KOLLMORGEN SERVOSTAR 610-AS Replacement for 600 Series

Product Overview

KOLLMORGEN SERVOSTAR 610-AS Replacement & Upgrade Solution for SERVOSTAR 600 Series

When your legacy KOLLMORGEN SERVOSTAR 600 series installation reaches end-of-life or a critical drive fails, the SERVOSTAR 610-AS offers a proven, drop-in-compatible upgrade path that minimizes engineering rework and plant downtime. Designed as a direct replacement within the SERVOSTAR 600 platform, the SERVOSTAR 610-AS preserves the original wiring topology, retains compatibility with existing SERVOSTAR programming environments, and supports the same STO (Safe Torque Off) safety architecture that your machine builder originally specified. For facilities running multi-axis servo systems — whether in packaging lines, CNC machining centers, semiconductor handling equipment, or industrial robotics — this unit delivers a seamless transition from obsolete or discontinued predecessors without requiring a full control cabinet redesign.

The SERVOSTAR 610-AS is rated at 10A continuous output current and is engineered for demanding servo motion applications where precise torque, velocity, and position control are non-negotiable. Its STO safety function (SIL 2 / PLd compliant) integrates directly with existing safety relay circuits and safety PLCs, eliminating the need to rewire the safety channel when replacing an older SERVOSTAR 601, SERVOSTAR 603, or SERVOSTAR 606 unit. The drive accepts standard resolver or encoder feedback signals, meaning your existing AKM series servo motors — including AKM21, AKM31, and AKM41 frame sizes — remain fully compatible without motor replacement or re-commissioning of feedback devices.

From a communication protocol standpoint, the SERVOSTAR 610-AS supports PROFIBUS-DP, CANopen, and RS-232/RS-485 serial interfaces, matching the fieldbus architecture of most legacy SERVOSTAR 600 installations. If your system uses a PROFIBUS master — such as a Siemens S7-300 or S7-400 PLC — the GSD file and node address configuration carry over directly, reducing PLC program modification to a minimum. For CANopen-based systems, the existing PDO/SDO mapping and node ID settings are preserved, allowing the replacement drive to come online without rewriting the motion controller’s communication layer.

Physical installation is equally straightforward. The SERVOSTAR 610-AS occupies the same DIN-rail or panel-mount footprint as its predecessors in the SERVOSTAR 600 family, and the connector pinout for the X1 power connector, X3 motor output, X4 feedback interface, and X6 I/O terminal block is pin-for-pin compatible. This means your existing cable harnesses, motor power cables, and feedback cables can be reconnected without modification — a critical advantage when performing emergency replacements during unplanned downtime events. The 24VDC logic supply input and the DC bus voltage range (up to 320VDC) are unchanged from earlier SERVOSTAR 600 variants, so your existing power supply modules and DC bus capacitor banks remain in service.

For multi-axis systems, the SERVOSTAR 610-AS can share a common DC bus with other SERVOSTAR 600 series drives, including SERVOSTAR 620, SERVOSTAR 640, and SERVOSTAR 660 units already installed in the same control cabinet. This shared bus topology reduces regenerative braking losses and allows energy to be redistributed across axes during deceleration cycles — a feature that was present in the original system design and is fully preserved in the replacement configuration. The SERVOSTAR S300 and S700 series drives from the same KOLLMORGEN ecosystem can also coexist in adjacent cabinet sections, sharing the same 24VDC logic rail and safety circuit without interference.

Commissioning the SERVOSTAR 610-AS is performed using KOLLMORGEN’s DRIVE.EXE or WorkBench software, both of which are backward compatible with parameter files (.drc) saved from earlier SERVOSTAR 600 drives. In most cases, the original parameter file can be loaded directly into the replacement unit, with only minor adjustments required for motor-specific tuning parameters. This dramatically reduces the time a qualified servo technician needs to spend on-site, lowering both labor costs and production loss during the changeover window.

From a procurement and supply chain perspective, TOPNLMS maintains verified stock of the SERVOSTAR 610-AS sourced through authorized industrial distribution channels. Each unit undergoes pre-shipment functional verification, including power-on testing, STO channel continuity check, and feedback interface validation. Units are shipped in original or equivalent protective packaging with full ESD precautions. Standard lead time from our Xiamen warehouse is 3–7 business days for international express shipments, with DHL, FedEx, and UPS options available. For urgent replacement scenarios, same-day dispatch is available for in-stock units confirmed before 14:00 CST.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful SERVOSTAR 610-AS retrofit rarely involves the drive alone. In most SERVOSTAR 600 installations, the drive operates as part of a tightly integrated motion system. During the upgrade process, engineers commonly address adjacent components to ensure the entire axis performs reliably after the changeover.

The feedback cable connecting the AKM series servo motor to the SERVOSTAR 610-AS X4 interface is a frequent point of inspection — particularly in installations where the original cable has been routed through cable trays for many years. Replacing the resolver or encoder feedback cable with a shielded, twisted-pair equivalent rated for continuous flexing eliminates a common source of intermittent faults after drive replacement. Similarly, the motor power cable connecting X3 to the AKM motor’s terminal box should be inspected for insulation degradation, especially in high-cycle applications.

For systems where the SERVOSTAR 610-AS communicates over PROFIBUS-DP, the PROFIBUS connector at the X5 interface — typically a 9-pin Sub-D connector with integrated termination resistor — should be verified for contact integrity. In multi-drop PROFIBUS networks, a faulty terminator on a replaced node can cause bus errors across all connected devices, including other SERVOSTAR 600 drives and the upstream Siemens S7 PLC or Beckhoff CX series controller.

The 24VDC logic power supply feeding the SERVOSTAR 610-AS and its neighboring drives in the cabinet is another component worth evaluating during a planned replacement. A PULS, Phoenix Contact, or WAGO 24VDC DIN-rail power supply that has been in continuous service for over five years may exhibit voltage ripple that affects drive initialization. Replacing or paralleling the logic supply during the same maintenance window avoids a secondary failure shortly after the drive replacement is complete.

In systems using a KOLLMORGEN AKD-PDMM or AKD2G series multi-axis controller as the motion coordinator, the EtherCAT or PROFIBUS master configuration may need a node re-scan after the SERVOSTAR 610-AS is installed. The WorkBench software’s auto-scan function handles this automatically, but the motion program’s axis assignment table should be verified to confirm the replacement drive maps to the correct logical axis number.

For installations where the SERVOSTAR 610-AS replaces a drive in a shared DC bus configuration alongside SERVOSTAR 620 or SERVOSTAR 640 units, the bus capacitor module and regenerative braking resistor should be inspected. If the original braking resistor shows signs of thermal stress — discoloration, cracked ceramic, or increased resistance — replacement with an equivalent 100Ω / 100W braking resistor is recommended before returning the axis to full-speed operation.

Finally, if the retrofit involves updating the safety circuit, the safety relay module — such as a Pilz PNOZ or Sick safety relay — connected to the STO input terminals (X1 pins STO+ and STO-) should be tested for correct response time and reset behavior after the SERVOSTAR 610-AS is wired in. This ensures the machine’s safety function meets the original SIL 2 / PLd performance level without requiring a full safety re-validation.

Retrofit Guidance FAQ

Q: Can I use my existing wiring harness when replacing an older SERVOSTAR 600 drive with the SERVOSTAR 610-AS?
A: Yes. The SERVOSTAR 610-AS uses the same connector layout (X1, X3, X4, X6) as earlier SERVOSTAR 600 series drives. In the vast majority of retrofit scenarios, existing motor power cables, feedback cables, and I/O wiring can be reconnected without modification. Always verify pin assignments against the SERVOSTAR 610-AS hardware manual before energizing.

Q: Will my existing PROFIBUS or CANopen configuration work without reprogramming?
A: In most cases, yes. The SERVOSTAR 610-AS supports the same PROFIBUS-DP GSD file structure and CANopen object dictionary as earlier SERVOSTAR 600 drives. Node address and baud rate settings are preserved. Minor parameter re-tuning via WorkBench or DRIVE.EXE may be required for motor-specific gains, but the communication layer typically requires no changes.

Q: Does the SERVOSTAR 610-AS fit in the same cabinet space as the drive it replaces?
A: Yes. The SERVOSTAR 610-AS shares the same physical form factor as the SERVOSTAR 600 series. DIN-rail mounting dimensions and panel-mount hole patterns are identical, so no cabinet modification is required.

Q: Can I load my existing parameter file (.drc) from the old drive into the SERVOSTAR 610-AS?
A: Yes. WorkBench and DRIVE.EXE are backward compatible with .drc parameter files from earlier SERVOSTAR 600 drives. Load the saved file, verify motor nameplate data, and perform a short auto-tune cycle to confirm current loop stability before returning the axis to production.

Q: What happens to the shared DC bus when I replace one drive in a multi-axis cabinet?
A: The SERVOSTAR 610-AS is fully compatible with shared DC bus configurations involving SERVOSTAR 620, 640, and 660 units. Disconnect the bus link before removing the old drive, install the replacement, reconnect the bus link, and power up the cabinet in the standard sequence. No bus reconfiguration is required.

Q: How do I verify the STO safety function after installation?
A: With the drive powered and the motor at standstill, open the STO circuit at X1 (STO+ / STO-). The drive should immediately disable the output stage and display the STO status on the front panel LED. Restore the STO signal and confirm the drive re-enables correctly. Document the test result as part of your safety validation record.

Warranty Assurance

Every SERVOSTAR 610-AS unit supplied by TOPNLMS is covered by a 12-month warranty from the date of shipment. This warranty covers manufacturing defects, component failures under normal operating conditions, and any fault that prevents the drive from meeting its published specifications. The warranty does not cover damage resulting from incorrect installation, overvoltage events, or operation outside the rated environmental conditions.

Prior to dispatch, each unit undergoes a structured pre-shipment inspection that includes: power-on functional test at rated voltage, STO channel continuity and response verification, feedback interface signal integrity check (resolver and encoder), and communication port loopback test. Units that do not pass all inspection criteria are quarantined and not shipped.

In the event of a warranty claim, TOPNLMS provides a replacement unit dispatch within 5 business days of claim approval, subject to stock availability. For critical production environments, advance replacement (ship-before-return) is available upon request. Our technical support team is reachable at [email protected] or +86 18359293191 to assist with installation questions, parameter file recovery, and fault diagnosis during the warranty period.

All units are shipped with full ESD protective packaging, moisture barrier bags where applicable, and a unit-level inspection record. Export documentation, including commercial invoice, packing list, and certificate of origin, is provided for all international shipments to support customs clearance.

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