KOLLMORGEN SERVOSTAR 610-AS Retrofit-Ready AC Servo Drive for 600 Series

KOLLMORGEN SERVOSTAR 610-AS Retrofit-Ready AC Servo Drive for 600 Series Control Systems

The KOLLMORGEN SERVOSTAR 610-AS is a high-performance AC servo drive engineered for seamless integration into existing SERVOSTAR 600 series control architectures. Whether you are managing a planned system upgrade, responding to an end-of-life notification on legacy drives, or executing an emergency replacement after an unplanned failure, the SERVOSTAR 610-AS delivers the electrical compatibility, communication flexibility, and mechanical form factor required to minimize engineering rework and reduce total downtime. With 10A continuous output current, integrated Safe Torque Off (STO) safety function, and support for CANopen and PROFIBUS-DP fieldbus protocols, this drive is purpose-built for industrial retrofit projects across machine tool, packaging, material handling, and process automation environments.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful retrofit of the SERVOSTAR 610-AS into an existing control cabinet begins with a thorough audit of the current installation. Engineers should first verify the DC bus power supply capacity — the existing KOLLMORGEN PST power supply module or equivalent regenerative supply must be rated to support the 610-AS inrush and continuous load profile. Terminal wiring on the X3 motor power connector and X1 control connector follows the same pinout convention as the legacy SERVOSTAR 600 series, which significantly reduces rewiring time; however, the STO wiring on X4 must be reviewed and updated if the original installation used a simple hardware enable relay rather than a certified STO circuit.

Backplane and rack integration should be confirmed before installation. If the existing control cabinet uses a KOLLMORGEN multi-axis backplane or shared DC bus bar, verify that the 610-AS bus bar connector aligns with the installed rail pitch. Module addressing — particularly node ID assignment for CANopen or PROFIBUS station address — must be configured via the onboard DIP switches or through KOLLMORGEN WorkBench prior to powering the axis. Failure to match the original node address will cause the PLC — typically a Siemens S7-300, S7-400, or equivalent — to report a communication fault on startup.

Program compatibility is a critical checkpoint. If the machine program was developed using KOLLMORGEN’s legacy S600 DriveGUI parameter set, the parameter file must be exported and re-imported into WorkBench, with attention paid to changes in parameter numbering between firmware generations. HMI screens referencing drive status words, fault codes, or axis state variables via PROFIBUS-DP should be validated against the 610-AS GSD file to confirm that data block offsets remain consistent. In many retrofit projects, the KOLLMORGEN AKD series or SERVOSTAR S300 drives are used in adjacent axes within the same cabinet, and the 610-AS communicates seamlessly with these platforms over a shared CANopen network.

For I/O-intensive applications, the 610-AS supports expansion through the KOLLMORGEN I/O expansion module connected via the X6 auxiliary interface, allowing additional digital inputs and outputs without modifying the main PLC I/O rack. Communication link integrity between the drive and the upstream controller — whether a Siemens ET 200S distributed I/O node, a Beckhoff EtherCAT coupler, or a dedicated motion controller — should be verified using the drive’s built-in diagnostic LEDs and WorkBench oscilloscope function before returning the axis to production. A KOLLMORGEN programming cable (USB-to-RS232 adapter with the appropriate driver) is required for initial parameter upload if the fieldbus network is not yet active.

Downtime Control During System Migration

Minimizing production interruption during a SERVOSTAR 610-AS retrofit requires a structured hot-swap procedure. Begin by exporting the complete parameter set from the outgoing drive using DriveGUI or WorkBench while the machine is still operational. Document all active fault masks, speed loop gains, position window tolerances, and homing sequences. During the physical swap, label all terminal connections with numbered tags before disconnection — the X1, X2, X3, and X4 connectors on the 610-AS are keyed but terminal labeling prevents wiring errors on the control signal side.

After mechanical installation, import the saved parameter file into the 610-AS via WorkBench and perform a parameter validation check. Enable the drive in torque-limited jog mode first to confirm encoder feedback polarity and motor phasing before executing a full motion profile. If the original program uses a homing routine tied to a KOLLMORGEN HIPERFACE encoder or a Renishaw linear scale, verify that the reference mark search sequence completes correctly before releasing the axis to automatic mode. The entire swap procedure — from power-down to verified automatic operation — can typically be completed within two to four hours for a single-axis replacement, keeping unplanned downtime within acceptable limits for most production environments. All units are pre-tested and function-verified prior to shipment, and each drive is covered by a 12-month warranty from the date of delivery.

Retrofit Support FAQ

Q: Is the SERVOSTAR 610-AS a direct replacement for all SERVOSTAR 600 series variants?
A: The 610-AS is a direct electrical and mechanical replacement for SERVOSTAR 600 series drives rated at 10A continuous. For 3A or 6A variants, verify the motor nameplate current and confirm that the 610-AS output rating is appropriate for the application before installation.

Q: Do I need to reconfigure the PROFIBUS-DP station address after replacement?
A: Yes. The PROFIBUS station address must be set on the 610-AS DIP switches to match the address previously assigned to the outgoing drive. The PLC GSD configuration does not need to be modified if the address is preserved, but a hardware reset of the PROFIBUS master may be required to re-establish the connection.

Q: Can the 610-AS operate on the same DC bus as a SERVOSTAR S300 or AKD drive?
A: Yes, provided the shared DC bus voltage and power supply capacity are within specification for all connected axes. Consult the KOLLMORGEN shared bus application guide and verify that the PST or regenerative supply module is sized for the combined axis load.

Q: What does the 12-month warranty cover?
A: The 12-month warranty covers manufacturing defects and functional failures under normal operating conditions from the date of delivery. Each unit undergoes pre-shipment functional testing. Warranty claims are supported directly through our sales team with expedited replacement dispatch to minimize your production impact.

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