60WKS-CE24022PB Kollmorgen Analog Servo Amplifier

Description

Product Model: 60WKS-CE240/22PB
Product Brand: Kollmorgen (Seidel / Kollmorgen 60WKS series)
Product Series: 60WKS Analog Servo Amplifier

Product Features:

• 3-phase output, 4-quadrant control with integrated ballast circuit
• Accepts rotor position sensor (RLG) or tachometer feedback for brushed/brushless motors
• Dual differential setpoint inputs, enable input, isolated optocoupler logic (24V)
• Expansion slot for ramp logic / limit switch functions via optional plug-in PCB

Applications & Industry Context

In many legacy and specialty motion systems, an amplifier like the 60WKS-CE240/22PB remains relevant for driving synchronous servo motors in analog control architectures. Though digital drives dominate modern automation, the 60WKS series is often used in retrofit or maintenance scenarios where existing field wiring, analog servo loops, or controller interfaces demand a compatible amplifier.

Typical applications include:

• Small machine axes (positioning tables, rotary indexing modules)
• Laboratory or test benches with analog motion control
• OEM equipment that originally used the 60WKS family
• Systems needing a compact drive with limited power (60 W class)
• Environments where brushless motors with rotor position sensors (RLG) or tachometer feedback are used

Because it supports mixed feedback (rotor position + tachometer), the 60WKS-CE240/22PB can couple with various motors, giving flexibility in mixed machine fleets.

Moreover, devices like this are often resurrected in refurbishment efforts for older machines: integrators use them because they match the control logic (analog +/-10 V, setpoints, interlocks) of the original design.

Technical Features & Benefits

Analog Control & Feedback Flexibility
The 60WKS-CE240/22PB supports input of rotor position sensing (RLG) or tachometer feedback (brushless or DC), enabling both synchronous and tachometer-based control paths. That flexibility gives engineers options based on motor type or retrofit constraint.

3-Phase, 4-Quadrant Output
This amplifier implements a 3-phase PWM transistor stage that allows driving the motor in all four quadrants: motoring and generating, forward and reverse. This feature is essential for dynamic motion tasks, deceleration, or braking.

Integrated Ballast Circuit
When the motor is braking (regenerating energy), the built-in ballast circuit dissipates energy through a resistor. The ballast becomes active when DC-link voltage rises above ~285 V, and further shifts its threshold under repeated load cycles (to ~300 V) to distribute load among multiple amplifiers in parallel. This design helps protect the drive and manage regenerated energy.

Dual Differential Setpoints and Enable Logic
It includes two fully differential setpoint inputs (one adjustable) and an enable input, allowing flexibility in motion control or dual-loop configurations.Logic signals (24 V) are opto-isolated, improving noise immunity and system safety.

Expansion Slot (Option PCB)
A plug-in slot supports an optional “-01” PCB that adds ramp generation and limit-switch logic functions. This makes the drive more autonomous and simplifies motion sequencing without extra external modules.

Adjustable ±10 V Output & Instrument Current Reference
The output for control references is ±10 V relative to a ± “AGND” reference, which aligns with many analog control systems.

Robust Power & Internal Circuitry
The amplifier uses a 3-phase supply (via an isolating transformer), smoothing capacitors, and internal PSU modules. Auxiliary voltages can be derived from the DC-link, or externally supplied (option -24V).

All of these features make the 60WKS-CE240/22PB a capable analog servo amplifier with good feedback handling, power regeneration, and adaptability for traditional motion systems.

Technical Specifications

Here is a consolidated specification table, based on vendor documentation and listings:

Because this amplifier is relatively aged, some parameters (e.g. thermal limits, switching frequencies, gain bandwidths) may not be publicly documented. Always refer to the original service manual or lab test data for precise values.

Installation & Maintenance Insights

When working with the 60WKS-CE240/22PB, applying installation best practices ensures long life and stable operation:

Power Wiring & Supply

• Use a properly rated 3-phase isolating transformer to match expected input voltage range.
• Provide AC fusing (e.g. 3 × 20 A) as recommended.
• Ensure DC-link wiring from supply to amplifier has low impedance and proper filtering to reduce voltage ripple.

Grounding & Shielding

• Use solid earth grounding of the amplifier chassis.
• Signal cables (setpoints, feedback) should be shielded and routed away from power lines.
• Maintain opto-isolated logic lines to avoid interference from noise on power cabling.

Feedback / Sensor Wiring

• Rotor position sensors (RLG) and tacho inputs should use twisted-pair, shielded wiring with proper termination.
• Maintain wire length limits to avoid latency or signal degradation.
• Validate sensor signal levels before powering, especially after maintenance or cable replacement.

Control & Parameter Setup

• Begin with conservative PI tuning and ramp limits; avoid aggressive gains initially.
• Use one setpoint as master and the other adjustable for fine control adjustments.
• If using the optional -01 PCB, set up ramp limits and limit switch logic carefully to prevent overshoot or mechanical collisions.

Thermal & Regeneration Management

• Monitor DC-link voltage and watch for ballast activation (internal LEDs should blink when threshold exceeded). xiongba
• If the drive dissipates high brake energy, ensure adequate heat sinking or airflow near the ballast resistor.
• Avoid continuous heavy regenerative braking; distribute energy or use an external regeneration circuit if workload demands exceed internal ballast capacity.

Preventive Maintenance

• Periodically inspect for dust accumulation and clean ventilation paths.
• Check thermal imaging for hot spots on heat sinks or components.
• Inspect connectors and wiring for loosening or corrosion.
• Test enable / fault logic and setpoint inputs for proper response.
• Before replacing or swapping, store configuration / schematic for quick recovery.

Redundancy & Spare Strategy

• If the control system is critical, maintain a known-good spare 60WKS module (same variant).
• Keep spare option PCB modules (if used).
• Document setpoint calibration, offsets, and gains for rapid reprogramming.

With due diligence, a 60WKS amplifier can remain reliable even in modern usage or maintenance environments.