Analog setpoint inputs (X3) ...................................................................41
- A.4.031.1/23
III.5.2 Digital setpoint inputs (X3) ...................................................................42
- A.4.031.1/24
III.5.3 Digital control outputs (X3) ...................................................................43
- A.4.031.1/20
III.5.4 Monitor outputs (X3) ........................................................................44
- A.4.031.1/22
III.6 Encoder emulations ...............................................................................45
III.6.1 Incremental-encoder interface (X5) .............................................................45
- A.4.031.1/11
III.6.2 SSI-Interface (X5)...........................................................................46
- A.4.031.1/12
III.7 RS232 interface, PC connection (X6) .................................................................47
- A.4.031.1/13,14
III.8 CANopen Interface (X6) ...........................................................................48
- A.4.031.1/15, 1/36
III.9 Interface for stepper-motor controls (X5) ..............................................................49
- A.4.031.1/10,3/2
III.10 Interface for master-slave operation, encoder input (X5) ..................................................50
- A.4.031.1/16,3/2
IV Commissioning
IV.1 Important notes...................................................................................51
IV.2 Parameter setting .................................................................................53
IV.2.1 Multi-axis systems ..........................................................................53
- A.4.031.4/37
IV.2.2 Key operation / LED display ..................................................................54
IV.2.2.1 Key operation ..........................................................................54
- A.4.031.3/4
IV.2.2.2 Structure ..............................................................................55
- A.4.031.3/3
IV.3 Error messages ...................................................................................56
IV.4 Warning messages ................................................................................56
V Accessories
V.1 External 24V DC supply for one servo amplifier ........................................................57
- A.4.012.4/32
V.2 External 24V DC supply for up to 7 servo amplifiers .....................................................58
- A.4.012.4/33
V.3 External regen resistor BARxxx .....................................................................59
- A.4.947.4/22
VI Appendix
VI.1 Transport, storage, maintenance, disposal ..............................................................61
VI.2 Removing faults ..................................................................................62
VI.3 Glossary ........................................................................................64
VI.4 Index...........................................................................................67
Drawing Page

This page has been deliberately left blank
SERVOSTAR™ 600 Installation-manual 5
Kollmorgen 02.99

Safety Instructions
lOnly properly qualified personnel are permitted to perform activities such as
transport, installation, commissioning and maintenance. Properly qualified
persons are those who are familiar with the transport, assembly,
installation, commissioning and operation of the product, and who have the
appropriate qualifications for their job. The qualified personnel must know
and observe:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110
national accident prevention regulations or VBG 4
lRead this documentation before carrying out installation and
commissioning. Incorrect handling of the servo amplifier can lead to
personal injury or material damage. It is vital that you keep to the technical
data and information on connection requirements (on the nameplate and in
the documentation).
lThe 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
(artifical fabrics, plastic film etc.). Place the servo amplifier on a conductive
surface.
lDo not open the units. Keep all covers and switchgear cabinet doors closed
during operation. Otherwise there are deadly hazards, with the possibility of
severe danger to health or material damage.
lDuring operation, servo amplifiers, according to their degree of enclosure
protection, may have uncovered live components. Control and power
connections may be live, even if the motor is not rotating.
lServo amplifiers may have hot surfaces during operation. Since the front
panel is used for cooling, it can reach temperatures above 80°C.
lNever undo the electrical connections to the servo amplifier while it is live.
There is a danger of electric arcing with damage to contacts and danger to
persons.
lWait at least two minutes after disconnecting the servo amplifier from the
mains supply voltage before touching live sections of the equipment (e.g.
contacts) or undoing connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply voltages.
To be sure, measure the voltage in the DC-link circuit and wait until it has
fallen below 40V.
Safety instructions
6 SERVOSTAR™ 600 Installation-manual
Safety instructions 02.99 Kollmorgen

European directives and standards
Servo amplifiers are components which are intended to be incorporated into electrical plant and machines for
industrial use.
When the servo amplifiers are built into machines or plant, the intended operation of the amplifier is
forbidden until it has been established that the machine or plant fulfills the requirements of the EC Directive
on Machines 89/392/EEC and the EC Directive on EMC (89/336/EEC). EN 60204 and EN 292 must also be
observed.
In connection with the Low Voltage Directive 73/23/EEC , the harmonized standards of the EN 50178 series
are applied to the amplifiers, together with EN 60439-1, EN 60146 and EN 60204.
The manufacturer of the machine or plant is responsible for ensuring that they meet the limits which are
required by the EMC regulations. Advice on the correct installation for EMC - such as shielding, grounding,
arrangement of filters, treatment of connectors and the laying out of cabling - can be found in this
documentation.
- conformance
Conformance with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is
mandatory for the supply of servo amplifiers within the European Community.
The servo amplifiers of the SERVOSTAR™ 600 series have been tested by an authorized testing laboratory
in a defined configuration with the system components which are described in this documentation. Any
divergence from the configuration and installation described in this documentation means that you will be
responsible for the performance of new measurements to ensure that the regulatory requirements are met.
UL and cUL- Conformance (listing in 4. quarter 1998)
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Canadian
standard (in this case UL 840 and UL 508C).
This standard describes the fulfillment by design of minimum requirements for electrically operated power
conversion equipment, such as frequency converters and servo 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) fire 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 fulfillment 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 being caused by such equipment.
UL 840
UL 840 describes the fulfillment by design of air and insulation creepage spacings for electrical equipment
and printed circuit boards.
Directives and standards
SERVOSTAR™ 600 Installation-manual 7
Kollmorgen 02.99 Directives and standards

Abbreviations used in this manual
The abbreviations used in this manual are explained in the table below.
Symbols used in this manual
danger to personnel
from electricity
and its effects
general warning
general instructions
mechanical hazard
ðsee Chapter (cross-ref.) lspecial emphasis
Keys on the servo amplifier panel :
U
press once : move up one menu item, increase number by one
press twice in rapid succession : increase number by ten
U
press once : move down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
U
U
hold right key pressed, and then press left key as well :
to enter number, “Return” function
Abbreviations / symbols
8 SERVOSTAR™ 600 Installation-manual
Abbreviations / symbols 02.99 Kollmorgen
Abbrev. Meaning
AGND Analog ground
BTB/RTO Ready to operate
CE Communité Européenne (EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN Deutsches Institut für Normung
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable memory
EMV Electromagnetic compatibility
EN European standard
ESD Electrostatic discharge
IEC International Electrotechnical Commission
IGBT Insulated Gate Bipolar Transistor
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
MS-DOS Operating system for PC-AT
NI Zero pulse
Abbrev. Meaning
NSTOP Limit-switch input, rot. dir. CCW (left)
PC-AT Personal computer with 80x86 Prozessor
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input, rot. dir. CW (right)
PWM Pulse-width modulation
RAM Volatile memory
Rregen Regen resistor
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
SW/SETP. setpoint
UL Underwriters Laboratory
V AC AC voltage
V DC DC voltage
VDE Verein deutscher Elektrotechniker
XGND Ground for the 24V supply

I General
I.1 About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR™ 600 series
(standard version). You can find information about:
lTechnical data of the servo amplifier Chapter I
lAssembly / installation Chapter II
lInterfaces Chapter III
lCommissioning the servo amplifier Chapter IV
lAccessories Chapter V
lTransport, storage, maintenance, disposal of the servo amp. Chapter VI
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 95 with Internet browser) in English, German
and French versions.
You can print out this documentation on any standard printer. A printed copy of the documentation
is available from us at extra cost.
This manual makes the following demands on qualified personnel :
Transport : only by personnel with knowledge in handling
electrostatically sensitive components.
Installation : only by electrically qualified personnel
Commissioning : onyl by personnel with extensive knowledge of
electrical technology / drive technology
I.2 Prescribed use (“Use as directed”) of the servo amplifier
The servo amplifiers are components which are built into electrical equipment or machines, and
can only be commissioned as integral components of such equipment.
The SERVOSTAR™ 600 family of servo amplifiers is to be used only on earthed three-phase
industrial mains supply networks ( TN-system, TT-system with earthed neutral point).
The servo amplifiers must not be operated on power supply networks without an earth or with an
asymmetrical earth.
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.
The SERVOSTAR™ 600 family of servo amplifiers is only intended to drive specific brushless
synchronous servomotors from the 6SM series, 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-link voltage of the
servo amplifier.
Observe the reduction factor for current and power (see techn. data).
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined in Chapter I.7.2 .
We only guarantee the conformance of the servo amplifiers with the standards for industrial areas
(page 7), if the components (motors, cables, amplifiers etc) are delivered by Seidel Servo Drives.
SERVOSTAR™ 600 Installation-manual 9
Kollmorgen 02.99 General

I.3 Nameplate
The nameplate depicted below is attached to the side of the servo amplifer.
The information described below is printed in the individual fields.
I.4 Instrument description
I.4.1 Package supplied
When you order a SERVOSTAR™ 600 series amplifier from us, 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 Commissioning Instructions
— Online documentation on CD-ROM
— Operator software SR600 on 3.5" diskettes
Accessories: (must be ordered separately if required)
— Servomotor 6SM
— motor cable (pre-assembled), or
both motor connectors separately, with motor cable as a cut-off length
— feedback cable (pre-assembled, see manual Servomotors) or
both feedback connectors separately, with feedback cable as length
— motor chokes (for cable length above 25m)
— external regen resistor
— communications cable to the PC(ðIII.7) or Y-adapter (ðIV.2.1) for parameter-
setting of up to 4 servo amplifiers from one PC
— power cable, control cables, fieldbus cables (as lengths)
- A.4.028.6/10
10 SERVOSTAR™ 600 Installation-manual
General 02.99 - A.4.028.6/10 Kollmorgen
CONNECT-module
and options
Serial numberServo amplifier type
Electrical supply
Installed load
Output current
in S1 operation Protection

I.4.2 The digital servo amplifiers of the SERVOSTAR™ 600 family
Standard version
l5 current ratings (1.5A,3A,6A,10A,14A,20A)
ltwo instrument widths : 70 mm up to 10A rated current
100 mm for 14 up to 20A rated current
lwide range of rated voltage (3x230V –10% to 3x480V +10%)
lshield connection directly at the servo amplifier
ltwo analog setpoint inputs
lintegrated CANopen (default 500 kBaud), for integration into CANbus systems and for
setting parameters for several amplifiers via the PC-interface of one amplifier
lintegrated RS232, electrically isolated
lintegrated pulse-direction interface
Options
l-AS- built-in safety relay (personnel-safety starting lock-out),
see Chapter I.11.1 and leaflet “Option -AS-”
lPROFIBUS DP expansion card (from 1st. quarter 1999)
lSERCOS expansion card (from 1st. quarter 1999)
lI/O expansion card
Open architecture
lopen hardware and software architecture
lslot for an expansion card
lintegrated macro language, including compiler
lprepared for all conceivable customer-specific extensions
I.4.3 Operation directly from supply
Electrical supply
lDirectly off earthed 3~ system, 230V
-10%
— 480V
+10%
, 50 — 60 Hz,
TN-system or TT-system with earthed neutral point
lFusing (e.g. fusible cutout) provided by the user
lsingle-phase supply (e.g. for commissioning or setting-up) is possible
Auxiliary supply voltage 24V DC
lElectrically isolated, from an external 24V DC psu, e.g. with insulating transformer
Power input filter
lInterference suppression filter for the supply input (to Class A) is integrated
lInterference suppression filter for the 24V aux. supply (to Class A) is integrated
SERVOSTAR™ 600 Installation-manual 11
Kollmorgen 02.99 General

I.4.4 Digital servo amplifier concept
Operation and parameter setting
lWith the comfortable Seidel operator-software through the serial interface of a PC
lDirect operation by means of two keys on the servo amplifier and a 3-character LED
display for status display in case of no PC available
lFully programmable via RS232 interface
Power section
lPower supply : B6 rectifier bridge, directly off 3-phase earthed supply
system, integral power input filter and inrush circuit
lAll shielding connections directly on the amplifier
lOutput stage : IGBT- module with isolated current measurement
lRegen circuit : with dynamic distribution of the regen power between
several amplifiers on the same DC-link circuit
internal regen resistor as standard, external regen
resistors if required
lDC-link voltage 300 — 900 V DC, can be paralleled
Completely digital control
lDigital current controller (space vector pulse-width modulation, 62.5 µs)
lFreely programmable digital speed controller (250 µs)
lIntegral position controller with adaptation possibilities for customer needs (250 µs)
lPulse direction interface integrated for connection of a servomotor to a stepping- motor
control
lEvaluation of the resolver signals or sine-cosine signals of a high-resolution encoder
lEncoder emulation (incremental ROD 426-compatible or SSI)
Comfort functions
lAdjustable setpoint ramps
l2 analog monitor outputs
l4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l2 programmable digital outputs
lFreely programmable combinations of all digital signals
Integrated safety
lSafe electrical separation to EN 50178 between the power input / motor connections and
the signal electronics, provided by appropriate insulation/creepage distances and complete
electrical isolation
lSoft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
lTemperature monitoring of servo amplifier and motor
(when using motors from the 6SM series with our pre-assembled cables)
12 SERVOSTAR™ 600 Installation-manual
General 02.99 Kollmorgen

I.5 Block diagram
- A.4.031.1/28
SERVOSTAR™ 600 Installation-manual 13
Kollmorgen 02.99 - A.4.031.1/28 General

I.6 Components of a servo system
14 SERVOSTAR™ 600 Installation-manual
General 02.99 Kollmorgen
24V supply
fuses
drive contactor
terminals
motor
SERVOSTAR™ 600
PC
Control / PLC

I.7 Technical data of the SERVOSTAR™ 600 series
SERVOSTAR™
Rated data DIM 601 603 606 610 614 620
Rated supply voltage V~ 3 x 230V
-10%
... 480V
+10%
, 50 ... 60 Hz
Rated installed load for S1 operation kVA 1 2 4 7 10 14
Rated DC-link voltage V= 310 - 675
Rated output current (rms value, ±3%) A
rms
1,5 3 6 10 14 20
Peak output current (max. ca. 5s, ±3%) A
rms
3 6 12 20 28 40
Clock frequency of the output stage kHz 8
Technical data for regen circuit — ðI.10
Overvoltage protection treshold V 450...900
Form factor of the output current
(at rated data and min. load inductance) — 1.01
Bandwidth of subordinate current
controller kHz > 1,2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage
disabled W15
Dissipation at rated current (incl. power
supply losses, without regen dissipation) W 30 40 60 90 160 200
Internal fusing (external fusing ðI.7.1)
Auxiliary supply 24V internal 3,15 AT
Regen resistor internal, electronic
Inputs
Setpoint 1/2, resolution 14bit/12bit V ±10
Common-mode voltage max. V ±10
Input resistance kΩ20
Digital inputs V low 0...7 / high 12...36
mA 7
Aux. power supply, electrically isolated V 20...36
without brake A 1
Aux. power supply, electrically isolated V 24 (-0% +15%)
with brake A 3
Max. output current, brake A 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 emulation, ROD/SSI SubD 9pole (plug)
Mechanical
Weight kg 2,5 3
Dimensions (HxWxT) without
connectors mm 275x70x265 275x100x265
I.7.1 External fusing
Fusible cutouts or similar SERVOSTAR™
601 / 603
SERVOSTAR™
606 / 610
SERVOSTAR™
614 / 620
AC supply F
N1/2/3
6AT 10AT 20AT
24V supply F
H1/2
max. 16 AF
Regen resistor F
B1/2
4AF 6AF 6AF
SERVOSTAR™ 600 Installation-manual 15
Kollmorgen 02.99 General

I.7.2 Permissible ambient conditions, ventilation, mounting position
Storage temperature/humidity,
storage duration ðVI.1
Transport temperature / humidity ðVI.1
Supply voltage tolerances
Input power
Aux. power supply
without brake
with brake
min 3x230V
-10%
AC / max 3x 480V
+10%
, 50 ... 60 Hz
20...36 V DC
24 V DC (-0% +15%)
Ambient temperature in operation 0to+40
o
C at rated data
+40 to +55°C with power derating 2.5% / °C
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 EN60204/EN50178
Enclosure protection IP 20
Mounting position generally vertical. ðII.2
Ventilation
SERVOSTAR™ 601/603
SERVOSTAR™ 606-620
natural convection
built-in fan
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
I.7.3 Conductor cross-sections
Following EN 60204, we recommend for single-axis systems :
AC connection SERVOSTAR™ 601-610 : 1,5 mm²
SERVOSTAR™ 614/620 : 4 mm²
DC-link SERVOSTAR™ 601-610 : 1,5 mm²
SERVOSTAR™ 614/620 : 4 mm²
Shielded,
for lengths > 20 cm
Motor cables up to 25 m length SERVOSTAR™ 601-610 : 1 - 1,5 mm²
SERVOSTAR™ 614/620 : 2,5 mm² shielded
Motor cables 25 to 100 m length
(consult our applications department)
SERVOSTAR™ 601-606 : 1 mm²
SERVOSTAR™ 610-620 : 2,5 mm²
Shielded,
with motor choke
Resolver, thermostat-motor 0.25 mm² twisted pairs, shielded, max.100m
Setpoints, monitors, AGND 0.25 mm² twisted pairs, shielded
Control signals, BTB, DGND 0,5 mm²
Holding brake (motor) min. 0.75 mm², shielded, check voltage drop
+24 V / XGND max. 2.5 mm², check voltage drop
For multi-axis systems, please note the special operating conditions in your installation
Technical data for connection cables. ðII.3.5 .
I.7.4 LED display
A 3-character LED display shows the amplifier status after switching on the 24V supply
(ðIV.2.2). During operation and parameter setting of the amplifier via the keys on the front panel,
the parameter and function numbers (ðIV.2.2.2) are displayed, as well as the numbers of any
errors which occur (ðIV.3).
16 SERVOSTAR™ 600 Installation-manual
General 02.99 Kollmorgen

I.8 Grounding system
AGND — ground for analog inputs/outputs, internal analog ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder emulation, RS232, CAN, optically isolated
The potential isolation is shown in the block diagram (ðI.5).
I.9 Control for motor-holding brake
A 24V / max. 2A holding brake in the motor can be controlled directly by the servo amplifier.
This function does not ensure personnel safety! The brake function must be enabled through the
BRAKE parameter: setting WITH. 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 the speed setpoint of the servo amplifier is
internally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of the final
speed is reached. The rise (fbrH) and fall (fbrL) times of the holding brake which is built into the
motors are different for the various types of motor (see motor manual). A description of the
interface can be found in Chapter III.2 .
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact
in the brake circuit and a suppressor device (varistor) for the recommended brake circuit diagram :
- A.4.031.3/01, 1/35
SERVOSTAR™ 600 Installation-manual 17
Kollmorgen 02.99 - A.4.031.3/01, 1/35 General
external
safety circuit

I.10 Regen circuit
During braking with the aid of the motor, energy is fed back to the servo amplifier. This energy is
converted into heat in the regen resistor. The regen resistor is switched into circuit by the regen
circuit. The regen circuit (thresholds) are adjusted to the supply voltage with the help of the
operator software
Our applications department can help you with the calculation of the regen power which is
required. A description of the interface can be found in Chapter III.3 .
Internal regen resistor : SERVOSTAR™ 601/603 66 Ohm
SERVOSTAR™ 606-620 33 Ohm
External regen resistor : SERVOSTAR™ 601-620 33 Ohm
Functional description :
1.- Individual amplifiers, not coupled through the DC-link (DC+, DC-)
The circuit starts to respond at a DC-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 higher than the preset regen power, then the servo amplifier will output
the status “regen power exceeded” and the regen circuit will be switched off. At the next
internal check of the DC-link voltage (after a few ms) an overvoltage will be detected and
the servo amplifier will be switched off with the error message “Overvoltage” (ðIV.3).
The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ðIII.5.3)
2.- Several servo amplifiers coupled through the DC-link circuit (DC+, DC-)
Thanks to the built-in regen circuit with its patented w-characteristic, several amplifiers
(even with different current ratings) can be operated off a common DC-link. This is
achieved by an automatic adjustment of the regen thresholds (which vary, because of
tolerances). The regen 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 (ðIII.5.3).
Regen circuit: technical data SERVOSTAR™
Supply voltage Rated data DIM 601 - 603 606 - 620
3 x 230 V
Upper switch-on level of regen circuit V 400 - 430
Switch-off level of regen circuit V 380 - 410
Continuous power of regen circuit (R
Bint
) W 80 200
Continuous power of regen circuit (R
Bext
) max. kW 0,25 0,75
Pulse power, internal (R
Bint
max. 1s) kW 2,5 5
Pulse power, external (R
Bext
max. 1s) kW 5
3 x 400 V
Upper switch-on level of regen circuit V 720 - 750
Switch-off level of regen circuit V 680 - 710
Continuous power of regen circuit (R
Bint
) W 80 200
Continuous power of regen circuit (R
Bext
) max. kW 0,4 1,2
Pulse power, internal (R
Bint
max. 1s) kW 8 16
Pulse power, external (R
Bext
max. 1s) kW 16
3 x 480 V
Upper switch-on level of regen circuit V 840 - 870
Switch-off level of regen circuit V 800 - 830
Continuous power of regen circuit (R
Bint
) W 80 200
Continuous power of regen circuit (R
Bext
) max. kW 0,5 1,5
Pulse power, internal (R
Bint
max. 1s) kW 10,5 21
Pulse power, external (R
Bext
max. 1s) kW 21
18 SERVOSTAR™ 600 Installation-manual
General 02.99 Kollmorgen

I.11 Switch-on and switch-off behaviour
The diagram below illustrates the correct functional sequence for switching the servo amplifier on
and off. If you are using the digital output function MAINS-BTB/RTO, you can find a diagram
which is valid for this case in the “Operator Software” manual.
I.11.1 Stop function to EN 60204 (VDE 0113)
If a fault occurs (ðIV.3) the output stage of the servo amplifier is switched off and the BTB/RTO
contact is opened. In addition, a global error signal can be given out at one of the digital outputs
(terminals X3/16 and X3/17) (see “Operator Software”). These signals can be used by the higher-
level control to finish the current PLC cycle or to shut down the drive (with additional brake or
similar.).
Instruments which are equipped with a selected “Brake” function use a special sequence for swit-
ching off the output stage (ðI.9).
The -AS- option can be used to switch off the drive via a positive-action (BG-approved) safety
relay, so that personnel safety is ensured at the drive shaft. The -AS- option is described in more
detail in a special leaflet. You will find this leaflet on the CD-ROM in German and English.
The Stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3.
There are three categories of Stop functions:
Category 0: Shut down by immediately switching off the supply of energy to the
drive machinery (i.e an uncontrolled shut-down);
Category 1: A controlled shut-down, during which the supply of energy to the drive
machinery is maintained to perform the shut-down, and where the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, where the supply of energy to the drive machinery
is maintained.
Every machine must be equipped with a Stop function to Category 0. Stop functions to Categories
1 and/or 2 must be provided if the safety or functional requirements of the machine make this
necessary.
You can find additional information and implementation examples in our application note “Stop
and Emergency Stop functions with SERVOSTAR™ 600” (available from february 1999).
-A.4.031.3/6
SERVOSTAR™ 600 Installation-manual 19
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DC-link

I.11.2 Emergency Stop strategies
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
Implementation of the Emergency Stop function :
You can find wiring recommendations in our application note (available from february 1999)
“Stop and Emergency Stop functions with SERVOSTAR™ 600”
Category 0:
The controller is switched to “disable”, the electrical supply (400VAC) is
disconnected. The motor leads are disconnected by a changeover switch (contactor,
e.g. Siemens 3RT1516-1BB40) and short-circuited by resistors connected in a star
configuration. The drive must be held by an electromagnetical holding device (brake).
Category 1:
If hazardous conditions can result from an emergency stop switch-off with an unbraked
run-down, then the drive can be switched off by a controlled shut-down.
Stop Category 1 permits electromotive braking with a switch-off when zero speed has
been reached. Safe shut-down can be achieved with a safety relay with delayed drop-out
(e.g. Siemens 3TK28- series, Pilz PNOZ- series).
In the normal situation, only the supply power is switched off in a safe manner.
The 24V auxiliary supply remains switched on.
20 SERVOSTAR™ 600 Installation-manual
General 02.99 Kollmorgen