SERVOSTAR 600 User Guide

Systems
Technical
Publication

SERVOSTAR

®

600

with Kollmorgen GOLDLINE™

BH/MH Motors

Kollmorgen SERVOST AR®600 Amplifier

• 400 to 480 Volt Three Phase
AC Input Power

• Resolver Feedback

• Integrated Power Supply

• Fully Digital Control

• CE, UL, cUL

The SERVOSTAR 600 amplifier is a compact, fully digital
drive-amplifier designed to simplify installation, system set­up, and system reliability.

FEATURES:

Servo Control

• Easy to tune servo loops

• Advanced sinewave commutation technology
provides smooth, precise low-speed control and
high speed performance

• Velocity loop bandwidths to 400 Hz

• DQ Current control increases high speed peak torque
performance for faster cycle rates

• Space Vector Modulation reduces normal power stage
switching loses

• Torque angle control enhances motor performance

• Fully digital control loops

• Compact and attractive rugged metal package for space­saving, modern appearance - metal package minimizes
electrical noise emmision & suceptability

• Command modes: Torque, Velocity, Position, Electronic
Gearing Pulse Following, and Motion Task

• Five current ratings: 3, 6, 10, 14, and 20 amp RMS/phase

continuous

• 2 to 1 peak/continuous current rating (5 second at peak)

• Run time counter

Easy Connectivity

• Built in encoder equivalent output can eliminate the need
for an additional position feedback device

• RS-232 Communication

• Unique multi-drop configuration allows a PC or PLC to

communicate to multiple SER VOSTAR600 amplifiers via
single RS-232 connection

• SERVOSTAR 600’s versatile communication capabilities

make it easy to integrate machine control data directly
from the factory floor to your information system

• Analog ±10V, pulse/direction, master encoder, and serial
port, I/O command options

Robust Design

• ESD rugged circuit design and fully metallic enclosure

• Full protection against short circuit, overvoltage,
undervoltage, heatsink overtemperature, motor overtem­perature, overspeed, overcurrent, and feedback loss

• UL , cUL listed, and CE

• Built-in line filter for CE

• Flash memory

Windows Start-up Environment

• Graphical environment simplifies set up

• PC “Oscilloscope” for measuring real-time

motion performance

• Interactive MOTIONTASK Programming

Configurable I/O

• 2 separate analog inputs (14 and 12 bit resolution)
configurable to 6 different command modes

• 2 analog outputs

• 4 digital inputs

• 2 digital outputs

• I/O can be configured to a variety of functions to
customize the SERVOSTAR 600 to individual machines

I/O Option Card (see page 5)

• Adds 14 additional digital inputs and 8 digital outputs

• All I/O are optically isolated

• Simple plug in to top face of Amplifier

Regenerative Power Sharing

• Patented circuitry allows the DC bus from two or more
amplifiers to be connected together allowing regen power
to be shared among multiple drives

Built in Parameter Unit

• Perform basic drive set up without
the need for a PC

• Provides diagnostic information

• Allows motor selection from
parameters store in memory

Built in Safety Relay

• Switches off the power stage to ensure personnel safety
and prevents an unintended restart of the drive, even in
the event of a fault

• Allows DC bus to remain on

INTRODUCTION

SERVOSTAR®600

KOLLMORGEN

2

INCREMENT ALMOVE

ABSOLUTE MOVE

ELECTRONIC GEARING 5:1 (MASTER/SLAVE)

MACRO MOVE

• material handling

• bottle making

• packaging

• soft positioning

• robot

• conveyor belt controlling

• fast positioning

• special cleaning process

• part selection

• glass processing

• robot

• wirepuller

• textile industry

• printing

• electronics

• web converting

• cut to length

SERVOSTAR 600

KOLLMORGEN

INTRODUCTION

3

Motion Capabilities

The SER VOSTAR 600 can be configured to perform motion
control that normally requires a fully programmable drive
with a motion language. With the SERVOSTAR 600 there is
no programming language to learn; the user only “fill in the
blanks” to create common motion tasks

• Up to 180 motion task can be stored in
permanent memory

• Motion Tasked can be linked together.

• 10 types of homing

• Speed profile/registration control

• Adjustable S curve acceleration

• Absolute and relative (index) moves

• Linking of motion task (sequencing)

• Adjustable Following-Error window

• Adjustable window for the In Position signal
Linked motion tasks are started:

• Immediately upon reaching a targeted position

• Digital Input upon reaching the targeted position

• APreset Time Delayafter the targeted position is reached

Motion Examples Application Examples

Velocity

Time

Velocity

Position

Velocity

Time

Velocity

Time

CONNECTOR INFORMATION

SERVOSTAR 600

AGND
BTB/RTO
BTB/RTO
SW/SETP.1+
SW/SETP.1­SW/SETP.2+
SW/SETP.2­MONITOR1
MONITOR2
AGND
DIGITAL-IN1
DIGITAL-IN2
PSTOP
NSTOP
ENABLE
DIGITAL-OUT1
DIGITAL-OUT2
DGND

1
2
3
4

X3 I/O

5
6
7
8

9
10
11
12
13
14
15
16
17
18

+24V 1
+24V 2
XGND 3
XGND 4

1
2
3
4

X4 24V INPUT

+8V
CANL
RxD

TxD

N.C.
CANH
PGND

X6 PC

1

6

2

7

3

8

4

9

5

PGND
B+ (DATA)
Motor +
B- (/DATA)
Motor ­+5V
A- (CLK)

N.C.
A+ (/CLK)

X5 Encoder Equivalent Output

1

6

2

7

3

8

4

9

5

R2
R1
S3
S1
S4
S2
THERMOSTAT
THERMOSTAT
SHIELD

X2 RESOLVER

5

9

4

8

3

7

2

6

1

L1

L2

L3

PE

-RB+R

Bint

R

BEXT

n.c.

1

2

3

4

XO

B

X8 R

REGEN

XO

A

X7 DC-circuit

Brake-

Brake+PEU2

V2

W2

1

2

3

4

5

6

X9 motor/brake

1

2

3

4

L1

L2

L3

PE

+DC

-DC

+DC

-DC

1

2

3

4

1

2

3

4

Connectors underneath:

KSO1 1
KSO2 2
KSI- 3
KSI+ 4

1
2
3
4

X10 MOTOR

DISCONNECT

RELAY

KOLLMORGEN

4

CONNECTOR POSITION

CONNECTOR ASSIGNMENTS

Connector Connector

X11A X11B

Terminal Fn. Description Terminal Fn. Description

1 In A0 1 In MT_Restart
2 In A1 2 In Start_MT
3 In A2 3 Out InPos
4 In A3 4 Out Next-InPos
5 In A4 5 Out Sfault
6 In A5 6 Out PosReg1
7 In A6 7 Out PosReg2
8 In A7 8 Out PosReg3

9 In Reference 9 Out PosReg4
10 In Sfault_clear 10 Out Reserve
11 In Start_MT Next 11 Sup. 24V DC
12 In Start_Jog v=x 12 Sup. I/O-GND

SERVOSTAR 600

I/O OPTION CARD

ERR I/O-14/08 X11A

X11

X11B

12112124V

The I/O option card is an extremely economical way of operating
servo controllers under position control for simple automation tasks.

14 additional digital inputs permit the selection and start of the motion
tasks that are stored in the motion-task memory of the SERVOSTAR

®

600. All the important functions for the position controller that
is integrated into the servo controller can thus be operated from a
small, independent control system.

8 digital outputs report the status of the drive to the higher-level control.

KOLLMORGEN

5

AMPLIFIER SPECIFICATIONS

SERVOSTAR 600

Electrical characteristics

• Closed loop velocity bandwidth up to 400 Hz

• Motor current ripple frequency 16 kHz

• Switching frequency: 8 kHz

• Long term speed regulation (0.01%)

• Position loop update rate 250 µs (4 kHz)

• Velocity loop update rate 250 µs (4 kHz)

• Commutation update rate 62.5 µs (16 kHz)

• SVM Current loop update rate 62.5 µs (16 kHz)

Fault protection

• Output phase to phase and phase to ground short circuit protection

• Overvoltage

• Undervoltage

• Overtemperature (motor and amplifier)

• Overspeed

• Overcurrent

• Feedback loss

• Foldback

• Supply loss

• Excessive position error

Environmental

• Operation range

- Ambient 0 to 45°C (derated above ambient up to 55˚C)

- Storage -25°C to 55°C

• Humidity (non-condensing) max 85%

Velocity Loop Compensation

• PI Plus controller (PDFF Format) or PI controller

• Field tunable and digital repeatability

Position Loop Compensation

• Proportional loop with Feed Forward

Analog I/O

• 2 Configurable Inputs: ±10V, 12 and 14 bit resolution

• 2 Configurable Outputs: ±10V, 10 bit resolution

Digital I/O

• 4 Configurable Inputs: 24 volts, PLC-compatible

• 2 Configurable Outputs: 24 volts (open collector), PLC-compatible

• Remote enable Input: 24V, PLC-compatible

Drive Status Relay (BTB/RTO)

• Contact closure rated for 0.5 amps, 24 Volt

Pulse or Master/Slave Input

• Pulse command: pulse/direction or quadrature encoder format

• RS-485 receivers

• Up to 16 slave amplifiers can be connected together

• Input ratio is configurable

Position Feedback For User (Encoder Equivalent Output Port)

• Configurable to Encoder Equivalent (ROD) or SSI format

• Encoder Equivalent (ROD): A Quad B with Marker (zero) pulse,
RS-485 driver

• SSI (serial synchronous interface): max clock frequency is 1.5 Mhz,
RS-485 driver

• Programmable resolution

I/O Extension Card (Option)

• Field Installable

• 14 Digital Inputs 24V, PLC-compatible

• 8 Digital Outputs 24V, PLC-compatible

• 24V PLC Interface

Communications

• RS-232 Interface

Operational modes

• Torque control — from analog or digital command

• Velocity control — from analog or digital command

• Pulse following

• Gearing from quad encoder input

• Motion Task

• Serial Commands

Diagnostics

• 3 digit Seven segment LED display

• Error history log

• Internal variable monitoring

• PC scope

Motor Feedback

• Resolver

Motor Brake Control

• 24V optional holding brake in the motor can be controlled directly by
the SERVOSTAR 600

Power Inputs

• 400 to 480VAC 3phase, 50 or 60 Hz, built in line filter for
CE requirements

• 24 VDC @ 1 amp (3 amps with brake) For Logic

Power Regeneration Options

• Internal

• External - using BAR housed resistors

• Bus Sharing - Distributes regen power among multiple amplifiers

Built in Parameter Unit

• Displays drive status information

• Parameters: Drive Address, baud rate, Velocity loop tuning, Motor
type, Position output information format, brake, regen type

Model Output Continuous Output Peak Internal Power AC Input Rated Continuous Continuous

Current Per Phase Current Per Dissipation Line Input Internal External

(RMS/phase) Phase (Watts) Voltage Power (KVA) Regen Power Regen Power

(5 sec) (3 phase) @480 V (Watts) (Watts)

S603 3 6 40 400-480 2.3 80 500
S606 6 12 60 400-480 4.6 200 1,500
S610 10 20 90 400-480 8.1 200 1,500
S614 14 28 160 400-480 11.6 200 1,500
S620 20 40 200 400-480 16.6 200 1,500

Amplifier Ratings

KOLLMORGEN • keyfaith • 0755-83288220

6

DIMENSIONS/ORDERING INFORMATION

Resistive Regeneration Sizing

Shunt regeneration is required to dissipate energy that is pumped back
into the DC bus during load deceleration. The amount of shunt regener­ation required is a function of the sum of simultaneously decelerating
loads. The loads need to be defined in terms of system inertia, maximum
speed, and deceleration time. In addition, the duty cycle must be known.
Application Note AS6000H details a calculation method to determine
proper regeneration sizing.

SERVOSTAR 600

SERVOSTAR 600 DIMENSIONS

S603/06/10

Dimensions in mm (inches)

Model Watts Ohms Amplifiers A B C D E1 E2 F G

BAR-250 250 33 S603, S606, S610 330(12.99) 390(15.35) 412(16.22) 66(2.60) 44(1.73) 35(1.38) 4,5x9(.20x.35) 77(3.03)
BAR-500 500 33 S603, S606, S610 400(15.75) 426(16.77) 486(19.13) 92(3.62) 64(2.52) 64(2.52) 6,5x9(.20x.35) 120(4.72)
BAR-1500 1500 33 S606, S610 500(19.69) 526(20.71) 586(23.07) 185(7.28) 150(5.91) 150(5.91) 6,5x9(.20x.35) 120(4.72)

DIM. “A”

3 AMP 70 (2.8)

6 AMP 70 (2.8)
10 AMP 70 (2.8)
14 AMP 100 (3.9)
20 AMP 120 (4.7)

KOLLMORGEN • keyfaith • 0755-83288220

7

F

E2

E1

D

A

B

C

G

265 (10.4)

with connector:

273 (10.7)

275

(10.8)

"A"

325

(12.8)

ADDITIONAL FUNCTIONS

KOLLMORGEN • keyfaith • 0755-83288220

8

MOTIONLINK SERVOSTAR 600

PC Oscilloscope:
For closely evaluating system
performance MOTIONLINK includes
the functionality of an oscilloscope.
Y ou can very easily excite the load then
review performance graphically on
your computer screen.

Tuning:
Velocity and position loop tuning is
straight forward, allowing the novice user
to achieve the best machine performance.

Auto Set-up:
MOTIONLINK auto set-up environment

walks even the first time user through line
voltage, motor, operation mode and load
tuning to make system configuration
friendly and fast.

Direct Terminal Mode:
This mode turns your computer into a
“dumb terminal.” Variables or parameters
can be monitored and changed using
the SERVOSTAR

600’s

command
language. This mode is ideal for
advanced users who want to get directly
in the “heart” of the SERVOSTAR

600

.

Monitor Mode:
Allows you to monitor key operation
variables. Speed, torque, and other
variables can be viewed in real
PSEUDO time in linear gauge format.

Configuring I/O:
Inputs & Outputs are configurable to a
wide variety of functions to configure
the

SERVOSTAR 600

to individual

machine needs.

MOTIONLINK®for Windows takes the fear out of setting up a servo system. Designed for the novice as well as
the advanced user, MOTIONLINK lets users quickly set-up and fine tune system performance.

MOTIONLINK has many other features including: • Saving drive configuration to disk

• Activating position limits

• Displaying amplifier status

• Setting acceleration amps

• Limiting max speed or torque

KOLLMORGEN • keyfaith • 0755-83288220

9

CONFIGURABLE AND READABLE FUNCTIONS

Basic Set Up

• Input Power

• Main Phase Missing

• Max Regen Power

• Internal or External Regen Resistor

• Drive Name and Serial No *

• Run Time *

• Firmware Version *

• Hardware Version *

Drive Operation Modes

• Digital Speed

• Analog Speed

• Digital Torque

• Analog Torque

• Electronic Gearing

• External Position Control

• Internal Position - MotionTasks

Digital Scope Tool

• Record real time data

• Display on PC Oscilloscope

• Start Current Move

• Start Jog Move

• Start Position Move

• Record Start

• Adjust Trigger

• Recording in Process *

• Cancel Recording

• Recording Done *

• Transmit Data to PC Oscilloscope

Feedback Configuration

Resolvers:

• Number of Poles

• Resolver-zero offsetting

• Resolver Bandwidth

• Feedback Gain

Drive Monitoring

• Regen Wattage *

• Actual Position (within one rev) *

• Actual Position *

• Actual Speed *

• Command Speed *

• Current Foldback Level *

• Drive Temperature *

• Heatsink Temperature *

• Effective Current *

• D Current Component *

• Q Current Component *

• Analog Commands *

• DC Bus voltage *

MOTIONLINK

Velocity Control

• Speed Command Scaling

• Speed Command Ramp (Accel)

• Speed Command Ramp (Decel)

• Maximum Speed

• Proportional Gain

• Integral Time Constant

• Feedback Filter

• Motion direction

Current Control

• Current Command Scaling

• Current Foldback

• Cont Drive Current

• Peak Drive Current

• Proportional Gain

• Integral Time Constant

Motor Configuration

• Motor Name and Number *

• Motor Continuous Current

• Motor Peak Current

• Motor Inductance

• Motor Poles

• Motor Max Speed

• Motor Brake (with or without)

• Motor Adaptive Gain

• Motor Speed Angle Advance

• Motor Torque Angle Advance

Drive Status

• Actual Error *

• Actual Warning *

• Last 10 Errors *

• Rate of Occurrence *

• Drive Reset Command

Others

• Stop Drive

• Drive Enable

• Drive Disable

* READ ONLY

Motion Homing/Jogging

• Direction

• Homing Type

• Reference Offset

• Start Command

• Jog Command

• Homing Velocity

• Jog Velocity

Communications

• RS-232 from PC

• Drive Address

• Message Types from Drive

• Prompt Configuration

• Scan

Position Output (Motor)

• Format: Off, Encoder equivalent

output or SSI format

Encoder Equivalent Output

• Resolution of Encoder Equiv Output

• Marker Pulse Offset

SSI

• Baud rate of SSI Output

• Format type (binary or gray code)

• Standard or Inverted Clock

• Input Edge Positive or Negative

Position Control

• Proportional Gain

• Integral Action Time

• Feed Forward

• Following Error *

Motion-Gear Mode

• GearMode Type:

• Encoder Follower

• Pulse Follower