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Kollmorgen 603-S60300

Product Overview

603-S60300 is a single-axis high-performance digital servo drive from Kollmorgen S600 platform, designated for medium-current three-phase industrial motion control applications. Model coding breakdown: 603 = 3Arms continuous output current grade; S60300 = base hardware variant without factory pre-installed communication expansion cards.
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Detailed content

Technical & Performance Specifications

  • Input Power Supply: Three-Phase 230–480 VAC (±10%), 50/60Hz mains input
  • Continuous Output Current: 3 Arms per phase RMS
  • Peak Output Current: 6 Arms RMS (sustainable 5 seconds)
  • DC Bus Intermediate Circuit Voltage: Max 560 VDC
  • Control Loop Bandwidth: Max 400Hz velocity loop bandwidth
  • Current Loop Refresh Rate: 16kHz (62.5μs sampling cycle)
  • Position Loop Refresh Rate: 4kHz (250μs sampling cycle)
  • PWM Switching Frequency: 8kHz fixed
  • Analog I/O Channels: 2x ±10VDC analog input, 2x ±10VDC analog output
  • Digital I/O Channels: 8x 24VDC sinking/sourcing input, 4x 24VDC output
  • Standard Onboard Communication: CANopen DS402 protocol, RS232 diagnostic serial port
  • Optional Expansion Bus Cards: PROFIBUS-DP, SERCOS III, DeviceNet
  • Integrated EMC Filter: 20A rated CE-compliant mains filter
  • Cooling Method: Built-in axial fan forced air cooling
  • Protection Function Set: Overcurrent, overvoltage, undervoltage, heatsink overheat, motor winding overtemperature, encoder feedback loss, output phase short circuit, earth leakage short circuit, overspeed fault lockout
  • Physical Dimension (W × H × D): 55mm × 280mm × 210mm
  • Weight: 3.4 kg
  • Protection Class: IP20 (cabinet internal installation only)

Material Composition

  1. Outer Chassis: Cold-rolled steel sheet with matte black electrostatic anti-static paint coating
  2. Power Module Heat Sink: Extruded high-purity aluminum alloy finned radiator
  3. Main Control PCB: FR4 high-temperature flame retardant circuit board with tin-lead-free plating
  4. Power Semiconductors: IGBT three-phase power bridge modules encapsulated with thermal conductive silicone gel
  5. Terminal Blocks: Nickel-plated copper screw terminal connectors with PA66 flame retardant insulation housing
  6. Cooling Fan: Brushless DC centrifugal fan with stainless steel impeller

Structural Features

  • Vertical stack modular layout separating power circuit zone and low-signal control zone with metal shielding partition
  • Front panel three-digit LED fault status display with dedicated fault code indicator lamps
  • Separate top-mounted mains power terminal block, mid-section motor power terminal block, bottom control signal terminal zone
  • Dedicated expansion card slot on rear side for plug-and-play fieldbus communication upgrades
  • Integrated encoder emulation output channel eliminating external position feedback repeater hardware
  • RS232 multi-drop diagnostic port allowing single PC connection to synchronously configure multiple drives

Working Principle

Three-phase AC mains input passes integrated EMC filter then full-wave diode rectifier to generate stable DC bus voltage. DSP main controller executes space vector modulation (SVM) algorithm to generate PWM drive signals for IGBT power stage, converting DC bus voltage to variable frequency three-phase sinusoidal AC for motor stator excitation. Real-time encoder feedback signals are sampled at 16kHz to close current, velocity and position triple control loops; PI Plus PDFF control algorithms dynamically adjust output current to eliminate position tracking deviation. Digital I/O and fieldbus interfaces receive motion command signals from host PLC/CNC, execute electronic gearing, electronic cam and multi-axis synchronization motion profiles stored in on-board flash memory. Internal fault monitoring circuit continuously samples voltage, current and temperature signals, triggering hardware interlock shutdown upon threshold violation.

Function Features

  1. Automatic full-spectrum motor tuning wizard eliminating manual PID gain adjustment
  2. Built-in electronic gearing and electronic cam motion trajectory function with 300 editable motion task storage
  3. Multi-feedback signal compatibility: incremental sine/cosine encoder, EnDat 2.2, Hiperface, resolvers, SFD single-cable feedback
  4. Encoder signal emulation output for secondary external position monitoring equipment
  5. RS232 multi-drop serial communication supporting multi-drive single-point programming
  6. Configurable restart lock safety (-AS) option for personnel hazard prevention
  7. DQ vector current control suppressing low-speed torque ripple below 0.5% rated torque
  8. Fault data logging storage retaining 50 sets of historical fault codes with timestamp

Advantage Highlights

  1. Compact single-unit design integrating EMC filter without external accessory installation
  2. 400Hz maximum velocity bandwidth delivers ultra-fast dynamic response for high-speed automation axes
  3. Modular fieldbus expansion architecture enables future system upgrade without drive hardware replacement
  4. Universal motor compatibility supporting all Kollmorgen rotary, cartridge DDR and DDL linear servo motors
  5. UL, cUL, CE, RoHS global safety compliance certification
  6. Full isolation between power and signal circuits minimizing industrial EMI interference

Applicable Industries

CNC machine tools, multi-axis robotic cells, automated packaging lines, laser cutting equipment, printing converting machinery, semiconductor backend assembly, aerospace precision test rigs, textile high-speed weaving equipment

Installation Requirements

  1. Mandatory vertical cabinet mounting orientation only; horizontal installation prohibited to maintain fan cooling airflow path
  2. Vertical stacking installation minimum vertical clearance: 100mm above drive top, 50mm below drive bottom for unobstructed fan exhaust
  3. Cabinet ambient operating temperature limited to 0°C ~ +45°C; 45°C ~ 55°C operation requires 20% continuous output current derate
  4. Power wiring specification: Mains three-phase cable ≥2.5mm² shielded copper wire; motor power cable ≤25m length use 1.5mm² four-core shielded cable
  5. Signal wiring specification: Encoder/feedback cable double twisted shielded 0.25mm² cable, maximum transmission distance 100m
  6. Grounding rule: Cabinet mounting plate connected to factory star earth grid; drive chassis M6 ground bolt wired via ≥10mm² copper earth conductor
  7. Cable separation rule: Power cables and low-level signal cables routed in separate cable ducts; unavoidable crossing implemented at strict 90-degree perpendicular angle

Operation & Maintenance Precautions

  1. Enclosure cabinet must maintain IP54 minimum protection rating to prevent dust and conductive particle ingress onto drive PCB
  2. Do not operate drive without installed fan unit; fan failure triggers permanent power module thermal damage within 15 minutes
  3. Disconnect all three-phase mains supply and wait minimum 10 minutes for DC bus capacitor discharge before disassembling terminal wiring
  4. Monthly visual inspection of fan intake filter screen to remove accumulated dust blocking cooling airflow
  5. All feedback connectors must remain fully shielded with double-end shield grounding to avoid position signal noise drift
  6. Maximum continuous motor cable extension length 25m; cable exceeding 25m requires matching external output choke accessory
  7. Regular firmware upgrade via Kollmorgen WorkBench software only; third-party firmware prohibited to void factory warranty

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