Kollmorgen SERVOSTAR 600 Servo Drive Field Troubleshooting and Maintenance Guide

Correct configuration of motor holding brake

SERVOSTAR 600 can directly control the built-in 24V/2A brake of the motor (without the need for external relays). But it must be noted that:

No functional safety! Vertical loads require additional mechanical brakes (compliant with EN 954-1 or higher).

The parameter BRAKE must be set to WITH BRAKE.

Timing: After the enable signal is removed, the driver slows down the speed to below 5rpm in a 10ms ramp, and then the brake output is turned on (engaged). The delay time (t_brH) and closing delay (t_brL) of the mechanical release of the brake vary depending on the motor, and it is necessary to refer to the motor manual.

Voltage drop inspection: When using long cables, it is necessary to measure the voltage of the brake terminal to ensure that it is not less than 20V (24V-0%+15%).

The brake output is at terminals 4 (+24V) and 5 (GND) of X9. Be aware that reversing the polarity will burn out the internal freewheeling diode.

Quick Debugging Guide (using DRIVE. EXE software)

Kollmorgen provides DRIVE. EXE setup software (running on Windows 95 to 7, not supporting Windows 10/11 native, but available for virtual machines). Basic process:

Hardware connection: Use a null mode cable to connect the RS232 port of the PC to X6. Connect the 24V auxiliary power supply.

Software startup: Double click DRIVE. EXE, select the COM port, and click ONLINE.

Motor selection: Click on Motor → Press F12 (software disabled), and select the matching Kollmorgen motor model from the drop-down list. If it is not in the list, please contact technical support to manually input the parameters.

Feedback configuration: Click Feedback → Select the correct FBTYPE:

0: Resolver

2：Hiperface

3：EnDat 2.1

6: SinCos has no data channel (wake&shake)

20：BiSS

Save and restart: Automatically cold start after parameters are written to EEPROM (approximately 10 seconds).

Jogging test: Hardware enabled (X3/15 connected to 24V), software enabled (Shift+F12). Select Service Mode: Speed, enter the safe speed value, and click Start. Observe the motor running smoothly, and the LED displays "E xx".

Optimize parameters: Use the Oscilloscope function to collect speed/current curves, adjust Kp and Tn (integration time) until there is no overshoot in the response.

Common debugging issues:

Motor "spitting" sound: The encoder cable is not properly connected or the FBTYPE is incorrect.

Report F04: Check the wiring of the rotary transformer/encoder. For Hiperface, it is necessary to confirm that the Encoder+and Encoder - terminal resistors (120 Ω) have been correctly connected.

Software cannot connect: Check COM port, cable, 24V power supply. Some USB to RS232 adapters are unstable, it is recommended to use a native serial port.

Braking circuit and multi axis energy management

10.1 Internal and External Braking Resistors

Internal resistance: only suitable for occasional deceleration. The continuous braking power is only 80W (S601-603) or 200W (S606-620). Exceeding this value will cause the resistor to overheat and report "F18".

External resistance: must be 33 Ω, with a maximum continuous power of 1.5kW (@ 480V). Connect the wires to X8 (+BR, - BR). Users are required to provide their own fuses (6AT for S601-603, 10AT for S606-620).

Braking threshold: automatically adjusted according to the main power supply voltage (400V: 720V on, 480V: 840V on).

10.2 Common DC bus multi axis system

Multiple SERVOSTAR 600 can share braking energy by parallel connecting DC bus (+DC/- DC) through X7 terminal. requirements

All amplifiers must be connected to the same power grid (with the same voltage).

The sum of parallel total currents shall not exceed 40A.

Bus cable length ≤ 200mm (unshielded) or longer requires shielding.

When energy feedback occurs, the braking chopper of all amplifiers automatically distributes the load evenly. If any machine stops due to overvoltage protection (F02) or brake power exceeding the limit (F18), its BTB/RTO contacts will disconnect, and the upper computer can cut off the main contactor accordingly.

Multi axis system CAN bus settings

SERVOSTAR 600 has a built-in CANopen interface (default 500kbps) and supports DS301 and DS402. During multi axis debugging, a Y-shaped cable (SR6Y) can be used to connect up to 6 amplifiers to one PC.

Set node address:

Press and hold the right button to power on and enter the extended menu.

Select nAdr from the menu and use the ▲/▼ keys to set the address (1-127).

Set bAud again (baud rate encoding: 0=125k, 1=250k, 2=500k, 3=1M).

Power off and restart will take effect.

Common CAN faults:

Report F23 (CAN bus closed): Check the terminal resistance (120 Ω at both ends), bus cable impedance, and ensure a single grounding point.

Communication instability: Reduce baud rate and check the grounding of the shielding layer.

Optional security feature - AS (restart lock)

Option "- AS" provides a safety relay that complies with EN 954-1 (Category 1 or 3) to prevent accidental restart of the drive. It does not cut off the main power supply, but safely shuts off the output stage drive power supply and shorts the internal given signal.