Kollmorgen DIGIFAS 7202 Digital Servo Amplifier

Description

Key Technical Specifications

Product Introduction & Supply Chain Strategy

The Kollmorgen DIGIFAS 7202 is a digital 3-phase AC servo amplifier engineered to operate directly off a 400 VAC mains supply. Designed to drive Kollmorgen 6SM series synchronous brushless AC servomotors, the 7202 unit delivers 2.8 A continuous output current (1.7 kVA) for high-precision speed, position, and torque control loops. It incorporates onboard galvanic isolation, internal ballast circuitry, and dedicated analog/digital I/O channels for integration with legacy CNC and automation control platforms.

With the Digifas 7200 series now obsolete from the OEM, acquiring this module in New Surplus condition provides a strategic safety net against unscheduled factory downtime. Unlike refurbished drives—which frequently suffer from aged, degraded power capacitors and thermal fatigue on internal IGBT modules—New Surplus inventory delivers full 10-15 year operational expectancy. Maintaining 1-2 buffer units on-site eliminates the need for expensive motion controller retrofits and protects your plant’s Total Cost of Ownership (TCO).

DIGIFAS 7202

DIGIFAS 7202

Installation & Configuration Guide

Stage 1: Pre-Installation (Prep & Safety)

1. Execute Lock-Out/Tag-Out (LOTO) on the primary 400 VAC mains circuit breaker and the auxiliary 24 VDC control power.
2. Put on a grounded ESD wrist strap before handling the drive’s internal jumpers or interface ports.
3. Record all dip switch settings, option card configurations (e.g., -SPS, -L2/DP, or -CAN modules), and cable label assignments from the existing drive.

Stage 2: Removal

1. Wait at least 5 minutes after disconnecting power to allow the DC bus capacitors to fully discharge below 50 VDC.
2. Disconnect the motor power leads, resolver/encoder feedback cables, and terminal block plugs.
3. Unbolt the DIGIFAS 7202 mounting screws from the electrical cabinet panel and pull the drive straight forward out of its mounting slot.

Stage 3: Installation (Clone & Seat)

1. Inspect the backplane connectors and terminal pins on the new surplus unit for physical damage.
2. Replicate all hardware jumpers and option card selections on the replacement DIGIFAS 7202.
3. Secure the drive tightly to the enclosure backplate using M5 mounting screws to ensure proper ground continuity and thermal dissipation through the heat sink.
4. Reconnect all signal, resolver, 24 VDC control, and 400 VAC mains wiring according to original schematic labels.

Stage 4: Power-On & Testing

1. Apply 24 VDC control supply voltage first. Verify the front panel LED power status indicator illuminates without fault warnings.
2. Connect a PC running BS7200 configuration software via the dedicated PC interface cable to download the stored motor parameter file (.CFG).
3. Re-apply 400 VAC mains power. Enable the drive via the controller software and verify smooth axis motion during low-speed jog testing.

Firmware/Software Versions & Upgrade Notes

• Software Compatibility: The DIGIFAS 7202 is commissioned and tuned using Kollmorgen BS7200 operator software.
• Operating Environment: BS7200 is a legacy DOS application that communicates via a 25-pin to 9-pin LPT/serial connection. When running BS7200 on modern x86/x64 hardware, use a DOS emulator (such as DOSBox with LPT passthrough) or run a CPU throttling utility like SLOWDOWN.COM to prevent communication handshake timeouts.
• Firmware Notes: Firmware revisions (e.g., 5L80/5A77, 6L40/6A40) are tied to specific processor board releases. Parameter files created in BS7200 are generally portable across identical hardware revisions, but motor feedback parameters (resolver offsets) must be checked whenever replacing a drive.

Frequently Asked Questions (FAQ)

Is this Kollmorgen DIGIFAS 7202 drive brand new or refurbished?

This module is strictly New Surplus (Original Unused inventory). It has never been installed on an active machine, pulled from a plant decommissioning, or subjected to board repairs.

What are the operational risks of buying a refurbished DIGIFAS 7202 instead of New Surplus?

Refurbished drives from the 1990s often contain dried electrolytic DC-bus capacitors, stressed optocouplers, and degraded thermal paste. A failure on a 400V power stage can trigger an over-voltage trip or short out the mains power, resulting in hours of unplanned production downtime that far exceeds the small initial savings of a used unit.

Can I replace a DIGIFAS 7202 with another current rating in the 7200 series (e.g., 7204 or 7206)?

No. The DIGIFAS 7202 is rated for 2.8 A continuous output current. Up-sizing to a 7204 (4 A) or 7206 (6 A) changes the internal current loop scaling, power stage dissipation, and fuse protection requirements. Always match the exact unit model number for direct drop-in replacement.

Do I need special software to configure the drive parameters during replacement?

Yes. Drive parameters (current loop gains, speed profile, motor feedback) are configured using Kollmorgen software. If you have backed up your original parameter file (.CFG), you can reload it directly onto the replacement unit.

What warranty is provided with this New Surplus unit?

All New Surplus Kollmorgen DIGIFAS 7202 drives include a comprehensive 1-year warranty covering full functional operation from the date of delivery.