Kollmorgen Seidel SERVOSTAR 601 User manual

Assembly, Installation, Setup
Edition 06/02
file 601620hw.xxx
EU order.No.: 90162
NA: M-SS-004-0216
Digital servo amplifier
SERVOSTAR®601...620

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 switching
behavior added, Installation/setup divided into two chapters
01/99 614 added, various minor corrections
02/99 Interface relay for digital outputs (pages 26, 43)
06/99 various corrections, cables and connectors removed, choke box added
08/99 24V tolerance, encoder wiring, ventilation
11/99 Packaging, regen resistor
12/99 Option -AS- integrated, ground-bolt, master-slave
04/00 various corrections, setup software on CDROM only, motors 6SM27LL and 6SM37VL added
06/00 Wiring diagrams electr. gearing, warning and error messages, recommended torque
08/00 Wiring diagram in chapter III.9.2 corrected
07/01 S610-30 and-Options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for PROFIBUS and
SERCOS, nameplate, motor list and connector assignment corrected, LED-display corrected, error messages expanded
09/01 Dimensions BARxxx corrected
02/02 various corrections, new layout
06/02 Front page new design, corrections to US english, motor table removed, order numbers added,
last page new design and contents, new: connection to diff. mains supply networks, block diagram to ch.III
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.
Manufactured under one or more of the following US patents:
4,434,389 4,447,771 4,456,934 4,463,299 4,479,078
4,490,661 4,504,755 4,508,988 4,532,461 4,538,080
4,541,575 4,543,520 4,551,646 4,559,485 4,562,399
4,572,999 4,579,012 4,633,151 4,644,199 4,647,824
4,661,756 4,670,696 4,675,547 4,679,313 4,682,093
4,686,437 4,698,537 4,729,160 4,763,049 4,763,056
4,763,057 4,733,149 4,782,272 4,797,592 4,857,816
4,868,475 4,868,970 4,912,381 4,926,063 4,935,080
4,943,760 4,954,739 4,992,716 5,051,634 5,144,183
5,173,651 5,194,786 5,399,908 5,435,517 5,530,396
5,574,636 5,606,791 5,625,265 5,633,793 5,646,467
5,715,590 5,736,916 5,739,648 5,754,732 5,789,841
5,829,118 5,912,638 5,949,202 5,949,359 5,998,905
6,002,234
Technical changes which improve the performance of the equipment may be made without prior notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method)
or stored, processed, copied or distributed by electronic means without the written permission of Kollmorgen Seidel Corporation.

Contents
SERVOSTAR®601...620 Installation Manual 3
Seidel 06/02 Contents
I General
I.1 About this manual...................................................................................9
I.2 Prescribed use (Use as directed) of the servo amplifier.....................................................10
I.3 Nameplate........................................................................................11
I.4 Instrument description...............................................................................11
I.4.1 Package supplied ............................................................................11
- A.4.028.6/10
I.4.2 The digital servo amplifiers of the series SERVOSTAR 600............................................12
I.4.3 Operation directly from supply...................................................................12
I.4.4 Digital servo amplifier concept...................................................................13
I.5 Connection to different mains supply networks ...........................................................14
- A.4.031.1/52
I.6 Components of a servo system .......................................................................15
I.7 Technical data ....................................................................................16
I.7.1 External fusing...............................................................................16
I.7.2 Permissible ambient conditions, ventilation, mounting position..........................................17
I.7.3 Conductor cross-sections ......................................................................17
I.7.4 Recommended torque.........................................................................17
I.7.5 LED display .................................................................................17
I.8 Grounding system..................................................................................18
I.9 Control for motor-holding brake .......................................................................18
- A.4.031.3/01, 1/35
I.10 Regen circuit......................................................................................19
I.11 Switch-on and switch-off behavior .....................................................................20
I.11.1 Stop function to EN 60204 (VDE 0113)............................................................20
- A.4.031.3/6
I.11.2 Emergency Stop strategies .....................................................................21
II Installation
II.1 Important instructions ...............................................................................23
II.2 Assembly ........................................................................................24
- A.4.031.4/15
II.2.1 Dimensions .................................................................................25
- A.4.031.4/14
II.3 Wiring ...........................................................................................26
II.3.1 Connection diagram ..........................................................................28
- A.4.031.1/02
II.3.2 Example of connections for multi-axis system ......................................................29
- A.4.031.1/19
II.3.3 Pin assignments .............................................................................30
- A.4.031.4/21
II.3.4 Notes on connection techniques .................................................................31
II.3.4.1 Shielding connection to the front panel ........................................................31
- A.4.029.4/25
II.3.4.2 Technical data for connecting cables..........................................................32
II.4 Setup software ....................................................................................33
II.4.1 General ....................................................................................33
II.4.1.1 Use as directed ..........................................................................33
II.4.1.2 Software description ......................................................................33
II.4.1.3 Hardware requirements ....................................................................34
II.4.1.4 Operating systems........................................................................34
II.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT................................................34
Drawing Page
Contents ...............................................3
Safety instructions ........................................6
European directives and standards .............................7
- / UL- conformance ......................................7
Abbreviations and symbols...................................8

Contents
4 SERVOSTAR®601...620 Installation Manual
Contents 06/02 Seidel
III Interfaces - A.4.031.1/47
III.1 Power supply .....................................................................................36
III.1.1 Mains supply connection (X0) ..................................................................36
III.1.2 24V auxiliary supply (X4).......................................................................36
III.1.3 DC-link (X7).................................................................................36
- A.4.031.1/21,25
III.2 Motor connection with brake (X9) ......................................................................37
III.3 External regen resistor (X8) ..........................................................................37
- A.4.031.1/17,18
III.4 Feedback ........................................................................................38
III.4.1 Resolver connection (X2) ......................................................................38
- A.4.031.1/26
III.4.2 Encoder (X1) ................................................................................39
- A.4.031.1/27
III.5 Control signals, monitor signals .......................................................................40
III.5.1 Analog setpoint inputs (X3) .....................................................................40
- A.4.031.1/23
III.5.2 Monitor outputs (X3) ..........................................................................41
- A.031.1/22
III.5.3 Digital control inputs (X3) ......................................................................42
- A.4.031.1/24
III.5.4 Digital control outputs (X3) .....................................................................43
- A.4.031.1/20
III.6 Encoder simulations ................................................................................44
III.6.1 Incremental encoder simulation - A quad B position output (X5) ........................................44
- A.4.031.1/11
III.6.2 SSI encoder simulation - position output (X5).......................................................45
- A.4.031.1/12
III.6.3 Interface for master-slave operation, encoder input ..................................................46
III.6.3.1 Connection to a SERVOSTAR master, 5V signal level (X5) ........................................46
- A.4.031.1/16,3/2
III.6.3.2 Connection to encoders with 24V signal level (X3) ...............................................47
III.6.3.3 Connection to a sine-cosine encoder (X1)......................................................47
- A.4.031.1/44,43
III.7 Interface for stepper-motor controls (pulse-direction).......................................................48
- A.4.031.3/2
III.7.1 Connection to stepper-motor controller with 5V signal level (X5)........................................49
III.7.2 Connection to stepper-motor controller with 24V signal level (X3).......................................49
- A.4.031.1/10,45
III.8 RS232 interface, PC connection (X6) ...................................................................50
- A.4.031.1/13,14
III.9 CANopen Interface (X6) .............................................................................51
- A.4.031.1/15, 1/36
IV Setup
IV.1 Important notes....................................................................................53
IV.2 Parameter setting ..................................................................................55
IV.2.1 Multi-axis systems ............................................................................55
IV.2.1.1 Node address for CAN-bus .................................................................55
IV.2.1.2 Baud rate for CAN-bus.....................................................................55
- A.4.031.4/37
IV.2.2 Key operation / LED display ....................................................................56
IV.2.2.1 Key operation............................................................................56
IV.2.2.2 Status display............................................................................56
- A.4.031.3/4
IV.2.2.3 Standard menu structure ...................................................................57
IV.2.2.4 Extended menu structure...................................................................57
- A.4.031.3/3
IV.3 Error messages....................................................................................58
IV.4 Warning messages .................................................................................59
Drawing Page

Contents
SERVOSTAR®601...620 Installation Manual 5
Seidel 06/02 Contents
V Extensions / Accessories
V.1 Option -AS-, restart lock for personal safety..............................................................61
V.1.1 Advantages of the -AS- option...................................................................61
V.1.2 Functional description .........................................................................61
V.1.3 Block diagram ...............................................................................62
V.1.4 Signal diagram (sequence) .....................................................................62
- A.4.031.1/32,30
V.1.5 Installation / Setup............................................................................63
V.1.5.1 Safety instructions ........................................................................63
V.1.5.2 Functional test ...........................................................................63
V.1.5.3 Connection diagram.......................................................................63
- A.4.031.1/30
V.1.6 Application examples..........................................................................64
V.1.6.1 Moving single axes or axis-groups in setting-up operation .........................................64
V.1.6.2 Switching off grouped axes with separate working areas ..........................................64
V.1.6.2.1 Control circuit.......................................................................64
- A.4.031.1/311
V.1.6.2.2 Mains supply circuit ..................................................................65
- A.4.031.3/05
V.2 Expansion card -I/O-14/08-...........................................................................66
V.2.1 Fitting the expansion card ......................................................................66
V.2.2 Technical data ...............................................................................66
V.2.3 Light emitting diodes (LEDs) ....................................................................66
V.2.4 Position of the connectors ......................................................................67
- A.4.031.4/42
V.2.5 Connector assignments........................................................................68
V.2.6 Select motion task number (Sample) .............................................................68
V.2.7 Connection diagram ..........................................................................69
- A.4.012.4/33
V.3 Expansion card -PROFIBUS-.........................................................................70
V.3.1 Position of the connectors ......................................................................70
V.3.2 Fitting the expansion card ......................................................................70
- A.031.4/62
V.3.3 Connection technology ........................................................................71
V.3.4 Connection diagram ..........................................................................71
- A.4.031.1/41
V.4 Expansion card -SERCOS-...........................................................................72
V.4.1 Position of the connectors ......................................................................72
V.4.2 Fitting the expansion card ......................................................................72
- A.4.031.4/69
V.4.3 Light emitting diodes (LEDs) ....................................................................73
V.4.4 Connection technology ........................................................................73
V.4.5 Connection diagram ..........................................................................73
- A.4.037.4/02
V.5 Expansion module -2CAN- ...........................................................................74
V.5.1 Position of the connectors ......................................................................74
V.5.2 Fitting the expansion module....................................................................74
- A.4.031.4/70
V.5.3 Connection technology ........................................................................75
V.5.4 Connector assignments........................................................................75
V.5.5 Connection diagram ..........................................................................75
- A.4.037.4/08
V.6 Accessories.......................................................................................76
V.6.1 External 24V DC / 5A supply ....................................................................76
- A.4.037.4/07
V.6.2 External 24V DC / 20A supply...................................................................77
- A.4.012.4/33
V.6.3 External regen resistor BARxxx .................................................................78
- A.4.947.4/22
V.6.4 Motor choke box 3YL-20 .......................................................................79
- A.4.030.4/10
VI Appendix
VI.1 Transport, storage, maintenance, disposal...............................................................80
VI.2 Removing faults ...................................................................................81
VI.3 Glossary .........................................................................................83
VI.4 Order numbers ....................................................................................85
VI.5 Index............................................................................................86
Drawing Page

Safety Instructions
lOnly properly qualified personnel are permitted to perform activities such as
transport, installation, setup and maintenance. Properly qualified persons
are those who are familiar with the transport, assembly, installation, setup
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 BGV A2
lRead this documentation before carrying out installation and setup.
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 manufacturer of the machine must generate a hazard analysis for the
machine, and take appropriate measures to ensure that unforeseen
movements cannot cause injury or damage to any person or property.
lThe servo amplifiers contain electrostatically sensitive components which
may be damaged by incorrect handling. Ground yourself before touching the
servo amplifier by touching any unpainted metal surface. Avoid contact with
highly insulating materials (artificial 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 (176°F).
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 five 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®601...620 Installation Manual
Safety instructions 06/02 Seidel

European directives and standards
Servo amplifiers are components which are intended to be incorporated into electrical plants and machines for
industrial use.
When the servo amplifiers are built into machines or plants, 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
98/37/EC and the EC Directive on EMC (89/336/EEC). EN 60204 and EN 292 must also be observed.
The manufacturer of the machine must generate a hazard analysis for the machine, and take
appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any
person or property.
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
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 fulfilment by design of minimum requirements for electrically operated power
conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the
risk of fire, electric shock, or injury to persons, being caused by such equipment. The technical conformance
with the U.S. and Canadian standard is determined by an independent UL (cUL) inspector through the type
testing and regular check-ups.
Apart from the notes on installation and safety in the documentation, the customer does not have to observe
any other points in direct connection with the UL (cUL)-certification of the equipment.
UL 508C
UL 508C describes the fulfilment by design of minimum requirements for electrically 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 fulfilment by design of air and insulation creepage spacings for electrical equipment and
printed circuit boards.Directives and standards
SERVOSTAR®601...620 Installation Manual 7
Seidel 06/02 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
ðp. see page (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®601...620 Installation Manual
Abbreviations / symbols 06/02 Seidel
Abbrev. Meaning
AGND Analog ground
AS Restart Lock, option
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Européenne (EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN German Institute for industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EN European standard
ESD Electrostatic discharge
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
Abbrev Meaning
NI Zero pulse
NSTOP Limit-switch input for CCW rotation (left)
PC-AT Personal computer with 80x86 Processor
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input for CW rotation (right)
PWM Pulse-width modulation
RAM Volatile memory
Rregen Regen resistor
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD 426 A quad B encoder
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
SW/SETP. setpoint
UL Underwriters Laboratory
VAC AC voltage
VDC 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, 1.5 to 20 Amps nominal current).
Note:
SERVOSTAR 601 is sold in Europe only
In this manual you can find information about:
lTechnical data of the servo amplifiers Chapter I
lAssembly / installation Chapter II
lInterfaces Chapter III
lSetup the servo amplifier Chapter IV
lAccessories Chapter V
lTransport, storage, maintenance, disposal of the servo amplifiers 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, Acrobat Reader > 4.0) in Eng-
lish, German, Italian and French versions.
You can print 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
Setup : only by personnel with extensive knowledge of electrical
engineering / drive technology
SERVOSTAR®601...620 Installation Manual 9
Seidel 06/02 General

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 used as integral components of such equipment.
The manufacturer of the machine must generate a hazard analysis for the machine, and take
appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any
person or property.
The SERVOSTAR 600 family of servo amplifiers 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 5000 rms symmetrical amperes, 480VAC maxi-
mum].
The servo amplifiers must not be operated directly on power supply networks >230V without an
earth (ground) or with an asymmetrical earth (ground).
Connection to different mains supply networks (with additional isolating transformer) ðp.14.
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier may
not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
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, with closed-loop control of torque, speed and/or position. The rated volt-
age of the motors must be at least as high as the DC-link voltage of the servo amplifier.
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on page 17 and the dimensions shown on page 24. Ventilation or cool-
ing 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).
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.
Option -AS-, restart lock for personnel safety
The -AS- restart lock is exclusively intended to provide safety for personnel, by preventing the
restart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the
safety requirements of EN60204, EN292 and EN 954-1.
The -AS- restart lock must only be activated,
— when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).
— when the monitoring contacts (KSO1/2 and BTB/RTO) for all servo amplifiers are
wired into the control signal loop (to recognize a cable break).
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons :
1. - cleaning, maintenance and repair operations
- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,
and secured (main switch).
2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off
(by the emergency-stop button or the BTB-contact in the safety circuit).
10 SERVOSTAR®601...620 Installation Manual
General 06/02 Seidel

I.3 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
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, you will receive:
— SERVOSTAR 6xx
— mating connectors X3, X4, X0A, X0B, X7, X8
The mating SubD connectors and motor connector X9 are not part of the package!
— Assembly, Installation and Setup Instructions
— Online documentation on CD-ROM
— Setup softwareDRIVE.EXE on CD-ROM
Accessories: (must be ordered separately)
— AC synchron servomotor (linear or rotary)
— motor cable (pre-assembled), or both motor connectors separately, with motor cable as a
cut-off length
— feedback cable (pre-assembled, see application note “Cables and connectors”) or both
feedback connectors separately, with feedback cable as length
— motor choke 3YL-20 (ðp.79), for cable length above 25m
— external regen resistor (ðp.71)
— communications cable to the PC(ðp.50) or Y-adapter (ðp.55) for setting parameters of up
to 6 servo amplifiers from one PC
— power cable, control cables, fieldbus cables (as lengths) - A.4.028.6/10
SERVOSTAR®601...620 Installation Manual 11
Seidel 06/02 General
Customer Service
Europe Tel. +49 (0)203 / 9979 0
Italy Tel. +39 (0)362 / 594260
North America Tel. [phone]
Typenbezeichnung
Spannungsversorgung
Model Number
Power Supply
Ser. Nr
Nennstrom
Ser. No.
Nom. Current
Bemerkung
Schutzart
Comment
Encl.Rating
CONNECT-module
and options
Serial numberServo amplifier type
Electrical supply
Installed load Output current in S1 operation Enclosure Rating

I.4.2 The digital servo amplifiers of the series SERVOSTAR 600
Servoamplifiers of the SERVOSTAR 640/670 series are described in additional manuals.
Standard version
l6 current ratings (1.5 A -Europe only- ,3A,6A,10A,14A,20A)
lthree instrument widths : 70 mm for 1.5A up to 10A rated current
100 mm for 14A rated current
120 mm for 20A rated current
lwide range of rated voltage (3x208V –10% to 3x480V +10%)
lshield connection directly at the servo amplifier
ltwo analog setpoint inputs
lintegrated CANopen (default 500 kBaud), for integration into CAN bus systems and for
setting parameters for several amplifiers via the PC-interface of one amplifier
lintegrated RS232, electrically isolated, integrated pulse-direction interface
Open architecture
lopen hardware and software architecture
lslot for an expansion card
lintegrated macro language, including compiler
lprepared for all conceivable customer-specific extensions
Options
l-AS- built-in safety relay (personnel-safety starting lock-out), ðp. 61
lI/O expansion card, ðp. 66
lPROFIBUS DP expansion card, ðp. 70
lSERCOS expansion card, ðp. 72
l-2CAN- Expansion module, separated connectors for CAN bus and RS232, ðp. 74
lThird party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for fur-
ther information)
I.4.3 Operation directly from supply
Electrical supply
lDirectly off grounded 3 phase system,
230V-10% ... 480V+10%,50Hz,
208V-10% ... 480V+10%,60Hz
TN-system or TT-system with grounded neutral point, max. 5000 rms symmetrical amperes.
Connection to other mains supply networks only with insulating transformer ðp. 14
lFusing (e.g. fusible cutout) provided by the user
lsingle-phase supply (e.g. for setup) is possible
Auxiliary supply voltage 24VDC
lElectrically isolated, internal fusing (3.15 AT), from an external 24VDC psu, e.g. with insulat-
ing 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
12 SERVOSTAR®601...620 Installation Manual
General 06/02 Seidel

I.4.4 Digital servo amplifier concept
Operation and parameter setting
lWith our user-friendly software for setup 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 there is no PC available
lFully programmable via RS232 interface
Power section
lPower supply: B6 rectifier bridge, directly off 3-phase earthed (grounded)
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 260 — 900 VDC, can be switched in parallel
Completely digital control
lDigital current controller (space vector pulse-width modulation, 62.5 µs)
lFreely programmable digital speed controller (65µs or 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 and sine-cosine signals of a high-resolution encoder
lEncoder simulation (incremental or SSI)
Auxiliary 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 elec-
trical isolation
lSoft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
lTemperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)
SERVOSTAR®601...620 Installation Manual 13
Seidel 06/02 General

I.5 Connection to different mains supply networks
On this page you'll find all possible connection variations to different mains supply networks.
An isolating transformer is always required for 400...480V mains networks without
earth(ground) and for networks with asymmetrical earth(ground).
- A.4.031.1/52
14 SERVOSTAR®601...620 Installation Manual
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SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
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208V with 60Hz only
230...480V with 50Hz or 60Hz

I.6 Components of a servo system
SERVOSTAR®601...620 Installation Manual 15
Seidel 06/02 General
24V supply
fuses
drive contactor
terminals motor
SERVOSTAR 600
PC
Control / PLC
Option -AS-

I.7 Technical data
SERVOSTAR
Rated data DIM 601 603 606 610 610-30 614 620
Rated supply voltage (grounded system) V~ 3 x 230V-10% ... 480V+10%,50Hz
V~ 3 x 208V-10% ... 480V+10%,60Hz
Rated installed load for S1 operation kVA 1 2 4 7 7 10 14
Rated DC-link voltage V= 260 - 675
Rated output current (rms value, ±3%) Arms 1.5 3 6 10 10 14 20
Peak output current (max. ca. 5s, ±3%) Arms 3 6 12 20 30 (2s) 28 40
Clock frequency of the output stage kHz 8 (16 with VDCmax=400V)
Technical data for regen circuit — ðp.19
Overvoltage protection threshold 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 W 15
Dissipation at rated current (incl. power
supply losses, without regen dissipation) W 30 40 60 90 90 160 200
Internal fusing (external fusing ðp.16)
Auxiliary supply 24V — internal 3.15 AT
Regen resistor — internal, electronic
Inputs
Setpoint ½, resolution 14bit/12bit V ±10
Common-mode voltage max. V ±10
Input resistance to AGND kW20
Digital inputs V low 0...7 / high 12...36
mA 7
Aux. power supply, electrically isolated V 24 (-0% +15%)
without brake A 1
Digital outputs, open collector V max. 30
mA 10
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%) A1
Aux. power supply, electrically isolated with
brake (consider voltage loss!) V 24 (-0% +15%) A3
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 simulation, ROD (EEO) / SSI — SubD 9pole (plug)
Mechanical
Weight kg 4 5 7.5
Height without connectors mm 275
Width mm 70 100 120
Depth without connectors mm 265
I.7.1 External fusing
Fusible cutouts or similar
(Fuse UL time delay)
SERVOSTAR
601 / 603
SERVOSTAR
606 / 610
SERVOSTAR
614 / 620
AC supply FN1/2/3 6 AT (FRx-6) 10 AT (FRx-10) 20 AT (FRx-25)
24V supply FH1/2/3 max. 12 AF (max. FRx-12)
Regen resistor FB1/2 4 A (FRS-6) 6 A (FRS-6) 6 AF(FRS-10)
(x=SorS-Rfor480V applications x=NorN-Rfor230V applications)
16 SERVOSTAR®601...620 Installation Manual
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I.7.2 Allowable ambient conditions, ventilation, mounting position
Storage temperature/humidity, storage duration ðp.80
Transport temperature / humidity ðp.80
Supply voltage tolerances
Input power
Aux. power supply
min 3x 230V-10%AC / max 3x 480V+10%,50Hz
min 3x 208V-10% AC / max 3x 480V+10%,60Hz
24 VDC (-0% +15%)
Ambient temperature in operation
0to+45
oC (32 to 113 °F) at rated data
+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 EN60204/EN50178
Enclosure protection IP 20
Mounting position generally vertical. ðp.24
Ventilation forced convection by built-in fan
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
I.7.3 Conductor cross-sections
Following EN 60204 (for AWG: table 310-16 of the NEC 60°C or 75°C column), we recommend for
single-axis systems:
AC connection SERVOSTAR 601-610 : 1.5 mm² (14 awg)
SERVOSTAR 614/620 : 4 mm² (12 awg) 600V,105°C (221°F), twisted
DC-link SERVOSTAR 601-610 : 1.5 mm² (14 awg)
SERVOSTAR 614/620 : 4 mm² (12 awg) 600V,105°C (221°F), shielded for lengths>20cm
Motor cables up to 25 m length SERVOSTAR 601-610 : 1-1.5 mm² (14 awg)
SERVOSTAR 614/620 : 2.5 mm² (12 awg)
600V,105°C (221°F),
shielded,
capacitance <150pF/m
Motor cables 25 to 100 m length,
with motor choke 3YL-20
(consult our customer service)
SERVOSTAR 601-606 : 1 mm² (14 awg)
SERVOSTAR 610-620 : 2.5 mm² (12 awg)
600V,105°C (221°F),
shielded,
capacitance <150pF/m
Resolver, thermostat-motor 4x2x0.25 mm² (22awg) twisted pairs, shielded, max.100m,
capacitance <120pF/m
Encoder, thermostat-motor 7x2x0,25 mm² (22 awg) twisted pairs, shielded, max.50m,
capacitance <120pF/m
Setpoints, monitors, AGND 0.25 mm² (22 awg) twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20 awg)
Holding brake (motor) min. 0.75 mm² (18 awg), 600V,105°C (221°F), shielded, check voltage drop
+24 V / XGND max. 2.5 mm² (14 awg), check voltage drop
For multi-axis systems, please note the special operating conditions in your installation
Technical data for connection cables ðp.32 .Observe our application note “Cables and connectors”.
I.7.4 Recommended torque
Connector Recommended torque
X3, X4 0.3 Nm(2.25 in lb)
X0A, X0B, X7, X8, X9 1.3 Nm (12 in lb)
Ground bolt 3.5 Nm (31 in lb)
I.7.5 LED display
A 3-character LED display shows the amplifier status after switching on the 24V supply
(ðp.56). During operation of the amplifier via the keys on the front panel, the parameter and func-
tion numbers (ðp.57) are displayed, as well as the numbers of any errors which occur (ðp.58).
SERVOSTAR®601...620 Installation Manual 17
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I.8 Grounding system
AGND — ground for analog inputs/outputs, internal analog/µC ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder simulation, RS232, CAN, optically isolated
The potential isolation is shown in the block diagram (ðp.35).
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 BRAKE). In the diagram below you can see the time and func-
tional 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 (tbrH) and fall (tbrL) 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 on page 37 .
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
18 SERVOSTAR®601...620 Installation Manual
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SERVOSTAR 600

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 circuit (thresholds) are adjusted to the supply
voltage with the help of the setup software.
Our customer service can help you with the calculation of the regen power which is required. A
description of the interface can be found on page 37 .
Internal regen resistor : SERVOSTAR 601/603 66 W
SERVOSTAR 606-620 33 W
External regen resistor : SERVOSTAR 601-620 33 W
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 F02" (ðp.58). The
BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ðp.43)
2.- Several servo amplifiers coupled through the DC-link circuit (DC+, DC-)
Thanks to the built-in regen circuit with its patented power distribution, 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. Thecombined 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 (ðp.43).
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
Overvoltage F02 V 450
Continuous power of regen circuit (RBint) W 80 200
Continuous power of regen circuit (RBext) max. kW 0.25 0.75
Pulse power, internal (RBint max. 1s) kW 2.5 5
Pulse power, external (RBext max. 1s) kW 5
External regen resistor W33
3 x 400 V
Upper switch-on level of regen circuit V 720 - 750
Switch-off level of regen circuit V 680 - 710
Overvoltage F02 V 800
Continuous power of regen circuit (RBint) W 80 200
Continuous power of regen circuit (RBext) max. kW 0.4 1.2
Pulse power, internal (RBint max. 1s) kW 8 16
Pulse power, external (RBext max. 1s) kW 16
External regen resistor W33
3 x 480 V
Upper switch-on level of regen circuit V 840 - 870
Switch-off level of regen circuit V 800 - 830
Overvoltage F02 V 900
Continuous power of regen circuit (RBint) W 80 200
Continuous power of regen circuit (RBext) max. kW 0.5 1.5
Pulse power, internal (RBint max. 1s) kW 10.5 21
Pulse power, external (RBext max. 1s) kW 21
External regen resistor W33
SERVOSTAR®601...620 Installation Manual 19
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I.11 Switch-on and switch-off behavior
The diagram below illustrates the correct functional sequence for switching the servo amplifier on
and off.
I.11.1 Stop function to EN 60204 (VDE 0113)
If a fault occurs (ðp.58) 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 online help for the setup 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
switching off the output stage (ðp.18).
The -AS- option can be used to switch off the drive via a positive-action (approved by the Trade
Liability Association) safety relay, so that personnel safety is ensured at the drive shaft (ðp.61).
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”. - A.4.031.3/6
20 SERVOSTAR®601...620 Installation Manual
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DC-link