Key Technical Specifications
| Parameter | Specification | Field Note |
|---|---|---|
| Input Voltage | 400-480 VAC (3-Phase) | Verify plant power; 480V nominal common |
| Continuous Current | 3A / 6A / 10A / 14A / 20A | Check nameplate suffix for exact rating |
| Peak Current | 2x Continuous for 5 sec | Enough for rapid acceleration/deceleration |
| Control Loops | Torque, Velocity, Position | Full digital, auto-tune capable |
| Feedback | Resolver, Encoder, Sin/Cos | Configurable via DIP switches/software |
| Comm Options | RS-232, CANopen, PROFIBUS | Requires optional interface card |
| Motion Tasks | Up to 180 stored in memory | Standalone operation without PLC |
| Protection | Over-current, Over-temp, Over-voltage | LED fault codes on front panel |
| Bus Sharing | Regenerative power sharing | Link DC bus terminals for multi-drive |
| Safety | Built-in Safety Relay | ST0 function, prevents unexpected restart |
Product Introduction
I’ve tuned more ServoStar 600s than I can count, and the S61000 is the one that still shows up in high-speed packaging lines and semiconductor wafer handlers. It’s a full-digital drive that doesn’t just amplify current; it actually runs motion profiles internally. You can load 180 motion tasks directly into the drive’s flash memory, meaning if your PLC dies, the S61000 can keep the machine cycling through its home sequence or safe park routine. That alone has saved customers from days of downtime during controller failures.The real reason we still stock these isn’t nostalgia; it’s the DQ current control and space vector modulation. Older analog drives waste power as heat; the S61000 switches cleanly and keeps the motor cool even at high duty cycles. The catch? The front panel buttons are tactile, not membrane, and after 15 years in an oily environment, they get sticky. This specific revision is incredibly stable once tuned, but it demands a clean ground plane. If you’ve got VFDs on the same ground bus without isolation, expect to chase phantom encoder faults for a week.
Quality SOP & Tech Pitfalls
The Lab Report:
I don’t trust “tested” stickers from eBay sellers. Here is what actually happens on my bench:
- Visual/Counterfeit Check: Inspect the IGBT modules and DC bus capacitors. If the caps are bulging or the IGBTs look re-soldered, it’s a graveyard pull.
- DC Bus Pre-charge Test: Apply power through a variac. Watch the inrush current. If it spikes >10A, the pre-charge resistor is open or the IGBT is shorted.
- Output Waveform Check: Hook up a resistive load and scope the U/V/W outputs. Should be clean PWM. If you see massive ringing or missing pulses, the gate drivers are failing.
- Motion Task Verification: Load a test profile via RS-232. Execute a homing sequence. If it stalls or over-travels, the encoder interface or feedback config is corrupted.
- Burn-In & Seal: Run at 50% load for 2 hours. Bag with desiccant. Moisture in the conformal coating causes tracking faults at 480V.
The Engineer’s Warning:
⚠️ The Grounding Nightmare: This drive switches fast. If your motor cable shield isn’t grounded at both ends with a proper 360° clamp, you’re building an antenna. I’ve seen S61000s report “Feedback Loss” at exactly 3000 RPM because the encoder cable was running parallel to a 5HP VFD cable. Use shielded cable. Ground it at the drive AND the motor.⚠️ The Regeneration Trap: If you’re stopping a high-inertia load, that energy has to go somewhere. The internal resistor is for light duty. If you’re doing E-stops at full speed, add an external braking resistor. I’ve seen the internal resistor pop like a firecracker because someone trusted the internal specs for a centrifuge application.
Installation & Configuration Guide
- Pre-Installation Safety: ⚠️ LOCKOUT/TAGOUT. Verify 0V DC on the bus capacitors (wait 5 mins after power-off). Take a photo of the DIP switch settings and wiring. Do not trust your memory.
- Removal: Label U/V/W and encoder cables. Release DIN clip. Cap the DC bus terminals. A stray screwdriver across +DC/-DC will weld the tool to the bus bar.
- Installation: VERIFY DIP SWITCHES. Does the new S61000 have the same feedback type and comm address settings? Mount on clean DIN rail. Torque power terminals to 2.5 Nm.
- Power-On & Testing: Apply control power first. Verify green LED. Apply main power. Check for fault codes. Run auto-tune. Do not skip this. The old parameters won’t work with a new drive’s internal compensation.
Compatible Replacement Models
| Model | Status | Notes |
|---|---|---|
| KOLLMORGEN S61000 | ✅ Current Standard | Direct replacement. Verify current rating suffix. |
| KOLLMORGEN AKD-P00607 | ⚠️ Software Compatible | Same performance, but requires new wiring harness & AKD WorkBench. Not drop-in. |
| KOLLMORGEN S700 | ❌ Hardware Mod | Different footprint, different comm protocol. Only do this during a full machine rebuild. |
| INDRAMAT BDS4A | ❌ Obsolete | Older analog predecessor. Do not buy. Parts are gone. |
Frequently Asked Questions (FAQ)
Can I hot-swap this drive while the machine is powered?
Absolutely not. The DC bus holds lethal voltage. Even with the main breaker off, the capacitors stay charged. Wait for the LED to go out and verify 0V DC. Hot-swapping will destroy the IGBTs and likely the encoder feedback on the motor.My drive shows “Over-Temperature” but the motor is cool.
Check the internal fan (if equipped) or the cabinet airflow. The S61000 senses heatsink temp, not motor temp. If you’re running in a sealed NEMA 12 box with no ventilation, you’re cooking it. Add a filtered fan. Also, verify the ambient temp rating; standard units derate above 40°C.Do I need a PC to set this up?
You can use the front panel for basic moves, but you’ll hate yourself. Get the MotionWare software and an RS-232 cable. Tuning via buttons is like painting a portrait with a mop. The software lets you view the scope traces to see if you’re hunting or oscillating.Is this compatible with my old AKM motor?
Yes, but verify the feedback device. The S61000 supports resolvers, incremental encoders, and Sin/Cos. If your AKM has a Hiperface or EnDat encoder, you need the correct feedback option card. Check the motor nameplate and drive DIP switches.Why does it fault “Over-Voltage” on decel?
Your decel time is too fast for the load inertia. The motor is generating more power than the drive can dissipate. Slow down the decel ramp or install an external braking resistor. Don’t just crank up the OV limit in software; you’ll blow the DC bus caps.Can I use this with a PLC that only has analog output?
Yes. Wire the ±10V analog output to the velocity command input. Set the drive to Velocity Mode via DIP switch. But honestly, if you’re doing that, you’re wasting the S61000’s motion task capability. Use the serial port for position commands if possible.Is the S61000 still supported by Kollmorgen?
Officially, it’s legacy. But the AKD series is the direct successor. Support for S61000 is community-driven and third-party repair shops. We stock these because thousands are still running perfectly. Just keep a spare; they aren’t making new ones.
