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:

Common causes and solutions for code names

F01 radiator overheating environment temperature>45 ° C, fan failure, insufficient installation spacing. Check cabinet ventilation, clean fan filter, confirm reserved ≥ 100mm heat dissipation space above and below

F02 bus overvoltage, insufficient braking power, rapid deceleration, external braking resistor not connected or disconnected. Measure the DC bus voltage (normal should be...)< 450V@230V Input< 900V@480V Input). Check the X8 terminal brake resistor wiring and resistance value (33 Ω)

F04 feedback fault encoder cable breakage, shielding damage, connector looseness inspection X1 or X2 terminal. For Hiperface/EnDet, verify 5V power supply. Try replacing the cable

F05 bus undervoltage input phase loss, power supply voltage too low, fuse blown, measure L1/L2/L3 voltage, check external fuses (use 10AT for S606/610, 20AT for S614/620)

F06 motor overheating motor overload, temperature sensor disconnected (PTC), measure motor temperature with hand feel. Check the wiring of the thermistor (via X1 or X2). Reduce load or increase cooling

F11 brake fault: Short circuit or open circuit in the brake coil. Measure the voltage of the motor brake terminal (24V). Check the 4/5 wiring of X9 terminal, with a maximum holding current of 2A

Check the X9 connector for broken or poor contact of the F12 motor power line, and measure the U/V/W phase resistance (which should be balanced). Check the motor side terminals

F16 main power supply phase loss (BTB) input side is missing two or three phases. Check the main contactor and power supply. If single-phase debugging is required, phase loss detection (PMODE) can be performed through parameter shielding

F19 input phase loss (warning can be configured as fault) is missing the same F16. If the parameter is set to "n05" (warning), the machine will not shut down

F25 commutation error encoder initial phase error, or motor phase sequence reversal check feedback parameter (FBTYPE). For SinCos without data channel type, execute "wake&shake" or correctly set MPHASE

F26 limit switch triggers mechanical collision with hardware limit (PSTOP/NSTOP open circuit). Check if X3 terminal 13/14 is at high level (24V). If triggered, manually move out of the limit range and reset

Note: Faults marked with * (F01, F02, F05, F08, F16, F19, F30) can be cleared through the ASCII command CLRFAULT without the need for a complete power outage and restart.

Warning code (nxx) parsing

Warning does not close the output stage, but prompts potential issues:

Code meaning processing

Confirm whether the continuous power of the braking resistor is sufficient when the n02 braking power reaches the preset limit. For S606-620, the continuous power of the internal resistor is only 200W, and frequent braking requires the external connection of a larger power resistor (up to 1.5kW)

N05 input phase loss (warning) check power supply. If it is a temporary phase loss, it can be ignored, but the source needs to be investigated

N10/n11 PSTOP/NSTOP limit activation check limit switch and wiring. Usually a normally closed contact

N14 SinCos commutation incomplete (wake&shake) vertical axis strictly prohibited from using this mode! If necessary, ensure that the motor can shake freely, otherwise use an encoder with a data channel (EnDat/Hiperface) instead

Common on-site troubleshooting table (based on manual summary)

Possible causes and measures for the phenomenon

Motor not turning enable signal not applied (ENABLE=0V) X3/15+24V (high-level enable)

Check the voltage (24V) at terminal 4/5 of X9 if the brake is not released. Brake release requires a delay of approximately 100ms (parameter setting)

Wrong motor phase sequence, swapping any two phases (such as U and V)

Encoder wiring error check X1/X2 pin definition, use Kollmorgen prefabricated cable

Motor oscillation speed loop Kp is too high. Use DRIVE. EXE software to reduce Kp (speed loop proportional gain) and observe the response

If AGND is not connected to the controller ground, X3/1 (AGND) must be short circuited to the analog ground of the upper computer

Replace the damaged shielding layer of the feedback cable and ensure that the shielding layer is grounded through the front plate shielding clip

Driver following error (F03): If Ipeak or Irms is set too low, increase Ipeak (peak current limit), but not exceed the rated value of the motor

The acceleration and deceleration slope is too steep, which prolongs the speed slope time (parameters ACC/DEC)

Motor overheating Ims (effective current) exceeds the rated value of the motor, reducing the load or increasing the motor model; Check the I ² t threshold

Communication failure (RS232) using a straight line instead of a cross line requires the use of a null modem cable (2-3 cross, 5 straight)

COM port occupied by other programs. Close other software and select COM port again

The external resistance value of the brake circuit fails and does not match (must be 33 Ω). The measured resistance at both ends of X8 should be 33 ± 5%

Disconnect the brake resistor fuse and check the external fuse (10 AT for S606/610, 10 AT for S614/620)

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.

Application points:

It must be activated only when the motor is stationary (speed=0), the enable is removed, and the suspended load is mechanically locked.

The monitoring contacts (KSO1/2) must be connected in series to the control circuit, otherwise internal relay faults cannot be detected.

Cannot replace Emergency Stop or Maintenance Isolation.

The wiring terminal is X10 (24V coil input+monitoring contact output). Specific circuit examples (category 1 or 3) can be found on pages 97-98 of the manual.

Maintenance and Storage

13.1 Re forming of capacitors

If the amplifier is stored for more than 1 year, the DC bus electrolytic capacitor needs to be reactivated:

Disconnect all loads and encoder connections.

Connect only single-phase 230V AC to L1/L2 terminals (note: do not connect L3).

Power on for about 30 minutes.

This process will restore the capacitance characteristics and prevent damage when powered on.

13.2 Cleaning

The shell can be wiped with isopropanol, but be sure to turn off the power and wait for at least 30 minutes for it to evaporate before running.

Clean the fan protective net with a dry brush. It is strictly prohibited to spray liquids into the interior of the equipment.

13.3 Replacement

When replacing a faulty amplifier, it is necessary to record the original parameters (uploaded and saved through DRIVE. EXE). The new amplifier needs to use the same firmware version and hardware version (HWR), otherwise it may be incompatible.