KOLLMORGAN 64WKS-M240/50-RLG Retrofit Servo Control Module

KOLLMORGAN 64WKS-M240/50-RLG Retrofit Servo Control Module: Legacy-Compatible Servo Upgrade for Industrial Automation Systems

The KOLLMORGAN 64WKS-M240/50-RLG is a ruggedized servo control module engineered for demanding industrial environments where reliability, precision motion control, and long-term spare parts availability are non-negotiable. As legacy KOLLMORGAN servo drive platforms approach end-of-life, this module serves as a direct retrofit-compatible replacement, enabling plant engineers and maintenance teams to extend the operational life of existing servo axes without a full system overhaul. Whether you are managing a multi-axis CNC retrofit, upgrading a legacy packaging line, or restoring a discontinued servo drive platform, the 64WKS-M240/50-RLG provides a proven migration path with minimal disruption to your production schedule.

Designed for integration into existing KOLLMORGAN 64WKS-series control cabinets, this module maintains backward compatibility with established backplane architectures and terminal wiring configurations. Engineers replacing older KOLLMORGAN BDS4 or BDS5 series servo amplifiers will find that the 64WKS-M240/50-RLG aligns closely with the original power supply rail requirements, feedback interface pinouts, and enable/inhibit signal logic — significantly reducing the engineering hours required for a successful cutover. The ruggedized construction ensures reliable operation in environments subject to vibration, thermal cycling, and electrical noise, making it suitable for heavy industry, press automation, and material handling applications.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful retrofit of the KOLLMORGAN 64WKS-M240/50-RLG into an existing servo system begins well before the physical module swap. The first step is a thorough audit of the existing control cabinet, including the backplane slot assignment, the DC bus power supply capacity, and the terminal block wiring for the resolver feedback cable. In many legacy installations, the resolver cable — carrying sine, cosine, and reference signals — may have been routed with non-standard shielding practices. Before installing the replacement module, it is advisable to inspect the cable shield termination at both the motor end and the drive end to prevent resolver signal noise from causing erratic velocity feedback.

For systems where the upstream motion controller is a legacy KOLLMORGAN or third-party PLC — such as a Siemens S5 series or an Allen-Bradley SLC 500 — the analog command output card must be verified for ±10V output range and load impedance compatibility. If the existing motion controller is being retained, the servo enable and fault interlock wiring between the PLC output module and the 64WKS-M240/50-RLG must be mapped carefully, as enable signal polarity and fault acknowledgment logic can differ between module revisions.

In multi-axis installations, the 64WKS-M240/50-RLG will share a common DC bus with adjacent servo axes. It is critical to verify that the existing DC bus power supply — often a KOLLMORGAN or compatible third-party regenerative power supply unit — has sufficient continuous and peak current capacity to support the replacement module’s rated output. If the original power supply is also approaching end-of-life, a concurrent replacement with a compatible regenerative power supply module should be considered to avoid a secondary unplanned outage.

The backplane itself deserves careful inspection. In aging 64WKS-series racks, backplane connector pins may show signs of oxidation or mechanical wear. Cleaning the backplane connector with an appropriate contact cleaner and verifying pin continuity before module insertion can prevent intermittent faults during initial commissioning. If the rack chassis is also being replaced as part of a broader control cabinet upgrade, ensure that the new chassis maintains the same slot addressing scheme to avoid conflicts with the PLC’s I/O mapping and the HMI screen tag assignments.

For facilities running KOLLMORGAN WorkBench or legacy servo configuration software, the drive parameters from the original module — including velocity loop bandwidth, current limit, and resolver offset — should be documented before removal. These parameters will serve as the baseline for initial commissioning of the replacement 64WKS-M240/50-RLG. In cases where the original parameter file is unavailable, the motor nameplate data and the original system documentation can be used to reconstruct the key tuning values. After installation, a no-load run at reduced speed is recommended before returning the axis to full production speed, allowing the maintenance team to verify resolver signal quality, drive enable response, and fault relay behavior without risk to the connected mechanical load.

Beyond the servo module itself, a complete retrofit plan should account for associated components that may require concurrent replacement. The resolver-to-digital converter board, if present as a separate module in the rack, should be inspected for compatibility with the replacement drive’s resolver excitation frequency. The axis enable relay — often a dedicated safety relay module mounted in the same control cabinet — should be tested for correct coil voltage and contact rating. If the system includes a KOLLMORGAN or compatible HMI panel for operator speed reference and fault display, the communication link between the HMI and the motion controller should be verified after the module swap, as some legacy HMI configurations store drive-specific status register addresses that may differ between module revisions. Programming cables and configuration adapters for the 64WKS series should be sourced alongside the replacement module to ensure that on-site commissioning can proceed without delay.

Downtime Control During System Migration

Minimizing unplanned downtime is the primary concern for any maintenance team undertaking a servo module replacement on a live production line. For the KOLLMORGAN 64WKS-M240/50-RLG, the recommended approach is a planned maintenance window replacement rather than a reactive swap, which allows the engineering team to pre-stage the replacement module, verify its configuration offline, and prepare all necessary tools and documentation before the production line is taken offline.

Before the maintenance window begins, the existing module’s parameter set should be read out and saved using the appropriate KOLLMORGAN configuration software. If the software is no longer available for the legacy platform, the key parameters — velocity loop gain, acceleration ramp time, current limit, and resolver offset — should be manually recorded from the drive’s front panel display or from the original commissioning documentation. This parameter backup is the single most important step in protecting the original control logic and ensuring a rapid return to production after the module swap.

During the physical replacement, the DC bus should be fully discharged before the module is removed from the backplane. Many 64WKS-series installations include a bus discharge resistor circuit, but the discharge time should be verified with a calibrated voltmeter before any backplane connector is touched. Once the replacement module is seated and the terminal wiring is reconnected — paying particular attention to the resolver cable shield termination and the enable signal polarity — the system should be powered up in a controlled sequence: auxiliary control power first, then DC bus, then servo enable.

The initial commissioning run should be performed at reduced speed with the mechanical load disconnected if possible, or at minimum with the machine guarding in place and all personnel clear of the motion zone. Velocity reference, feedback signal quality, and fault relay behavior should all be verified before the axis is returned to automatic mode. A structured commissioning checklist — covering resolver signal amplitude, drive enable response time, velocity loop stability, and fault acknowledgment — will ensure that no critical verification step is missed under the time pressure of a production restart. With proper pre-staging and a disciplined commissioning sequence, the total planned downtime for a 64WKS-M240/50-RLG replacement can typically be contained within a single maintenance shift.

Retrofit Support FAQ

Q1: Is the KOLLMORGAN 64WKS-M240/50-RLG a direct drop-in replacement for my existing 64WKS-series servo module?
In most cases, yes — the 64WKS-M240/50-RLG is designed as a retrofit-compatible replacement for discontinued modules in the KOLLMORGAN 64WKS series. However, you should verify the resolver feedback type (RLG = resolver with line driver interface), the AC input voltage (240V), and the backplane slot connector version against your existing installation before ordering. Our technical team can assist with compatibility confirmation based on your existing module’s nameplate data.

Q2: What commissioning steps are required after installing the replacement module?
After physical installation and wiring verification, the key commissioning steps include: loading the saved parameter set (or reconstructing key parameters from motor nameplate data), performing a no-load test run at reduced speed to verify resolver signal quality and velocity loop stability, confirming enable signal polarity and fault relay behavior, and verifying communication with the upstream PLC or motion controller. A full-speed loaded test run should follow before returning the axis to automatic production mode.

Q3: Do you provide pre-shipment testing, and what does the 12-month warranty cover?
Yes — all KOLLMORGAN 64WKS-M240/50-RLG units are functionally tested before shipment to verify power stage operation, resolver interface integrity, and control logic response. The 12-month warranty covers manufacturing defects and functional failures under normal operating conditions. Units showing signs of incorrect installation, overvoltage, or physical damage are excluded. Warranty claims are supported by our technical team with replacement or repair options.

Q4: What is your typical lead time and stock availability for the 64WKS-M240/50-RLG?
We maintain dedicated inventory of KOLLMORGAN 64WKS-series spare parts to support long-term procurement programs for customers managing legacy automation systems. Typical lead time for in-stock units is 3–7 business days for international shipments. For customers with planned maintenance schedules or multi-unit requirements, we recommend contacting our sales team to discuss stock reservation and long-term supply agreements to ensure availability when needed.