Kollmorgen SERVOSTAR 600 Servo Drive Field Troubleshooting and Maintenance Guide

Kollmorgen SERVOSTAR 600 Servo Drive Field Troubleshooting and Maintenance Guide

Introduction: Application of SERVOSTAR 600 Series in Industrial Servo

In the fields of automated production lines, packaging machinery, machine tools, robots, and material handling, Kollmorgen's SERVOSTAR 600 series digital servo amplifiers (covering models 601 to 620, rated current 1.5A to 20A) have become a common choice for driving brushless synchronous servo motors due to their full digital control, integrated CANopen, multiple feedback interfaces, and flexible expansion capabilities. However, on-site engineers often encounter problems such as driver alarms, motor non rotation, abnormal oscillation, and communication interruptions in daily operation and maintenance. This article is based on the official technical manual and combines practical on-site experience to provide you with a complete technical guide from hardware identification, safe installation, fault code analysis, parameter debugging, and option application.

Hardware Overview and Selection Identification

The SERVOSTAR 600 series includes the following standard models, all of which support 3 × 208-480V AC power supply (grounded TN/TT system), built-in EMC filter, and overvoltage category III.

Model Rated output current (Arms) Peak current (Arms) Width (mm) Built in braking resistor (Ω) Typical application scenarios

S601 1.5 3 70 66 Low power positioning, laboratory equipment

S603 3 6 70 66 Small packaging, conveyor belt

S606 6 12 70 33 General automation, robotic arm

S610 10 20 70 33 CNC machine tools, engraving machines

S610-30 10 30 (2s) 70 33 high overload demand

S614 14 28 100 33 Large packaging, stamping and feeding

S620 20 20 40 120 33 Heavy Duty, Centrifuge

Key identification points:

The model label is located on the side of the amplifier and includes the hardware version number (HWR). Ensure that the firmware version is ≥ 8.50 (corresponding to HWR 05.30/05.40).

The resistance value of the external braking resistor is uniformly 33 Ω (S601-620 can be used), and the continuous power needs to be selected according to the working conditions (maximum) 1.5kW@480V ）.

Key points for safe installation and wiring

3.1 Warning of dangerous voltage

The DC bus voltage of SERVOSTAR 600 can reach up to 900V DC. After cutting off the main power supply, the capacitor can still maintain dangerous voltage for up to 5 minutes. Before operation, it is necessary to:

Disconnect the main switch and lock it with a tag.

After waiting for 5 minutes, measure the DC bus voltage (X7 terminal+DC/- DC) and confirm that it is below 50V.

It is strictly prohibited to plug or unplug any connectors with power on (especially motor interface X9 and encoder interface X1/X2).

3.2 Leakage Current and Grounding

Due to the leakage current of PE>3.5mA (typical formula: I2 leak=n × 20mA+L × 1mA/m @ 8kHz carrier frequency), a dual PE connection or PE wire cross-sectional area>10mm ² must be used. Suggestion:

Connect the two PE terminals (X0A and X0B) that come with the device in parallel for grounding.

The installation board of the control cabinet must be a conductive bare board (not painted) to ensure high frequency grounding and low impedance.

3.3 24V auxiliary power supply

The X4 terminal requires external 24V DC power supply (-0%+15%). Current demand:

No brake: maximum 1A

With brake: maximum 3A (pay attention to cable voltage drop)

Built in 3.15AT fuse, polarity reverse protection.

3.4 Cable selection and shielding

Maximum length requirement for cable type

Motor power cable ≤ 25m (without choke coil); 25-100m (with 3YL choke) shielding, capacitance<150pF/m

Encoder cable (SinCos/EnDet) ≤ 50m twisted pair shielded, capacitance<120pF/m

Rotating transformer cable ≤ 100m 4 × 2 × 0.25mm ², shielded

Brake cable with motor cable of at least 0.75mm ², shielded

Shielding connection technique: Use the shielding clip (cable tie to fix the shielding layer) on the front board of the amplifier to ensure 360 ° large-area contact. Do not twist the shielded wire into a "pigtail" and ground it - the high-frequency EMC effect will be severely reduced.

LED status display and operation

There is a 3-character LED display on the front of the amplifier, used to indicate status, parameter editing, and error codes.

4.1 Normal state display

Display meaning

1. (Flashing) Waiting for power on (Main power not turned on, only 24V)

E+current value (e.g. E3) output stage enabled, motor has torque

The main power supply for P+current value has been connected, and the DC bus is live

8.8.8 Software version number (e.g. firmware 8.50)

4.2 Button operation

▲/▼ keys: Short press to change a value, quickly double-click to change a ten digit value.

Right click+left click: Confirm input or return function name.

By pressing the button, you can enter the standard menu (display parameters, status) or the extended menu (power on by holding down the right button) to modify the node address and baud rate.

Comprehensive analysis of fault code (Fxx)

When the amplifier detects a serious error, the output stage immediately shuts down, the BTB/RTO contacts open, and the LED displays Fxx. The following are the most common fault codes and their solutions on site: