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Migration Guide

Ultra3000 Digital Servo Drives to Kinetix 300 and


Kinetix 350 Servo Drives
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Rockwell Automation, Ultra, Kinetix, ControlLogix, CompactLogix, MicroLogix, RSLogix, ProposalWorks, Encompass, Rockwell Software, TechConnect, SLC, MP-Series, and TL-Series are trademarks of
Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.
Preface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ultra3000 Drive Catalog Number Descriptions . . . . . . . . . . . . . . . . . . . . . . 5
Kinetix 300/Kinetix 350 Drive Catalog Number Descriptions . . . . . . . . . 6
Kinetix 300 Drive Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Kinetix 350 Drive Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pre-migration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1
Engineering Review Essentials Engineering Effort and Product Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Major Product Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . 11
Minor Product Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . 13
Potential Hardware Design Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 2
Migration Considerations Selecting a Replacement Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Factors Affecting Drive Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Output Current Comparison. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Dimension Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ultra3000 (230V) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ultra3000 (460V) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Kinetix 300/Kinetix 350 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Input Wiring and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC Input Power Wire Length and Routing. . . . . . . . . . . . . . . . . . . . . 22
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive Interconnects and Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Encoder Feedback Replacement Cables. . . . . . . . . . . . . . . . . . . . . . . . . 27
2090-Series Motor/Actuator Cables Overview. . . . . . . . . . . . . . . . . . . . . . 30
I/O Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ultra3000 CN1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Kinetix 300/Kinetix 350 Expansion Block. . . . . . . . . . . . . . . . . . . . . . 32
Master Encoder/Gearing Signals/Buffered Encoder Signals . . . . . . 32
I/O Availability and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Auxiliary Logic Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Analog Current Limit Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Analog Current Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 3


Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Shunt Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Appendix A
Connectors and Field Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connections Encoder Wiring Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Control Wiring Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mains Power Wiring Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Appendix B
Specifications General Power Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ultra3000 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Kinetix 300/Kinetix 350 Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Digital I/O Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Digital Input Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Digital Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog I/O Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog Input Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog Output Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Environmental and Safety Feature Comparison . . . . . . . . . . . . . . . . . . . . . 61
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Safety Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Appendix C
Feature Comparison Chart Feature Comparison Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Appendix D
Hardware Layout with Ultra3000 Drive Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connections Kinetix 300/Kinetix 350 Drive Power Wiring . . . . . . . . . . . . . . . . . . . . . . 70

Appendix E
Topology/Architecture Layouts Ultra3000 (Analog) to Kinetix 300 Architecture . . . . . . . . . . . . . . . . . . . . 76
Ultra3000 (Indexing) to Kinetix 350 Architecture . . . . . . . . . . . . . . . . . . 77
Ultra3000 (SERCOS) to Kinetix 350 Architecture. . . . . . . . . . . . . . . . . . 78

4 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Preface

Overview The purpose of this migration guide is to provide you with the essential
information to determine what hardware design changes may be necessary when
migrating an Ultra™ 3000 servo drive to a Kinetix® 300 or Kinetix 350 servo drive.

This migration guide contains these chapters and appendices:

Chapter 1: Engineering Review Essentials Provides information on important differences


between the product families.
Chapter 2: Migration Considerations Provides information on drive sizing, input wiring
and fusing, motor power and I/O cabling, serial
communication, shunt resistors, and AC line
filters.
Appendix A: Connectors and Field Connections Provides information on connector locations, and
comparisons for encoder wiring, control wiring,
and mains power wiring.
Appendix B: Specifications Provides comparisons of the power
specifications, digital and analog I/O,
environmental specifications, and safety
features.
Appendix C: Feature Comparison Chart Compares the hardware and software features of
the product families.
Appendix D: Hardware Layout with Provides power wiring examples to assist you in
Connections comparing the power wiring for the Ultra3000
drive and the Kinetix 300/350 drive systems.
Appendix E: Topology/Architecture Layouts Provides information for typical Ultra3000 drive
architecture and Kinetix 300/350 drive
architecture.

Ultra3000 Drive Catalog


Number Descriptions 2098-DSD- xx xxx x-xx
Connectivity Option
DN = DeviceNet interface
SE = SERCOS interface
Blank = No network connectivity
Indexing Capability
X = Indexing
Blank = No indexing
Continuous Output Power
005 = 500 W 030 = 3 kW 100 = 10 kW
010 = 1 kW 050 = 5 kW 150 = 15 kW
020 = 2 kW 075 = 7.5 kW 220 = 22 kW
Input Power (VAC)
HV = High Voltage (230…480V AC)
Blank = Standard (100…240V AC)
Digital Servo Drive
Bulletin Number

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 5


Preface

Kinetix 300/Kinetix 350 Kinetix 300 Drive Kinetix 350 Drive Description Power
Drive Catalog Number Cat. No. Cat. No. (kW)
Descriptions Single-phase
2097-V31PR0 2097-V31PR0-LM 1Ø, 2 A, 120/240V, no filter 0.4
(120V-voltage doubler)
2097-V31PR2 2097-V31PR2-LM 1Ø, 4 A, 120/240V, no filter 0.8
(120V-voltage doubler)
2097-V32PR0 2097-V32PR0-LM 1Ø, 2 A, 240V, integral filter 0.4
2097-V32PR2 2097-V32PR2-LM 1Ø, 4 A, 240V, integral filter 0.8
2097-V32PR4 2097-V32PR4-LM 1Ø, 8 A, 240V, integral filter 1.7
Single-/Three-phase
2097-V33PR1 2097-V33PR1-LM 1Ø, 3Ø, 2 A, 240V, no filter 0.5
2097-V33PR3 2097-V33PR3-LM 1Ø, 3Ø, 4 A, 240V, no filter 1
2097-V33PR5 2097-V33PR5-LM 1Ø, 3Ø, 8 A, 240V, no filter 2
2097-V33PR6 2097-V33PR6-LM 1Ø, 3Ø, 12 A, 240V, no filter 3
Three-phase
2097-V34PR3 2097-V34PR3-LM 3Ø, 2 A, 480V, no filter 1
2097-V34PR5 2097-V34PR5-LM 3Ø, 4 A, 480V, no filter 2
2097-V34PR6 2097-V34PR6-LM 3Ø, 6 A, 480V, no filter 3

6 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Preface

Kinetix 300 Drive Features The Kinetix 300 drive offers a cost-effective, low axis count EtherNet/IP
indexing servo drive solution. Features of the Kinetix 300 drive include the
following:
• Indexing
– Five indexing types
– S-curve and trapezoidal moves
– 32 index capability
• Commanded control over the EtherNet/IP network
– Velocity and current
– Absolute and incremental position with or without registration
• Electronic gearing
• Analog input control
• Step and direction control
• Integrated safe torque-off

Kinetix 350 Drive Features The Kinetix 350 drive is a single-axis solution developed to provide scalability at
a low cost. It simplifies integration of the entire control solution on one network,
including human-machine interface (HMI), programmable automation
controller, I/O, and motion. Features of the Kinetix 350 drive include the
following:
• Connects via EtherNet/IP network with common industrial protocol
(CIP) Motion technology, which provides real-time, closed-loop motion
control with standard Ethernet
• Fully compatible in a star or linear topology
• Integrates with L6 and L7 ControlLogix® and CompactLogix™ controllers
supporting Integrated Motion on EtherNet/IP network
• Programming supported in RSLogix™ 5000 software, version 20.00.00
• Supports standard motion instruction set, including Kinematics
• Comes equipped with embedded safe torque-off functionality

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 7


Preface

Pre-migration Migrating from a motion control system that uses Ultra3000 drives to a system
that uses Kinetix 300 or Kinetix 350 drives requires a comprehensive design
review of the motion control system. There are multiple drive replacement
combinations, and multiple configurations for how the drives can be installed and
software applied. As a result, this migration guide is not an all-inclusive
document. It does not describe all the redesign steps that may be required, nor
does it contain the detailed product information necessary to finalize the
redesign. The generalities of the replacement process are covered, and the
decision-making steps likely to be encountered in a typical replacement scenario
are described.

Figure 1 - Suggested Migration Options

Analog Kinetix 300 Drive

Kinetix 300 Drive


Ultra3000 Drive Indexing
Kinetix 350 Drive

SERCOS Kinetix 350 Drive

Best Practices Motors – Verify that your current motor is compatible with the Kinetix 300/350
servo drive family. Kinetix 300/350 drives are compatible with MP-Series™ or
TL-Series™ servo motors or linear actuators.

IMPORTANT Third-party motors are not supported with Kinetix 300 drives. Check with
your Rockwell Automation representative to see if your third-party motor
is compatible with the Kinetix 350 drives.

Feedback Cable Length – Verify that the feedback cable length in your current
Ultra3000 system does not exceed the maximum feedback cable length for the
Kinetix 300/350 servo drives. The maximum feedback cable length for the
Kinetix 300/350 servo drives is 20 m (65.6 ft).

Configuration Files– Use the Ultraware software to upload and save the
Ultra3000 drive configuration file for future reference. If using a serial real-time
communication system (SERCOS) Ultra3000 drive, upload and save any
network files and programmable logic controller (PLC) programs.

Electrical Noise – Refer to the System Design for Control of Electrical Noise
Reference Manual, publication GMC-RM001, to better understand the concept
of electrical noise reduction.

8 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Preface

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.

Resource Description
Kinetix 300 and Kinetix 350 Drive Systems Design Guide, Provides information to assist you in identifying the drive system components and accessory
publication GMC-RM004 items you’ll need for your Kinetix 300/350 drive and motor/actuator combination.
Integrated Motion on SERCOS and EtherNet/IP Systems - Compares and contrasts Integrated Motion systems using SERCOS and EtherNet/IP with a
Analysis and Comparison White Paper, publication ControlLogix Programmable Automation Controller (PAC).
MOTION-WP001
Kinetix 350 EtherNet/IP Indexing Servo Drives User Provides installation instructions for mounting, wiring, and troubleshooting your Kinetix 350
Manual, publication 2097-UM002 drive; and system integration for your drive/motor combination with a Logix controller.
Kinetix 350 EtherNet/IP Indexing Servo Drive Installation Provides information on installing your Kinetix 350 drive system.
Instructions, publication 2097-IN008
Kinetix 300 EtherNet/IP Indexing Servo Drives User Provides installation instructions for mounting, wiring, and troubleshooting your Kinetix 300
Manual, publication 2097-UM001 drive; and system integration for your drive/motor combination with a Logix controller.
Kinetix 300 EtherNet/IP Indexing Servo Drive Installation Provides information on installing your Kinetix 300 drive system.
Instructions, publication 2097-IN001
Kinetix 300 Shunt Resistor Installation Instructions, Provides information on installing and wiring the Kinetix 300 shunt resistors
publication 2097-IN002 (also compatible with the Kinetix 350 drive).
Kinetix 300 AC Line Filter Installation Instructions, Provides information on installing and wiring the Kinetix 300 AC line filter
publication 2097-IN003 (also compatible with the Kinetix 350 drive).
Kinetix 300 I/O Terminal Expansion Block Installation Provides information on installing and wiring the Kinetix 300 I/O terminal expansion block
Instructions, publication 2097-IN005 (also compatible with the Kinetix 350 drive).
Kinetix 300 Memory Module Installation Instructions, Provides information on installing the Kinetix 300 memory module
publication 2097-IN007 (also compatible with the Kinetix 350 drive).
Kinetix 300 Memory Module Programmer Quick Start, Provides information on using the memory module programmer to duplicate the memory
publication 2097-QS001 module (also compatible with the Kinetix 350 drive).
1769-L32E and 1769-L35E CompactLogix Controller Information on how to assemble and mount the controller, how to upgrade firmware, and
Installation Instructions, publication 1769-IN020 controller technical specifications.
1769-L32C and 1769-L35CR CompactLogix Controller Information on how to assemble and mount the controller, how to upgrade firmware, and
Installation Instructions, publication 1769-IN070 controller technical specifications.
1769-L31 CompactLogix Controller Installation Information on how to assemble and mount the controller, how to upgrade firmware, and
Instructions, publication 1769-IN069 controller technical specifications.
Ultraware Software User Manual, publication Provides detailed installation instructions, defines software interface features, and
2098-UM001 programming assistance for Ultraware software.
Ultra3000 Digital Servo Drive with DeviceNet, publication Provides information on how to use DeviceNet to install, start up, and troubleshoot an
2098-RM004 Ultra3000 drive.
Ultra3000 Digital Servo Drives Installation Manual,
publication 2098-IN003 Provides mounting, wiring, and connecting procedures for the Ultra3000 drive.

Ultra3000 Digital Servo Drives Integration Manual, Information on configuring and troubleshooting your Ultra3000 drive.
publication 2098-IN005
Rockwell Automation Configuration and Selection Tools,
website www.ab.com/e-tools Online product selection and system configuration tools, including AutoCAD (DXF) drawings.

Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell Automation industrial system.
publication 1770-4.1
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at http://www.rockwellautomation.com/


literature/. To order paper copies of technical documentation, contact your local
Allen-Bradley® distributor or Rockwell Automation sales representative.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 9


Preface

Notes:

10 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Chapter 1

Engineering Review Essentials

Replacing an Ultra3000 drive with a Kinetix 300 or Kinetix 350 drive may
require some system design changes. Follow these steps to properly formulate the
design changes:

• Review the hardware and software design of the current Ultra3000 system.
The appendices in this document can help you with this process.

• Review the hardware and software specifications for the Kinetix 300/350
drives.

• Use this document as a guide for determining hardware design changes.

Engineering Effort and Thoroughly review this document before you begin to evaluate the design
changes required to successfully migrate your Ultra3000 drive to a Kinetix 300/
Product Liability 350 drive.

WARNING: Because of the variety of uses for the products described in


this publication, those responsible for the application and use of these
products must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and
safety requirements, including any applicable laws, regulations, codes
and standards. In no event will Rockwell Automation be responsible or
liable for indirect or consequential damage resulting from the use or
application of these products.

The following sections highlight the major and minor differences between the
Ultra3000 drives and Kinetix 300/350 drives. Additional differences may also
impact your application. Read this entire document before proceeding to qualify
the Kinetix 300/350 drives for your needs.

Major Product Listed here are some major differences between the Ultra3000 drives and the
Kinetix 300/350 drives.
Replacement
Considerations Serial Port – The Kinetix 300/350 drives do not have a serial port. The Kinetix
300/350 programming interface is via Ethernet, and the Kinetix 300 drive can be
programmed by using java-based embedded software. If your Ultra3000 drive
application uses host mode programming or the serial port for HMI
communication, the difference in communication and programming will have to
be addressed. See Appendix A.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 11


Chapter 1 Engineering Review Essentials

SERCOS or DeviceNet Networks – There are no SERCOS or DeviceNet


embedded options on the Kinetix 300/350 drives (but they may be used on the
Ultra3000 drives). Determine if your application depends on these options, and
verify whether your application can be modified or if the architecture can be
changed. See Appendix D and Appendix E.

Physical Dimensions – The physical size of the drive families are different (see
Drive Sizing on page 16). In most cases, the Kinetix 300/350 drives are smaller
and will fit into the existing space of the compatible Ultra3000 drives; however,
you should verify the physical size of the Kinetix 300/350 drive.

Shunting – The Ultra3000 drives (except micro sizes) have internal shunting
capability, while the Kinetix 300/350 drives have external shunting capability
only. See Shunt Resistors on page 45 to help you verify the differences and
determine if you need to resize the drive, or if your space requirements will
change with the Kinetix 300/350 drives if you require a shunt module to be
added in the panel.

Power Range – The Kinetix 300/350 drives have a different drive power range
that may not match directly with the Ultra3000 drive power range. See Drive
Sizing on page 16 and Dimension Comparison on page 17 to determine if your
power range is covered with the Kinetix 300/350 drives, or if resizing or a
different drive architecture is required.

Auxiliary Power – The Ultra3000 drives use a different method of providing


auxiliary power than the Kinetix 300/350 drives (see Auxiliary Logic Power on
page 35 and Appendix A). A 24V power supply may need to be added to the
Kinetix 300/Kinetix 350 drives if auxiliary power is required.

I/O Interface – The Ultra3000 drives have a D-shell connector for I/O interface
connection, while the Kinetix 300/350 drives use a small computer system
interface (SCSI) connector for I/O interface. If your application cannot modify
the cable interface or breakout board to the I/O, this may be an issue. See I/O
Cabling on page 31.

Cable Lengths – The Ultra3000 drives support cable lengths for motor and
power up to 90 m (295.2 ft), while the Kinetix 300/350 drives support cable
lengths up to 20 m (65.6 ft) only. See Drive Interconnects and Cabling on
page 24.

Output Frequency – If you are using the Ultra3000 (non-SERCOS version)


drives to interface to an external controller, the output encoder frequency can be
modified to provide a range of resolutions; while the Kinetix 300 drives have a
fixed output frequency of 4096 counts/motor rev with a maximum of 2 MHz
output frequency. The Kinetix 350 drives do not provide an output frequency.
See Master Encoder/Gearing Signals/Buffered Encoder Signals on page 32.

12 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Engineering Review Essentials Chapter 1

Dual Loop Operation – The Ultra3000 drives have the ability to power Aux
encoders for use in master gearing or dual loop modes. This power supply is not
available in the Kinetix 300/350 drives. If your application requires dual loop
operation, it is not supported with the Kinetix 300/350 drives. See Master
Encoder/Gearing Signals/Buffered Encoder Signals on page 32.

Minor Product Listed here are some minor differences between the Ultra3000 drives and the
Kinetix 300/350 drives. See Appendix C for a feature comparison chart that
Replacement shows the notable differences. Some key differences include the following:
Considerations
Relay Outputs – The I/O implementation between the drives is different (see
I/O Availability and Specifications on page 35 and Appendix B). Most notably,
there is no relay output on the Kinetix 300/350 drives. This has to be addressed
on replacement.

Hardware Enable Signal – The Ultra3000 drives can operate without a


hardware enable signal present. The Kinetix 300 drives require a hardware enable
signal. The Kinetix 350 drives can operate without a hardware drive enable signal.
See Appendix C.

Digital Inputs – The Ultra3000 drives have multiple assignment for digital
inputs, while the Kinetix 300/350 drives have single assignment for digital inputs
(see Digital Inputs on page 36 and Digital I/O Comparison on page 59).

Operation Mode Override – The Ultra3000 drives have an Operation mode


override that is capable of operation via digital I/O, while the Kinetix 300/350
drives do not. See Appendix C.

Potential Hardware Design The design changes required for converting to the Kinetix 300/350 drives
depend on the original/replacement drive combination and the specifics of the
Changes application. The objective is to determine which areas of a design may need to be
changed. This document provides you with knowledge about the type and extent
of work that may be required to successfully change from an Ultra3000 system to
a Kinetix 300/350 system.

IMPORTANT Due to the flexibility of drive installation and usage, it is not feasible to
cover all possible issues that may be encountered. In addition to the
items described in this document, the engineering/design team should
pay particular attention to unique features and functions of the Ultra3000
system when considering replacement with a Kinetix 300/350 system.

The following chapters and appendices cover the majority of hardware/design


considerations for the replacement of the Ultra3000 drives with Kinetix 300/350
drives.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 13


Chapter 1 Engineering Review Essentials

Notes:

14 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Chapter 2

Migration Considerations

Selecting a Replacement Drive sizing is the primary factor in selecting a replacement drive. To identify the
correct replacement drive size, compare the continuous and peak output current
Drive ratings.

In general, regarding the current ratings, the following rules apply:

These Ultra3000 drives can be replaced with a Kinetix 300/350 drive of similar,
or in some cases greater, output current capability:
• 2098-DSD-005
• 2098-DSD-010
• 2098-DSD-020
• 2098-DSD-030
• 2098-DSD-HV030
• 2098-DSD-HV050

The Kinetix 300/350 drives have similar current ratings and require less physical
space than the Ultra3000 drives.

These Ultra3000 drives do not have similar replacements in the Kinetix 300/350
drives series:
• 2098-DSD-075
• 2098-DSD-150
• 2098-DSD-HV150
• 2098-DSD-HV220

Factors Affecting Drive Replacement


Factors that affect the redesign effort include the following considerations:
• Drive Sizing (ratings and physical)
• Dimension Comparison
• Drive Interconnects and Cabling
• Serial Communication
• Accessories

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 15


Chapter 2 Migration Considerations

Drive Sizing This section lists the Ultra3000 drives and the suggested Kinetix 300/350
replacement drives, along with the output ratings and dimension differences of
the drives. Information in this migration guide is based on the drive combinations
shown in Table 1 and Table 2.

Output Current Comparison

IMPORTANT The performance capabilities of the replacement drive should be


reviewed to be sure that the replacement drive is capable of delivering
the required level of peak and continuous current to the motor.

Table 1 - Suggested Kinetix 300/350 Replacement Drives by Output Current


Ultra3000 Drives Kinetix 300/350 (2) Drives
Model Voltage Nominal Output Recommended Kinetix 300/ Voltage Nominal Output
Range Voltage Current Kinetix 350 Replacement Drives (2) Range Voltage Current
(V) Range Rating (V) Range Rating
(V) (0-pk) -A(1) (V) (0-pk) A(1)
70...264 120...240
2097-V31PR0-xx 2.8
1Ø 1Ø
80...264
2097-V32PR0-xx 240 1Ø 2.8

88...265 120...240 80...264 120...240
2098-DSD-005 2.5
1Ø 1Ø 1Ø 1Ø
2097-V33PR1-xx 2.8
80...264 240 3Ø

320...528
2097-V34PR3-xx 480 3Ø 2.8

70...132
2097-V31PR2-xx 120 1Ø 5.7

80...264
2097-V32PR2-xx 240 1Ø 5.7

88...265 120...240 80...264 120...240
2098-DSD-010 5
1Ø 1Ø 1Ø 1Ø
2097-V33PR3-xx 5.7
80...264 240 3Ø

320...528
2097-V34PR5-xx 480 3Ø 5.7

80...264
2097-V32PR4-xx 240 1Ø 11.3

88...265 120...240 80...264 120...240
2098-DSD-020 10
1Ø 1Ø 1Ø 1Ø
2097-V33PR5-xx 11.3
80...264 240 3Ø

80...264 120...240
88...265 120...240 1Ø 1Ø
2098-DSD-030 15 2097-V33PR6-xx 17
1Ø 1Ø 80...264 240 3Ø

88...265 120...240
2098-DSD-075 3Ø 3Ø 35 N/A

16 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Table 1 - Suggested Kinetix 300/350 Replacement Drives by Output Current (continued)


Ultra3000 Drives Kinetix 300/350 (2) Drives
Model Voltage Nominal Output Recommended Kinetix 300/ Voltage Nominal Output
Range Voltage Current Kinetix 350 Replacement Drives (2) Range Voltage Current
(V) Range Rating (V) Range Rating
(V) (0-pk) -A(1) (V) (0-pk) A(1)
88...265 120...240
2098-DSD-150 65 N/A
3Ø 3Ø
80...264
2097-V33PR5-xx 240 3Ø 11.3
207...528 230...480 3Ø
2098-DSD-HV030 7
3Ø 3Ø 320...528
2097-V34PR6-xx 480 3Ø 8.5

80...264
207...528 230...480 2097-V33PR5-xx 240 3Ø 11.3
2098-DSD-HV050 11 3Ø
3Ø 3Ø
N/A
207...528 230...480
2098-DSD-HV100 3Ø 3Ø 23 N/A

207...528 230...480
2098-DSD-HV150 3Ø 3Ø 34 N/A

207...528 230...480
2098-DSD-HV220 47 N/A
3Ø 3Ø
(1) Continuous output current ratings are used.
(2) The Kinetix 350 drive part number has a -LM at the end of the catalog string (see Kinetix 300/Kinetix 350 Drive Catalog Number Descriptions on page 6).

Dimension Comparison
Table 2 provides a comparison of the dimensions of the drives.

Table 2 - Suggested Kinetix 300/350 Replacement Drives by Dimensions

Ultra3000 Drive Kinetix 300/350 Drive Dimension Differences, Kinetix Referenced (1)
Model Number Height Width Depth Model Number Height Width Depth Height (2) Width (2) Depth (2)
mm mm mm mm mm mm mm (in.) mm (in.) mm (in.)
2098-DSD-005 198.12 95.5 144.27 2097-V31PR0-xx 190 68 185.1 -8.12 (-0.32) -27.5 (-1.08) 40.83 (1.61)
198.12 95.5 144.27 2097-V32PR0-xx 190 68 229.6 -8.12 (-0.32) -27.5 (-1.08) 85.33 (3.36)
198.12 95.5 144.27 2097-V33PR1-xx 190 68 185.1 -8.12 (-0.32) -27.5 (-1.08) 40.83 (1.61)
198.12 95.5 144.27 2097-V34PR3-xx 190 68.5 185.1 -8.12 (-0.32) -27.0 (-1.06) 40.83 (1.61)
2098-DSD-010 198.12 121.54 144.27 2097-V31PR2-xx 190 68.5 185.1 -8.12 (-0.32) -53.04 (-2.09) 40.83 (1.61)
198.12 121.54 144.27 2097-V32PR2-xx 190 68.5 229.6 -8.12 (-0.32) -53.04 (-2.09) 85.33 (3.36)
198.12 121.54 144.27 2097-V33PR3-xx 190 68.5 185.1 -8.12 (-0.32) -53.04 (-2.09) 40.83 (1.61)
198.12 121.54 144.27 2097-V34PR5-xx 190 94.4 185.1 -8.12 (-0.32) -27.14 (-1.07) 40.83 (1.61)
2098-DSD-020 198.12 121.54 144.27 2097-V32PR4-xx 190 86.8 229.6 -8.12 (-0.32) -34.74 (-1.37) 85.33 (3.36)
198.12 121.54 144.27 2097-V33PR5-xx 190 94.4 185.1 -8.12 (-0.32) -27.14 (-1.07) 40.83 (1.61)
2098-DSD-030 360.68 91.44 243.84 2097-V33PR6-xx 190 68 229.6 -170.7 (-6.72) -23.44 (-0.92) -14.24 (-0.56)
2098-DSD-HV030 360.7 138.7 242.2 2097-V33PR5-xx 190 94.4 185.1 -170.7 (-6.72) -44.3 (-1.74) -57.1 (-2.25)
360.7 138.7 242.2 2097-V34PR6-xx 190 68 229.6 -170.7 (-6.72) -70.7 (-2.78) -12.6 (-0.50)
2098-DSD-HV050 360.7 138.7 242.2 2097-V33PR5-xx 190 94.4 185.1 -170.7 (-6.72) -44.3 (-1.74) -57.1 (-2.25)
(1) Dimensions chosen were for Ultra3000 drives -SE, -DN, -XDN (see Ultra3000 (230V) Dimensions on page 18).
(2) A minus sign denotes that the height, width, or depth of the Kinetix 300/350 drive is shorter, narrower, or shallower than the comparable Ultra3000 drive.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 17


Chapter 2 Migration Considerations

Dimension Drawings This section provides dimensions of the drives to assist you in determining the
space needed to install the drives.

Ultra3000 (230V) Dimensions

In Figure 2, -xxx is replaced by -005, -010, or -020 to represent the Ultra3000


500 W, 1 kW, and 2 kW drives respectively.

Figure 2 - Ultra3000 (230V) Dimensions (catalog numbers 2098-DSD-xxx,


2098-DSD-xxxX, 2098-DSD-xxx-SE, 2098-DSD-xxx-DN, 2098-DSD-xxxX-DN)
A 129.03
38.1 C (5.08)
(1.5)

186.18 165.1 198.12


(7.33) (6.5) (7.8)

E 144.27
(5.68)
F
Dimensions are in mm (in.)
Unit shown is the 2098-DSD-005-SE drive.

Ultra3000 Drive A C E F
2098-DSD-005 72.64
2098-DSD-005X (2.86)
2098-DSD-010 65.02 13.26 32.77
2098-DSD-010X (2.56) (0.52) (1.29) 98.1
2098-DSD-020 (3.89)
2098-DSD-020X
2098-DSD-005-SE 95.5
2098-DSD-005-DN (3.76)
2098-DSD-005X-DN
2098-DSD-010-SE 87.88 24.64 43.94
2098-DSD-010-DN (3.46) (0.97) (1.73)
2098-DSD-010X-DN 121.54
2098-DSD-020-SE (4.79)
2098-DSD-020-DN
2098-DSD-020X-DN

18 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

In Figure 3, -xxx is replaced by -030, -075, or -150 to represent the Ultra3000 3,


7.5, and 15 kW drives respectively.

Figure 3 - Ultra3000 (230V) Dimensions (catalog numbers 2098-DSD-xxx,


2098-DSD-xxxX, 2098-DSD-xxx-SE, 2098-DSD-xxx-DN, 2098-DSD-xxxX-DN)

A
B 227.08
C (8.94)

349.25 360.68
(13.75) (14.2)
331.47
(13.05)

C
B J
Dimensions are in mm (in.)
Unit shown is the 2098-DSD-030 drive.

Ultra3000 Drive A B C J
2098-DSD-030
2098-DSD-030X 91.44 50.8 20.32 243.84
2098-DSD-030-SE (3.6) (2.0) (0.8) (9.6)
2098-DSD-030-DN
2098-DSD-030X-DN
2098-DSD-075
2098-DSD-075X
2098-DSD-075-SE 138.68 88.9 24.89 247.14
2098-DSD-075-DN (5.41) (3.5) (0.96) (9.73)
2098-DSD-075X-DN(1)
2098-DSD-150
2098-DSD-150X 188.97 139.7 24.6 241.05
2098-DSD-150-SE (7.44) (5.5) (0.97) (9.49)
2098-DSD-150-DN
2098-DSD-150X-DN(1)
(1) 2098-DSD-075 and 2098-DSD-150 Ultra3000 drives do not have similar replacements in the Kinetix 300/350
drives series.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 19


Chapter 2 Migration Considerations

Ultra3000 (460V) Dimensions

In Figure 4, xxx is replaced by 030, 050, 100, 150, or 220 to represent the
Ultra3000 3, 5, 10, 15, and 22 kW drives respectively.

Figure 4 - Ultra3000 (460V) Dimensions (catalog numbers 2098-DSD-HVxxx,


2098-DSD-HVxxxX, 2098-DSD-HVxxx-SE, 2098-DSD-HVxxx-DN,
2098-DSD-HVxxxX-DN)

A
225.8
B B C (8.89)

D H
I

B B C 242.2
(9.54)
Dimensions are in mm (in.)
Unit shown is the 2098-DSD-HV030 drive.

Ultra3000 Drive(1) A C B D H I
2098-DSD-HV030x
2098-DSD-HV030-xx 138.7 18.5
2098-DSD-HV050x 5.46) (0.73)
2098-DSD-HV050-xx 50.8 349.3 331.5 360.7
2098-DSD-HV100x (2.0) (13.75) (13.05) (14.2)
2098-DSD-HV100-xx 151.6 25
2098-DSD-HV150x (5.97) (0.99)
2098-DSD-HV150-xx (2)
2098-DSD-HV220x 203.2 25.4 76.2 380.4 362.6 391.8
2098-DSD-HV220-xx (2) (8.0) (1.0) (3.0) (14.98) 14.26) (15.43)
(1) The x represents the indexing (X) option. The -xx represents the SERCOS interface (SE) or DeviceNet (DN)
option. SERCOS interface is not available with the DeviceNet option.
(2) 2098-DSD-HV150, and HV220 Ultra3000 drives do not have similar replacements in the Kinetix 300/350 drives
series.

20 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Kinetix 300/Kinetix 350 Dimensions


Dimensions are in mm (in.).
A 30.8
5.0 7.1 (1.21)
(0.19) (0.28)

9.7
(0.38) 300

182
2097-TB1 (7.18)
238 I/O Terminal 190
(9.37) (7.50)
Expansion
Block

6.6
(0.26)
2090-K2CK-D15M 11.8 Ø 4.57
61.0 38.1 (0.18) 3x
Low-profile Connector Kit (2.40) (0.46) (1.5)
for Bulletin 2090 (flying- B
lead) Feedback Cable
Additional clearance below the connector kit is necessary
to provide the recommended cable bend radius.

Cat. No. Dimensions mm (in.) Cat. No. Dimensions mm (in.)


A B A B
2097-V31PR0-xx 185.1 (7.29) 68.0 (2.68) 2097-V33PR3-xx 185.1 (7.29) 68.5 (2.70)
2097-V31PR2-xx 185.1 (7.29) 68.5 (2.70) 2097-V33PR5-xx 185.1 (7.29) 94.4 (3.72)
2097-V32PR0-xx 229.6 (9.04) 68.0 (2.68) 2097-V33PR6-xx 229.6 (9.04) 68.0 (2.68)
2097-V32PR2-xx 229.6 (9.04) 68.5 (2.70) 2097-V34PR3-xx 185.1 (7.29) 68.5 (2.70)
2097-V32PR4-xx 229.6 (9.04) 86.8 (3.42) 2097-V34PR5-xx 185.1 (7.29) 94.4 (3.72)
2097-V33PR1-xx 185.1 (7.29) 68.0 (2.68) 2097-V34PR6-xx 229.6 (9.04) 68.0 (2.68)

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 21


Chapter 2 Migration Considerations

Input Wiring and Fusing This section provides information to assist you in determining the wiring and
fusing requirements of the drives.

AC Input Power Wire Length and Routing

Determine the wire length for the AC line input after the drive location and any
changes to routing are finalized.

In general, the recommended drive replacement should not require changes in


wiring length; however, the routing may need to change as the input power
(Mains IPD) and motor power (MP) connections on the Kinetix 300/350 drives
are on the top and bottom of the drive, respectively, while these same connections
are located on the front of the Ultra3000 drives. See Connectors and Field
Connections on page 49 for a comparison of the Ultra3000 drive and
Kinetix 300/Kinetix 350 drive terminals.

Fusing

Review the fusing requirements when changing drives.

The Ultra3000 drives are listed by Underwriters Laboratories, Inc. (UL) with
fuses sized at four times the continuous output current of the full load amps
(FLA) of the drive, according to UL 508C. In most cases, fuses selected to match
the drive input current rating meet the National Electrical Code (NEC)
requirements and provide the full drive capabilities. Use dual-element, time-delay
(slow-acting) fuses to avoid nuisance trips during the inrush current of power
initialization. The Kinetix 300/350 drives are also listed by UL 508C.

In general, the Ultra3000 drives use Class CC, G, J, L, R, or T fuses with current
ratings as indicated in Table 3. The Kinetix 300/350 drives use class CC or T
fast-acting, current limiting-type fuses; 200,000 A interrupting capacity (AIC)
preferred. Use Cooper Bussmann KTK-R, JJN, or JJS fuses. Table 3 shows the
fuses for the different drive sizes.

22 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Table 3 - Fuse Comparison

Ultra3000 Drives Kinetix 300/350 Drives


Model Voltage Nominal Input Aux Input Recommended Voltage Nominal Input Aux
Range (V) Voltage Power(1) Power(1) Kinetix 300/350 Range (V) Voltage Power(1) Input
Range (V) Replacement Range (V) Power(3)
Drives
2097-V31PR0-xx KTK-R-20
2097-V31PR0-xx 80...264 1Ø 240 1Ø KTK-R-10
2097-V32PR0-xx KTK-R-20
2098-DSD-005 88...265 1Ø 120...240 1Ø FNQ-R-6 FNQ-R-10 70...264 1Ø 120 1Ø KTK-R-20
2097-V33PR1-xx 80...264 1Ø 240 1Ø KTK-R-15
80...264 3Ø 240 3Ø KTK-R-15
2097-V34PR3-xx 320...528 3Ø 480 3Ø KTK-R-10
2097-V31PR2-xx 70...132 1Ø 120 1Ø KTK-R-30
2097-V32PR2-xx 80...264 1Ø 240 1Ø KTK-R-20
70...264 1Ø 120 1Ø KTK-R-20
2098-DSD-010 88...265 1Ø 120...240 1Ø FNQ-R-10 FNQ-R-10
2097-V33PR3-xx 80...264 1Ø 240 1Ø KTK-R-15
80...264 3Ø 240 3Ø KTK-R-15
2097-V34PR5-xx 320...528 3Ø 480 3Ø KTK-R-10
24V DC
2097-V32PR4-xx 80...264 1Ø 240 1Ø KTK-R-30 control
back-up
70...264 1Ø 120 1Ø KTK-R-30 power
2098-DSD-020 88...265 1Ø 120...240 1Ø FNQ-R-20 FNQ-R-10 supply
2097-V33PR5-xx 80...264 1Ø 240 1Ø KTK-R-20 (optional
equipment)
80...264 3Ø 240 3Ø KTK-R-20
70...264 1Ø 120 1Ø KTK-R-30
2098-DSD-030 88...265 1Ø 120...240 1Ø FNQ-R-30 FNQ-R-10 2097-V33PR6-xx 80...264 1Ø 240 1Ø KTK-R-30
80...264 3Ø 240 3Ø KTK-R-30
2098-DSD-075 88...265 3Ø 120...240 3Ø FNQ-R-30 FNQ-R-10 N/A
(2)
2098-DSD-150 88...265 3Ø 120...240 3Ø LPJ-60SP FNQ-R-10 N/A
FNQ-R-10 2097-V33PR5-xx 80...264 3Ø 240 3Ø KTK-R-20
2098-DSD-HV030 207...528 3Ø 230...480 3Ø KTK-R-5
FNQ-R-10 2097-V34PR6-xx 320...528 3Ø 480 3Ø KTK-R-20
FNQ-R-10 2097-V33PR5-xx 80...264 3Ø 240 3Ø KTK-R-20
2098-DSD-HV050 207...528 3Ø 230...480 3Ø KTK-R-8
FNQ-R-10 N/A
2098-DSD-HV100 207...528 3Ø 230...480 3Ø KTK-R-20 FNQ-R-10 N/A
2098-DSD-HV150 207...528 3Ø 230...480 3Ø KTK-R-30 FNQ-R-10 N/A
(2)
2098-DSD-HV220 207...528 3Ø 230...480 3Ø LPJ-35SP FNQ-R-10 N/A

(1) Class CC type Cooper Bussmann fuses are shown.


(2) Fuse shown is Class J Cooper Bussmann type fuse.
(3) A 24V power supply may need to be added to the Kinetix 300/Kinetix 350 drives if auxiliary power is required. See Auxiliary Logic Power on page 35 and Appendix A.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 23


Chapter 2 Migration Considerations

Drive Interconnects and This section provides information to assist you in determining the interconnects
and cabling requirements of the drives.
Cabling
Motor Power

Motor Power Wire Gauge

In general, an Ultra-series motor power cable (part number 2090-xxxx) can


connect directly to Kinetix 300/350 drives. This section provides information on
the motor power interconnects and cabling.

IMPORTANT The length of the power and/or feedback cables for the Kinetix 300/350
drives cannot exceed 20 m (65 ft). Performance was tested at this length
and meets CE requirements.

If you are using a new wire gauge, verify that the capacity of the new wire is
capable of handling the current to the actuator.

Motor Power Replacement Cables

The current motor power cabling system can be used for both the
Kinetix 300/350 drives, and the Ultra3000 drives. The motor power cables are
interchangeable and depend on the actuator used.

Cable shield and lead preparation is provided with most Allen-Bradley cable
assemblies. Follow these guidelines if your motor power cable shield and wires
require preparation.

Figure 5 - Cable Shield and Lead Preparation

Strip Length (see Table 5)

U
Outer Insulation
V

W
Motor Power Cable

Exposed Braid As required to have ground clamp within


25.4 mm (1.0 in.) 50…75 mm (2…3 in.) of the drive.

Table 4 - Motor Power (MP) Connector


MP-Series or TL-Series Terminal
Servo Motor
U = Brown U
V = Black V
W = Blue W
= Green/Yellow

24 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Table 5 - Motor Power (MP) Termination Specifications


Recommended
Drive Cat. No. Terminals Wire Size Strip Length Torque Value
mm (in.) N•m (lb•in)
mm2 (AWG)
2097-V31PR0-xx
2097-V31PR2-xx
2097-V32PR0-xx
2097-V32PR2-xx
2097-V32PR4-xx PE
2097-V33PR1-xx W 2.5 (14)
2097-V33PR3-xx 7 (0.28) 0.5 (4.5)
V
2097-V33PR5-xx U
2097-V34PR3-xx
2097-V34PR5-xx
2097-V34PR6-xx
2097-V33PR6-xx 4.0 (12)

Table 6 - Power/Brake Cable Descriptions (standard, non-flex)

Standard Cable Cable Configuration Motor/Actuator


Description
Cat. No. Motor/Acutator End Drive End Connector

• Drive-end flying-leads (DF)


2090-CPBM7DF-xxAAxx
• Power/brake wires (PB)
SpeedTec DIN
(M7)
• Drive-end flying-leads (DF)
2090-CPWM7DF-xxAAxx
• Power wires only (PW)

• Drive-end flying-leads
2090-XXNPMF-xxSxx
• Power/brake wires BR+
BR-

• Drive-end bayonet (E2), transition (TR) cable (1) Threaded DIN


2090-CPBM4E2-xxTR • Motor-end threaded DIN (M4) (M4)
• Power/brake wires (PB)
• Drive-end bayonet (E2), transition (TR) cable (1)
2090-CPWM4E2-xxTR • Motor-end threaded DIN (M4)
• Power wires only (PW)

• Drive-end flying-leads (DF)


2090-CPBM6DF-16AAxx
• Power/brake wires (PB) MBRK+
Circular Plastic
MBRK-
(M6)
• Drive-end flying-leads (DF)
2090-CPWM6DF-16AAxx
• Power wires only (PW)

(1) Threaded DIN connector (motor end) and bayonet connector for 2090-XXNFMP-Sxx cable. Refer to 2090-Series Motor Power and Feedback Transition Cables in the Kinetix
Motion Accessories Technical Data, publication GMC-TD004.

The current motor power cabling system can be used for both the Kinetix 300/
Kinetix 350 drives, and the Ultra3000 drives. The motor power cables are
interchangeable and depend on the actuator used.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 25


Chapter 2 Migration Considerations

Table 7 - Power/Brake Cable Descriptions (continuous-flex)

Standard Cable Cable Configuration Motor/Actuator


Description
Cat. No. Motor/Acutator End Drive End Connector

• Drive-end flying-leads (DF)


2090-CPBM7DF-xxAFxx
• Power/brake wires (PB)

SpeedTec DIN
• Drive-end flying-leads (DF) (M7)
2090-CPWM7DF-xxAFxx
• Power wires only (PW)

• Drive-end (male) connector, extension (E7) (1)


2090-CPBM7E7-xxAFxx
• Motor-end SpeedTec DIN cable plug (M7)

• Drive-end flying-leads (DF)


2090-CPBM4DF-xxAFxx
• Power/brake wires (PB) BR+
BR-
Threaded DIN
(M4)
• Drive-end flying-leads (DF)
2090-CPWM4DF-xxAFxx
• Power wires only (PW)

(1) SpeedTec DIN connector (motor end) and male connector for extending SpeedTec or threaded DIN cable. Refer to SpeedTec DIN Continuous-flex Extension Cables in the
Kinetix Motion Accessories Technical Data, publication GMC-TD004.

For further information, refer to the Motion Control Accessories section in the
Kinetix Motion Control Selection Guide, publication GMC-SG001, the bill of
materials (BOM) configuration tool within Motion Analyzer software, or
ProposalWorks™ from Rockwell Automation.

26 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Encoder Feedback Replacement Cables

The current motor encoder cabling system can be used for both the
Kinetix 300/350 drives, and the Ultra3000 drives.

IMPORTANT The length of the power and/or feedback cables for the Kinetix 300/350
drives cannot exceed 20 m (65 ft). Performance was tested at this length
and meets CE requirements.

Factory-made cables with premolded connectors are designed to minimize


electromagnetic interference (EMI). Rockwell Automation recommends
factory-made cables (over hand-built cables) to improve system performance.

Table 8 - Motor Feedback (MF) Connector Pinout

MF Pin Description Signal MF Pin Description Signal


Sine differential input+ SIN+
1 9 Reserved —
AM+ differential input+ AM+
Sine differential input- SIN- Data differential input - DATA-
2 10
AM- differential input- AM- Index pulse- IM-
Cosine differential input+ COS+ Motor thermal switch (normally
3 11 TS
BM+ differential input+ BM+ closed) (1)
Cosine differential input- COS- Single-ended 5V Hall effect
4 12 S1
BM- differential input- BM- commutation
Data differential input + DATA+ Single-ended 5V Hall effect
5 13 S2
Index pulse+ IM+ commutation
6 Common ECOM 14 Encoder power (+5V) EPWR_5V (3)
7 Encoder power (+9V) (2) EPWR_9V (3) 15 Reserved —
Single-ended 5V Hall effect
8 S3
commutation
(1) Not applicable unless motor has integrated thermal protection.
(2) +9V Encoder capability only available on standard size Ultra3000 drive (2098-DSD-030 or larger).
(3) Kinetix 300/350 drive encoder power supply uses either 5V or 9V DC based on encoder/motor used.

IMPORTANT Drive-to-motor power and feedback cable length for the Kinetix 300/
350 drives must not exceed 20 m (65.6 ft). Performance was tested at
this length and meets CE requirements.

Figure 6 - Pin Orientation for 15-pin Motor Feedback (MF) Connector


Pin 10
Pin 15 Pin 5

Pin 11 Pin 1
Pin 6

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 27


Chapter 2 Migration Considerations

Table 9 - Low Inertia and Integrated Gear Motors

Drive Family MPL-A (230V) Motors MPL-B (460V) Motors MPG-A MPG-B
(230V) Motors (460V) Motors
Absolute Incremental(2) Absolute Incremental(2) Absolute Absolute
High-Res(1) m (ft) High-Res(1) m (ft) High-Res(3) High-Res(3)
m (ft) m (ft) m (ft) m (ft)
Ultra3000 90 (295.3) 45 (147.6) 90 (295.3) 45 (147.6) 90 (295.3) 60 (196.8)
(1) Refers to MPL-A/BxxxxS/M (single-turn or multi-turn) low inertia motors with absolute high-resolution feedback.
(2) Refers to MPL-A/BxxxxH low inertia motors with 2000-line incremental feedback.
(3) Refers to MPG-A/BxxxxS/M (single-turn or multi-turn) integrated gear motors with absolute high-resolution feedback.

Table 10 - Maximum Cable Lengths for Ultra3000 Drives with MP-Series


Food-Grade Motors

Drive Family MPF-A (230V) Motors MPF-B (460V) Motors


Absolute Absolute
High-Resolution(1) High-Resolution(1)
m (ft) m (ft)
Ultra3000 90 (295.3) 90 (295.3)
(1) Refers to MPF-A/BxxxxS/M (single-turn or multi-turn) food-grade motors
with absolute high-resolution feedback.

Table 11 - Maximum Cable Lengths for Ultra3000 Drives with 1326AB (M2L/S2L) and
F-, H-, N-, and Y-Series Motors

Drive Family 1326AB (M2L/S2L) F-, H-, N-, or Y-Series


(460V) Motors (230V) Motors
Absolute Incremental(2)
High-Resolution(1) m (ft)
m (ft)
Ultra3000 90 (295.3) 30 (98.4)
(1) Refers to 1326AB-Bxxxx-M2L/S2L (single-turn or multi-turn) motors with
absolute high-resolution feedback.
(2) Refers to F-, H-, N-, or Y-series motors with incremental (optical encoder)
feedback.

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Migration Considerations Chapter 2

Table 12 - Motor Feedback Cables for Specific Motor/Feedback Combinations

Motor Cat. No. (1) Feedback Type Feedback Cable


Premolded Flying-lead (2)
MPL-A/B15xxx-V/Ex4xAA, 2090-XXNFMF-Sxx
High-resolution encoder
MPL-A/B2xxx-V/Ex4xAA(3) (standard)
MPL-A/B15xxx-Hx4xAA, 2090-CFBM4DF-CDAFxx
MPL-A/B2xxx-Hx4xAA (3) Incremental encoder (continuous-flex)

MPL-A/B3xxx-M/Sx7xAA,
MPL-A/B4xxx-M/Sx7xAA, High-resolution encoder
MPL-A/B45xxx-M/Sx7xAA
MPL-A/B3xxx-Hx7xAA,
MPL-A/B4xxx-Hx7xAA, Incremental encoder 2090-XXNFMF-Sxx
MPL-A/B45xxx-Hx7xAA (standard)
2090-CFBM7DF-CDAFxx
MPM-A/Bxxxxx-M/S (continuous-flex)
N/A
MPF-A/Bxxxx-M/S
MPAR-A/B3xxxx
MPAI-A/Bxxxx High-resolution encoder
MPS-A/Bxxxx-M/S
2090-XXNFMF-Sxx
MPAS-A/Bxxxx-V/A (standard)
2090-CFBM4DF-CDAFxx
MPAR-A/B1xxxx, (continuous-flex)
MPAR-A/B2xxxx
TLY-Axxxx-B
High-resolution encoder
TLAR-Axxxxx 2090-CFBM6DF-CBAAxx
(standard)
2090-CFBM6DD-
TLY-Axxxx-H Incremental encoder CCAAxx
(1) Some installations may use motors with bayonet connectors (for example, MPL-A310P-xx2xAA). These motors are being
discontinued and require 2090-XXNPMP-xxSxx (bayonet) transition cables. Refer to 2090-Series Motor Power and
Feedback Transition Cables in the Kinetix Motion Accessories Technical Data, publication GMC-TD004.
(2) For pin-outs, refer to Flying-lead Feedback Cable Pin-outs in the Kinetix 300 EtherNet/IP Indexing Servo Drives User
Manual, publication 2097-UM001.
(3) V/Ex4xAA and Hx4xAA motors were used in earlier installations, and Ex7xAA and Hx7xAA motors may have been used in
more recent installations. If your installation uses V/Ex7xAA and Hx7xAA motors, use 2090-CFBM7DF-CDAFxx for the
continuous-flex feedback cable.

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Chapter 2 Migration Considerations

2090-Series Motor/Actuator This section provides an overview of the 2090-series motor/actuator cables.
Cables Overview Table 13 - Feedback Cable Descriptions (standard, non-flex cable)

Standard Cable Description Cable Configuration Motor/Actuator


Cat. No. Connector
Motor/Acutator End Drive End

• Drive-end flying-leads (DF)


2090-CFBM7DF-CEAAxx
• High-resolution or resolver applications (CE)
SpeedTec DIN
(M7)
• Drive-end 15-pin connector (DD)
2090-CFBM7DD-CEAAxx
• High-resolution or resolver applications (CE)

• Drive-end flying-leads
2090-XXNFMF-Sxx
• High-resolution or incremental applications
Threaded DIN
• Drive-end bayonet (E2), transition (TR) cable (1) (M4)
2090-CFBM4E2-CATR • Motor-end threaded DIN (M4)
• All feedback types (CA)
• Drive-end flying-leads (DF)
2090-CFBM6DF-CBAAxx • High-resolution, battery backup or
Incremental applications (CB)
Circular Plastic
(M6)
• Drive-end 15-pin connector (DD)
2090-CFBM6DD-CCAAxx
• Incremental applications only (CC)

(1) Threaded DIN connector (motor end) and bayonet connector for 2090-XXNFMP-Sxx cable. Refer to 2090-Series Motor Power and Feedback Transition Cables in the Kinetix
Motion Accessories Technical Data, publication GMC-TD004.

Table 14 - Feedback Cable Descriptions (continuous-flex cable)

Standard Cable Cable Configuration Motor/Actuator


Description
Cat. No. Motor/Acutator End Drive End Connector

• Drive-end flying-leads (DF)


2090-CFBM7DF-CDAFxx
• High-resolution or incremental applications (CD)

• Drive-end flying-leads (DF)


2090-CFBM7DF-CEAFxx
• High-resolution or resolver applications (CE)
SpeedTec DIN
(M7)
• Drive-end 15-pin connector (DD)
2090-CFBM7DD-CEAFxx
• High-resolution or resolver applications (CE)

2090-CFBM7E7-CDAFxx • Drive-end (male) connector, extension (E7) (1)


2090-CFBM7E7-CEAFxx • Motor-end SpeedTec DIN cable plug (M7)

• Drive-end flying-leads Threaded DIN


2090-CFBM4DF-CDAFxx
• High-resolution or incremental applications (M4)

(1) SpeedTec DIN connector (motor end) and male connector for extending SpeedTec or threaded DIN cable. Refer to SpeedTec DIN Continuous-flex Extension Cables in the
Kinetix Motion Accessories Technical Data, publication GMC-TD004.

IMPORTANT Feedback cables with the CE designation, for example 2090-CFBM7DF-CEAAxx, are intended for high-resolution encoder
or resolver applications and have fewer conductors than feedback cables with the CD designation, for example
2090-CFBM7DF-CDAFxx, which are intended for high-resolution or incremental encoder applications.

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Migration Considerations Chapter 2

I/O Cabling

Ultra3000 drives and Kinetix 300/350 drives have similar signals that interface
with input/output (I/O) signals. Some of those signals include the following:
• Aux encoder input
• Master encoder input
• Digital inputs/outputs (DIs/DOs)
• Analog inputs/outputs (AIs/AOs)
• Registration inputs

There is a physical connector difference between the Ultra3000 drives and the
Kinetix 300/350 drives. Ultra3000 drives use a 44-pin, D-shell connector and the
Kinetix 300/350 drives use a 50-pin, SCSI connector.
Appendix A compares the I/O connectors and functions of the Ultra3000 drives
to the Kinetix 300/350 drives. Table 15 and Figure show the different interface
part numbers for the I/O connections between the two drive families.

Ultra3000 CN1 Connectors


Factory-made cables with premolded connectors are designed to minimize
electromagnetic interference (EMI). Rockwell Automation recommends
factory-made cables (over hand-built cables) to improve system performance.
However, options are available for building your own feedback and I/O cables.
Refer to Table 15 for the available options.

Table 15 - CN1 I/O Connector Options

Drive Connector Connector Option Option Cat. No.


44-pin drive-mounted breakout board with 24V to 5V 2090-U3CBB-DM44
auxiliary power converter
12-pin drive-mounted breakout board with 24V to 5V
auxiliary power converter for SERCOS interface 2090-U3CBB-DM12
applications

CN1 44-pin panel-mounted breakout board kit 2090-U3BK-D44xx


I/O connector 44-pin, drive-mounted breakout board(1) 2090-U3BB2-DM44
44-pin (high-density D-shell) drive connector kit 2090-U3CK-D44
Single-axis flying lead to 1756-M02AE module or 2090-U3CC-D44xx
1784-PM02AE PCI card
Two-axis pre-wired to 1756-M02AE module 2090-U3AE-D44xx

(1) This breakout board accepts 1...0.14 mm2 (16...26 AWG) wire. For applications that require a 44-pin
drive-mounted breakout board that accepts 4...0.5 mm2 (12...22 AWG) wire, contact your local Allen-Bradley
representative.

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Chapter 2 Migration Considerations

Kinetix 300/Kinetix 350 Expansion Block

Kinetix 300/
Kinetix 350
Drive

2097-TB1 Terminal
Expansion Block 50-pin I/O (IOD)
Connector

The 2097-TB1 I/O terminal expansion block is a drive-mounted breakout board


for making flying-lead cable connections to the 50-pin IOD connector.

Table 16 - 2097-TB1 I/O Terminal Block Specifications


Attribute Value
Wire size 1.5…0.2 mm2 (16…24 AWG)
Change in depth of drive (1) 11 mm (0.42 in.)
Change in width of drive (1) 10 mm (0.38 in.)
(1) Add this value to the dimensions of your Kinetix 300/350 drive.

Master Encoder/Gearing Signals/Buffered Encoder Signals


This section compares encoder and signal features of the drives.

Table 17 - Encoder and Signal Features Comparison

Feature Ultra3000 Kinetix Kinetix


300 350
Analog/ DeviceNet SERCOS
Indexing
Standalone electronic gearing
x x x
(ratios set using Ultraware/MotionView)
Electronic gearing via Logix
x x
(ratios set using RSLogix 5000)
Dual loop function x
Aux encoder PWR (output) x x x
Buffered encoder output
x x
(programmable output frequency)
Unbuffered encoder output
x x x x
(fixed output frequency)

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Migration Considerations Chapter 2

• The Ultra3000 drives (non-SERCOS) and Kinetix 300 drives have the
ability to electronically gear a master encoder signal to a single drive. This
function is not available on the Kinetix 350 drives.

• The Ultra3000 drives provide encoder power out to the auxiliary encoder,
while the Kinetix 300/350 drives do not.

• You can use the Ultra3000 SERCOS version as a dual loop servo and use
the aux encoder as your position loop closure. You cannot do this on the
Kinetix 300/350 drives.

Ultra3000 Drives - Auxiliary Encoder Operation

The Ultra3000 drives support auxiliary encoder operation. The pinout is shown
in Table 18.

Table 18 - Ultra3000 Drives Auxiliary Encoder Wiring

CN1 Pin Description Signal


1 Auxiliary encoder power out (+5V) EPWR
2 Common ECOM
3 Auxiliary logic power in (+5V) AUXPWR
4 Auxiliary A+/Step+/CW+ AX+
5 Auxiliary A-/Step-/CW- AX-
6 Auxiliary B+/Dir+/CCW+ BX+
7 Auxiliary B-/Dir-/CCW- BX-
8 Auxiliary encoder Ch I+ IX+
9 Auxiliary encoder Ch I- IX-

Kinetix 300 Drives - Master Gearing Operation

The Kinetix 300 drives supports master gearing operation. Wire the Master
signals to the drive as shown in Table 19.

Table 19 - Kinetix 300 Master Gearing Wiring

IOD Pin Description Signal


1 Master encoder A+/Step+ input MA+
2 Master encoder A-/Step- input MA-
3 Master encoder B+/Direction+ input MB+
4 Master encoder B-/Direction- input MB-

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Chapter 2 Migration Considerations

Ultra3000 Drives - Unbuffered Motor Encoder Operation

The Ultra3000 drives support unbuffered motor encoder operation. The pinouts
are shown in Table 20.

Table 20 - Ultra3000 Drives Unbuffered Motor Encoder Wiring

CN1 Pin Description Signal


Unbuffered
10 Unbuffered motor encoder Ch A+ AM+
11 Unbuffered motor encoder Ch A- AM-
12 Unbuffered motor encoder Ch B+ BM+
13 Unbuffered motor encoder Ch B- BM-
14 Unbuffered motor encoder Ch I+ IM+
15 Unbuffered motor encoder Ch I- IM-
Buffered
16 Buffered motor encoder Ch A+ AMOUT+
17 Buffered motor encoder Ch A- AMOUT-
18 Buffered motor encoder Ch B+ BMOUT+
19 Buffered motor encoder Ch B- BMOUT-
20 Buffered motor encoder Ch I+ IMOUT+
21 Buffered motor encoder Ch I- IMOUT-

The unbuffered signals are unfiltered encoder signals; there is no software


manipulation. The buffered encoder signals are modified by the internal software
divider of the Ultra3000 drive (divided encoder signals are not available on the
Ultra3000 SERCOS). This divider function is not available in the
Kinetix 300/350 drives.

Kinetix 300 Drives - Buffered Encoder Operation

The Kinetix 300 drives supports buffered encoder operation. Wire the signals to
the drive as shown in Table 21.

Table 21 - Kinetix 300 Drive Buffered Signals Wiring

IOD Pin Description Signal


7 Buffered encoder output: channel A+ BA+
8 Buffered encoder output: channel A- BA-
9 Buffered encoder output: channel B+ BB+
10 Buffered encoder output: channel B- BB-
11 Buffered encoder output: channel Z+ BZ+
12 Buffered encoder output: channel Z- BZ-

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Migration Considerations Chapter 2

These signals are unfiltered software signals and are fixed at 4096 pulses per
motor revolution. This function is limited to an output frequency of 2 MHz.

IMPORTANT You must qualify that your motor speed and resolution do not exceed
2MHz, or you may lose output counts.

I/O Availability and All Ultra3000 drives and Kinetix 300/350 drives have a comprehensive set of
digital I/O and analog I/O. To ensure proper operation, use the following
Specifications specifications to verify if the operation between drives will be consistent.

IMPORTANT All Ultra3000 drives and Kinetix 300/350 drives require an isolated
external 12...24V power supply for proper operation of the digital I/O.

Auxiliary Logic Power

The auxiliary power feature allows the drive to maintain logic power when main
power is removed. This allows communication between the controller and the
drive to continue and to maintain position feedback (aside from absolute
feedback).

Ultra3000 Drives

The Ultra3000 drives (catalog numbers 2098-DSD-005, 2098-DSD-010, and


2098-DSD-020) require an external, +5V power supply in applications where it
is necessary to maintain logic power when the AC line voltage is removed. The
+24V I/O supply (IOPWR) allows use of the drive-mounted breakout boards
with 24V to 5V DC converter (catalog numbers 2090-U3CBB-DM12 and
2090-U3CBB-DM44). Table 22 describes the +24V (IOPWR) power supply
requirements when it is used to maintain logic power.

Table 22 - Ultra3000 Drives +24V Power Supply Requirements for Logic Power

Parameter Description Min Max


Input voltage range of the external power
Input voltage range supply for drive-mounted breakout boards with 18V 30V
24V to 5V converter.
Input current draw from the external power
Input current supply for the drive-mounted breakout boards — 400 mA
with 24V to 5V converter.

IMPORTANT A single 24V power supply can be used to power the digital I/O and
supply 24V to the drive-mounted breakout boards (catalog numbers
2090-U3CBB-DMxx) provided the cumulative minimum current
requirements are met.

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Chapter 2 Migration Considerations

Table 23 - Ultra3000 Drives 5V Supply Specifications

Parameter Description Min Max


Voltage Voltage tolerance of the external logic supply. 5.1V 5.25V
Current output capability of the external +5V DC
Current 1.5A —
power supply.

IMPORTANT Using the drive-mounted breakout board with 24V to 5V auxiliary power
converter is preferred to using an external +5V DC power supply.

Kinetix 300/350 Drives

The Kinetix 300/350 drives use a 24V DC logic power source for all drives
(referred to as back-up power [BP]).

Table 24 - Kinetix 300/350 Drives Back-up Control Power Specification

Specification Description
Control power back-up input voltage 20...26V DC
Control power back-up input current
Nom 500 mA
Max inrush (0-pk) 30 A

Digital Inputs
Table 25 compares some key differences between the digital inputs of the two
drive families.

Table 25 - Digital Inputs Comparison

Feature Ultra3000 Kinetix 300 Kinetix 350


Non-SERCOS SERCOS
Inputs 8 inputs 6 inputs 12 inputs 5 inputs
3 groups (A,B,C)
I/O common points 1 1 each with an 1
isolated common
Pre-selectable indexes x
(using binary codes)
Multiple input assignment x
Fixed assignment for
x x x
Enable/Overtravel/Registration
Fixed assignment for Home Input x x
De-bounce for inputs x
x
Overtravels must be N.C. x x x
(can be N.O. also)

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Migration Considerations Chapter 2

Ultra3000 Drives

All digital inputs on the Ultra3000 drives (SERCOS and non-SERCOS) have
the same physical characteristics as shown in Table 26.

Table 26 - Ultra3000 Drives Digital Input Characteristics

Specification Description
I/O response 100 μs
Digital I/O firmware scan period 1 ms

Table 27 - Ultra3000 Drives Digital Input Parameters

Parameter Description Min Max


Voltage applied to the input, with respect
ON state voltage 10.8V 26.4V
to IOCOM, to guarantee an ON state.
ON state current Current flow to guarantee an ON State. 3.0 mA 12.0 mA
Voltage applied to the input, with respect
OFF state voltage -1.0V 2.0V
to IOCOM, to guarantee an OFF state.

Table 28 - Ultra3000 SERCOS Drives Dedicated Functionality Inputs

Pin Signal Description


Drive Enable Input, an active state enables the power electronics to
CN1-31 ENABLE control the motor.
Home Sensor, an active state indicates to a homing sequence that the
CN1-32 HOME sensor has been seen.
CN1-33 REG1
Registration Sensor, a transition is used to record position values.
CN1-34 REG2
CN1-37 OT_POS Overtravel Input, an inactive state indicates that a position limit has been
CN1-38 OT_NEG exceeded. An active state occurs when 24V is removed from the input.

For the Ultra3000 drives, there are eight optically isolated digital inputs. All
digital inputs (SERCOS and non-SERCOS) have the same configuration, as
shown in Figure 7.

Figure 7 - Ultra3000 Drive Digital Input Circuit


Ultra3000 Drive
+5V

2.7k Ω 10k Ω

INPUTS

1k Ω

TLP121

IOCOM IOCOM DGND

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Chapter 2 Migration Considerations

Kinetix 300/350 Drive Digital Input Characteristics

The digital inputs can be used for travel limit switches, proximity sensors, push
buttons, and hand shaking with other devices. Each input can be assigned an
individual de-bounce time via MotionView software or Explicit Messaging.

The inputs are separated into three groups: A, B, and C. Each group has four
inputs and share one common: ACOM, BCOM, and CCOM, respectively.
Travel limit switches, the inhibit/enable input, and registration input have
dedicated inputs as shown in Table 29.

Table 29 - Kinetix 300/350 Drives Fixed Digital Input Assignments

Digital Input Function


IN_A1 (pin 27) Negative travel limit switch
IN_A2 (pin 28) Positive travel limit switch
IN_A3 (pin 29) Inhibit/enable input
IN_C3 (pin 39) Registration input sensor

For the Kinetix 300/350 drives, the digital inputs are optically isolated and sink
up to 24V DC. You can set up the inputs for PNP sourcing or NPN sinking, as
shown in Figure 8.

Figure 8 - Kinetix 300/350 Drive Digital Input Circuits

Sourcing of Digital Inputs Sinking of Digital Inputs

1.2 kΩ 1.2 kΩ
+24V GND

IN_A1 IN_A1

1.2 kΩ 1.2 kΩ

IN_A2 IN_A2

IN_A_COM IN_A_COM
GND
+24V

Table 30 - Kinetix300/350 Digital Input Signal Specifications

Parameter Value
Scan time 500 µs
Current, max 9 mA, typical
Input impedance 1.2 kΩ, typical
Voltage range 5…24V DC

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Migration Considerations Chapter 2

Digital Outputs

Each drive has transistor-type digital outputs. The SERCOS Ultra3000 drives
(-SE) and the Kinetix 350 drives have holding brake actuation outputs available
only as outputs.

Table 25 compares some key differences between the digital outputs of the two
drive families.

Table 31 - Digital Outputs Comparison

Feature Ultra3000 Kinetix 300 Kinetix 350


Non-SERCOS SERCOS
Outputs 4 outputs + 1 relay 1 output + 1 relay 1 output, no relay 1 output, no relay
Brake output Fixed, Programmable, Fixed,
Programmable
assignment relay type transistor type transistor type
Use common
24V power to Has isolated 24V
x x x
energize supply outputs
outputs
Configurable
output x x
assignment

Ultra3000 Drives

Digital outputs: four optically isolated, 12...24V outputs, active high, current
sourcing.

Table 32 - Ultra3000 Drives Digital Outputs

Parameter Description Min Max


ON state Current flow when the output transistor is ON — 50 mA
current
OFF state Current flow when the output transistor is OFF — 0.1 mA
current
ON state Voltage across the output transistor when ON — 1.5V
voltage
OFF state Voltage across the output transistor when OFF — 50V
voltage

Figure 9 - Transistor Output Hardware Configuration


Ultra3000 Drive

200 Ω IOPWR

+5V

OUTPUT
OUT TLP127

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Chapter 2 Migration Considerations

Table 33 - Relay Output Specifications

Parameter Description Min Max


ON state Current flow when the relay is closed — 1A
current
ON state Contact resistance when the relay is closed — 1Ω
resistance
OFF state Voltage across the contacts when the relay is open — 30V
voltage

Table 34 - Relay Output Hardware Configuration


Ultra3000 Drive

CN1-43
Normally Relay +
Open
Relay
CN1-44
Relay -

IMPORTANT Relay output is not available on Kinetix 300/350 drives.

Kinetix 300/350 Drives


Table 35 - Digital Output Signal Specifications

Parameter Value
Scan time 500 µs
Current, max 100 mA
Voltage, max 30V DC

Figure 10 - Digital Output Circuit

Ultra3000
Drive
Logic Power

OUT1-C

OUT1-E

GND

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Migration Considerations Chapter 2

Analog Inputs

IMPORTANT The Ultra3000 SERCOS and Kinetix 350 drives do not have analog input
capability because their command reference comes digitally through
communication networks.

Ultra3000 Drives (non-SERCOS version)

Analog COMMAND Input

The analog COMMAND input to the drive can provide a position, velocity, or
current command signal. A 14-bit A/D converter digitizes the signal. The
configuration of the input is shown in Figure 11.

Figure 11 - Ultra3000 Drives (non-SERCOS version) Analog COMMAND Input


Configuration
Ultra3000 Drive

1000 pF

10k Ω 10k Ω
20k Ω
COMMAND +

0.01 μF

10k Ω 10k Ω
COMMAND -

0.01 μF 1000 pF 20k Ω

Table 36 - Ultra3000 Drives (non-SERCOS version) Analog COMMAND Input


Specifications

Parameter Description Min Max


Number of states that the input signal is divided into
Resolution 14 bits —
which is 2(to the number of bits).
Input Open circuit impedance measured between the + and 20 kΩ —
impedance - inputs.
Input signal Voltage applied to the input -10V +10V
range
Deviation from the correct value expected from
Offset error analog-to-digital conversion when 0V is applied to the — 50 mV
input.
Deviation of the transfer function from unity gain,
Gain error — 1%
expressed in a percent of full scale.
Propagation Delay from the input to the firmware-accessible — 100 μs
delay registers.

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Chapter 2 Migration Considerations

Kinetix 300 Drives

IMPORTANT The Kinetix 350 drive does not have analog input capability because its
command reference comes digitally through communication networks.

Analog Reference Input

The analog reference inputs AIN1+ and AIN1- (IOD-24 and IOD-25) accept
up to a ±10V DC analog signal as shown in Table 37. The analog signal is
converted to a digital value with 12-bit resolution (11-bit plus sign). The total
reference voltage as seen by the drive is the voltage difference between AIN1+
and AIN1-.

• If used in Single-ended mode, one of the inputs must be connected to a


voltage source while the other input must be connected to the analog
common (ACOM) terminal.

• If used in Differential mode, the voltage source is connected across


AIN1+ and AIN1- and the driving circuit common, if available, is
connected to the drive analog common (ACOM) terminal.

Table 37 - Analog Signal Input Specifications

Parameter Value
Scan time 0.0625 ms
Current, max Depend on load
Input impedance 47 kΩ, typical
Voltage range -10…10V DC

Analog Current Limit Input

Ultra3000 Drives (current limit N/A on the SERCOS version)

The ILIMIT input specifies to the drive if the drive output current should be
limited. If the ILIMIT input is not connected, current is not limited.

IMPORTANT This function is not available on the Kinetix 300/350 drives.

42 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Analog Current Output

IMPORTANT This output is not supported on the Ultra3000 SERCOS version or the
Kinetix 350 drives.

Ultra3000 Drives (non-SERCOS)


Figure 12 - Ultra3000 Drives (non-SERCOS) Analog Output Configuration
Ultra3000 Drive

AOUT
100 Ω
0.01 μF

IMPORTANT Output values can vary during powerup until the specified power
supply voltage is reached.

Table 38 - Ultra3000 Drives (non-SERCOS) Analog Output Specifications

Parameter Description Min Max


Number of states that the output signal is divided
Resolution 8 bits —
into, which is 2 (to the number of bits).
Output Current capability of the output. -2 mA +2 mA
current
Output signal Range of the output voltage. -10V +10V
range
Offset error Deviation when the output should be at 0V. — 500 mV(1)
Deviation of the transfer function from unity gain,
Gain error — 10%(1)
expressed in a percent of full scale.
Bandwidth Frequency response of the analog output 50 Hz —
(1) The offset and gain errors of the analog output can be corrected for an application using Ultraware scale and
offset settings.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 43


Chapter 2 Migration Considerations

Kinetix 300 Drives

IMPORTANT This analog output is not supported on the Kinetix 350 drives.

Figure 13 - Kinetix 300 Drive Analog Output Circuit

Kinetix 300
Drive
CH1 CH2

DAC

Table 39 - Kinetix 300 Drive Analog Output Specifications

Parameter Value
Scan time 0.0625 ms
Current, max 10 mA
Voltage range -10…10V DC

The analog output (AO) on pin IOD-23 has a 10-bit resolution. The analog
output is a single-ended signal with reference to analog common (ACOM) that
can represent the following motor data:

• Not assigned • Phase current V


• RMS phase current • Phase current W
• RMS peak current • Iq current
• Motor velocity • Id current
• Phase current U

Serial Communication The Ultra3000 drives use serial communication. The Kinetix 300/350 drives do
not use serial communication; the interface to the Kinetix 300/350 drives is
through the Ethernet port.

Accessories Application accessories, such as shunts and line filters, can impact drive
replacement. This section describes the following:
• Shunt Resistors
• AC Line Filters

44 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

Shunt Resistors

The Ultra3000 micro drives (-050, -010, -020) have no internal shunting
capability. All other Ultra3000 drives have internal shunting capability. The
Kinetix 300/350 drives do not have internal shunting capability. There are also
differences in the external shunting characteristics, which are described in this
section. Use Motion Analyzer software to determine the duty cycle requirements
and if a shunt is required for the Kinetix 300/350 drives.

Ultra3000 Drives

Ultra3000 drives have both an active shunt and passive shunt module:
• The active shunt module provides DC bus power to the Ultra3000 drive
and is available for the Ultra3000 micro drives (-005, -010, -020).
• The passive shunts are used in the traditional sense that they are wired to
the drive and are activated as the bus voltage rises above the trigger level.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 45


Chapter 2 Migration Considerations

Table 40 - Ultra3000 Drives Shunt Resistor Specifications

Specifications
(1) Shunt Module Fuse
Ultra3000 Fan Peak Peak Continuous Shipping
Drives Cat. No. Drive Voltage Resistance Power Current Power Weight Replacement
Voltage Ω
V AC kW A W kg (lb)
2098-xxx-005
2098-xxx-010 2090-UCSR-A300 36 4.0 10.5 300 1.51 (3.3) —
2098-xxx-020
230V AC N/A
2098-xxx-030 9101-1183 30 5.9 14.0 200 — CCMR-4-½ (2)
2098-xxx-075
2098-xxx-150 2090-UCSR-P900 18 10.0 23.3 4.08 (9.0) FWP-10A14F (3)

2098-xxx-HV030 900
2098-xxx-HV050 2090-SR120-09 120 5.3 6.7 3.63 (8.0) FWP-2.5A14F (3)

2090-SR040-09 460V AC N/A 40 20.0 3.63 (8.0) FWP-5A14F (3)


2098-xxx-HV100 16.0
2090-SR040-18 40 20.0 1800 8.6 (19.0) FWP-6.3A14F (3)
(1) Passive shunt solutions for Ultra3000 (460V) drives also exist with Rockwell Automation Encompass™ Partners. Refer to Bulletin 2090 Passive Shunt Modules in the
Kinetix Motion Control Selection Guide, publication GMC-SG001, for shunt module solutions outside the specifications in the table above, and for the 2098-xxx-HV150 and
2098-xxx-HV220 servo drives.
(2) LittelFuse part number.
(3) Cooper Bussmann part number.

Kinetix 300/350 Drives

The Kinetix 300/350 drives have pre-defined passive shunt modules used with
the particular drives. Table 41 lists the passive shunts for the Kinetix 300/350
drives.

Table 41 - Kinetix 300/350 Drives Passive Shunt Resistor Power Specifications

Kinetix 300/350 Attribute Specifications


Drives Cat. No.
% RD_Application, Resistor Value Peak Power Peak Current Continuous Weight,
max (1) Ω kW A Power Approx.
W kg (lb)
2097-V32PR4-xx 2097-R2 1.97 20 7.6 19.5
2097-V33PR5-xx 150 0.3 (0.7)
2097-V33PR6-xx 2097-R3 2.96 30 5.1 13.0
2097-V31PR0-xx
2097-V31PR2-xx
2097-V32PR0-xx
2097-R4 2.10 40 3.8 9.8 80 0.2 (0.4)
2097-V32PR2-xx
2097-V33PR1-xx
2097-V33PR3-xx
2097-V34PR5-xx
2097-R6 1.90 75 7.9 10.3 150 0.3 (0.7)
2097-V34PR6-xx
2097-V34PR3-xx 2097-R7 2.02 150 4.0 5.1 80 0.2 (0.4)
(1) RD_Application is the application duty cycle in percent. For the intermittent regeneration applications, use RD_Application = t/T. Where t is the duration when
regeneration is needed and T is the time interval between two regenerations. Both t and T must use the same time units, such as seconds.

46 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Migration Considerations Chapter 2

AC Line Filters

An AC line filter is a key component in achieving CE standards. The Kinetix


300/350 drives, and Ultra3000 drives, do not use the same line filters. The line
filters for the Kinetix 300/350 drives are designed to be an integral part of the
product. The filters are mounted at the rear of the drive or directly beside the
drive with close connections. Once you select your Kinetix 300/Kinetix 350 drive
for your application, choose the line filter that is appropriate for that particular
drive. This section describes the specifications for the line filters used for each
drive.

Ultra3000 Drives
Table 42 - Ultra3000 Drives AC Line Filter Selection

Drive AC Line Filter


Drive Family Motor Cables > 30 m
Cat. No. Cat. No.
2098-xxx-005 2090-UXLF-106 2090-UXLF-110
2098-xxx-010 2090-UXLF-110 2090-UXLF-110
2098-xxx-020 2090-UXLF-123 2090-UXLF-123
2098-xxx-030 2090-UXLF-136 2090-UXLF-132
2098-xxx-075 2090-UXLF-336 2090-UXLF-HV330
Ultra3000
2098-xxx-150 2090-UXLF-350 2090-UXLF-HV350
2098-xxx-HV030
2098-xxx-HV050 2090-UXLF-HV323 2090-UXLF-HV323
2098-xxx-HV100
2098-xxx-HV150
2098-xxx-HV220 2090-UXLF-HV330 2090-UXLF-HV330

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 47


Chapter 2 Migration Considerations

Table 43 - AC Line Filter Specifications

Specifications (1) (2)


AC Line Filter Current Leakage Weight,
Cat. No. Power Loss Operating
Voltage Phase A@ Current approx.
W Temperature
50 °C (122 °F) mA kg (lb)
2090-UXLF-106 6 3.5 2.26 0.3 (0.66)
2090-UXLF-110 10 2.7 45 0.95 (2.0)
-25…85 °C
2090-UXLF-123 23 10 90
1.6 (3.5) (-13…185 °F)
2090-UXLF-132 Single 32 20 90
250V AC
2090-UXLF-136 50/60 Hz 36 – 200 1.75 (3.9)
-25…100 °C
2090-XXLF-TC116 16 – 87 0.80 (1.7) (-13…212 °F)
2090-UXLF-336 36 – 138
2.7 (5.9)
2090-UXLF-350 50 25 138
2090-UXLF-HV323 520V AC 23 20 80 1.6 (3.5) -25…85 °C
Three
50/60 Hz (-13…185 °F)
2090-UXLF-HV330 30 51 24 1.8 (4.0)
500V AC
2090-UXLF-HV350 50 25 35 4.8 (10.6)
50/60 Hz
(1) For all filters, 90% relative humidity.
(2) For all filters, 10…200 Hz @ 1.8 g vibration.

Kinetix 300/350 Drives

The AC line filters are mounted directly beside the drive (side) with pig-tail
connections, or they are mounted at the rear of the drive.

Table 44 - Kinetix 300/350 Drives AC Line Filter Specifications


Current Leakage
AC Line Filter Mount
Voltage
Phase
Power Loss Current Weight, approx. Kinetix 300/350 Drive (1)
Cat. No. A@
50/60 Hz W kg (lb) Cat. No.
40 °C (104 °F) mA
2097-F1 120/240V AC 1 24.0 5.2 9.0 2097-V33PR6-xx (2)
Side 0.6 (0.13)
2097-F2 480V AC 3 10.0 2.8 2097-V34PR6-xx
120/240V AC 1 or 3 2097-V33PR1-xx
2097-F4 (3) 4.40 1.2
2097-V34PR3-xx
480V AC 3 1.0
Rear 0.8 (0.18) 2097-V34PR5-xx
2097-F5 (3) 6.90 1.3
1 or 3 2097-V33PR3-xx
120/240V AC
2097-F6 (3) 1 15.0 4.1 2097-V33PR5-xx

(1) Use 2090-XXLF-TC116 (single-phase) line filter for 2097-V31PR0 and 2097-V31PR2 drives. Use 2090-UXLF-336 line filter for 2097-V33PR5 (three-phase) drive applications.
Refer to Table 43 for more information.
(2) Use the 2097-F1 (single-phase) line filter only for 2097-V33PR6 (single-phase) drive operation.
(3) This filter is rated for multiple voltage/phase line conditions.

48 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Appendix A

Connectors and Field Connections

The following figure identifies the connector locations on the Ultra3000 230V
(500 W, 1 kW, and 2 kW) drives and the Kinetix 300/350 drives. (Refer to the
Ultra3000 Digital Servo Drives Installation Manual, publication 2098-IN003,
for connector locations of other Ultra3000 drive types.)

Connector Locations

2
5
3 00
00 8

3
1
6
6
2
4
9
7 1
3 7

Ultra3000 Drive, Front View Kinetix 300 Drive, Top View Kinetix 300 Drive, Front View Kinetix 300 Drive, Bottom View
(230V [500 W, 1 kW, and 2 kW] drive is shown) (2097-V33PR5 drive is shown) (2097-V33PR5 drive is shown) (2097-V33PR5 drive is shown)

Table 45 - Drive Connector Descriptions

Ultra3000 Drives Kinetix 300/350 Drives


Item Description Item Description
1 DC bus connections for active shunt resistor kit 1 Mains (IPD) connector
2 AC input power connections 2 Memory module socket
3 Motor power connections 3 Ethernet communication port
4 Motor power cable shield clamp 4 I/O (IOD) connector
5 CN3 9-pin serial port connector 5 Motor feedback (MF) connector
6 CN2 15-pin motor feedback connector 6 Back-up power (BP) connector
7 CN1 44-pin user I/O connector 7 Shunt resistor and DC bus (BC) connector
8 Motor power (MP) connector
9 Safe torque-off (STO) connector

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 49


Appendix A Connectors and Field Connections

Encoder Wiring Table 46 defines the encoder signal pinouts for these comparable encoder wiring
connectors:
Comparison
• Ultra3000 drive CN2 connector
• Kinetix 300/350 drive MF connector

Table 46 - Drive Encoder Wiring Comparison

Ultra3000 Drives Kinetix 300/350 Drives


CN2 Pin Description Signal Signal Description MF Pin
1 Channel A+/Sine AM+ SIN+ Sine differential input+ 1
Differential input+ AM+ AM+ differential input+
2 Channel A-/Sine AM- SIN- Sine differential input- 2
Differential input- AM- AM- differential input-
3 Channel B+/Cosine BM+ COS+ Cosine differential input+ 3
Differential input+ BM+ BM+ differential input+
4 Channel B-/Cosine BM- COS- Cosine differential input- 4
Differential input- BM- BM- differential input-
5 Channel I+/Index pulse+ IM+ DATA+ Data differential input + 5
IM+ Index pulse+
6 Common ECOM ECOM Common 6
7 N/C / Encoder power (+9V) (1) EPWR +9V EPWR_9V Encoder power (+9V) (2) 7
8 Commutation channel S3 S3 S3 Single-ended 5V Hall effect 8
commutation
9 Positive overtravel limit +LIMIT — Reserved/Not available 9
10 Channel I-/Index pulse- IM- DATA- Data differential input - 10
IM- Index pulse-
11 Thermostat TS TS Motor thermal switch 11
(normally closed) (3)
12 Commutation channel S1 S1 S1 Single-ended 5V Hall effect 12
commutation
13 Commutation channel S2 S2 S2 Single-ended 5V Hall effect 13
commutation
14 Encoder power (+5V) EPWR_5V EPWR_5V Encoder power (+5V) (2) 14
15 Negative overtravel limit -LIMIT — Reserved/Not available 15
(1) +9V encoder capability only available on standard size Ultra3000 drive (catalog number 2098-DSD-030 or larger).
(2) Kinetix 300/350 drive encoder power supply uses either 5V or 9V DC based on encoder/motor used.
(3) Not applicable unless motor has integrated thermal protection.

50 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Connectors and Field Connections Appendix A

Control Wiring Comparison Table defines the digital, analog, and auxiliary encoder signal pinouts for these
comparable control wiring connectors:
• Ultra3000 drives CN1 connector
• Kinetix 300/350 drives IOD connector

See Chapter 2 for details.

Table 47 - Drive Control Wiring Comparison


Ultra3000 Drives Kinetix 300/350 Drives
CN1 Pin Description Signal Signal Description IOD Pin
1 Auxiliary encoder power out (+5V) EPWR — — —
2 Common ECOM GND Drive logic common 5
3 Auxiliary logic power in (+5V) AUXPWR — — —
4 Auxiliary A+/Step+/CW+ AX+ — — —
MA+
5 Auxiliary A-/Step-/CW- AX- — — —
MA-
6 Auxiliary B+/Dir+/CCW+ BX+ — — —
MB+
7 Auxiliary B-/Dir-/CCW- BX- — — —
MB-
8 Auxiliary encoder Ch I+ IX+ — — —
9 Auxiliary encoder Ch I- IX- — — —
10 Unbuffered motor encoder Ch A+ AM+ — — —
11 Unbuffered motor encoder Ch A- AM- — — —
12 Unbuffered motor encoder Ch B+ BM+ — — —
13 Unbuffered motor encoder Ch B- BM- — — —
14 Unbuffered motor encoder Ch I+ IM+ — — —
15 Unbuffered motor encoder Ch I- IM- — — —
16 Buffered motor encoder Ch A+ AMOUT+ BA+ Buffered encoder output: channel A+ (1) 7
17 Buffered motor encoder Ch A- AMOUT- BA- Buffered encoder output: channel A- (1) 8
(1)
18 Buffered motor encoder Ch B+ BMOUT+ BB+ Buffered encoder output: channel B+ 9
19 Buffered motor encoder Ch B- BMOUT- BB- Buffered encoder output: channel B- (1) 10
(1)
20 Buffered motor encoder Ch I+ IMOUT+ BZ+ Buffered encoder output: channel Z+ 11
21 Buffered motor encoder Ch I- IMOUT- BZ- Buffered encoder output: channel Z- (1) 12
22 Common ACOM ACOM Analog common (1) 22
23 Programmable analog output AOUT AO Analog output (max 10 mA) (1) 23
24 Analog current limit input ILIMIT — — —
25 Command + COMMAND+ AIN1+ Positive (+) of analog signal input (1) 24
(1)
26 Command - COMMAND- AIN1- Negative (-) of analog signal input 25
27 I/O common IOCOM — — —
28 I/O common IOCOM — — —
29 I/O power IOPWR — — —
30 I/O power IOPWR — — —
31 Digital input 1 INPUT1 — — —
32 Digital input 2 INPUT2 — — —
33 Digital input 3 INPUT3 — — —

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 51


Appendix A Connectors and Field Connections

Table 47 - Drive Control Wiring Comparison (continued)


Ultra3000 Drives Kinetix 300/350 Drives
CN1 Pin Description Signal Signal Description IOD Pin
34 Digital input 4 INPUT4 — — —
35 Digital input 5 INPUT5 — — —
36 Digital input 6 INPUT6 — — —
37 Digital input 7 INPUT7 — — —
38 Digital input 8 INPUT8 — — —
39 Digital output 1 OUTPUT1 — — —
40 Digital output 2 OUTPUT2 — — —
41 Digital output 3 OUTPUT3 — — —
42 Digital output 4 OUTPUT4 — — —
43 Normally open relay output+ RELAY+ — — —
44 Normally open relay output- RELAY- — — —
— — — MA+ Master encoder A+/Step+ input (1) 1
— — — MA- Master encoder A-/Step- input (1) 2
— — — MB+ Master encoder B+/Direction+ input (1) 3
— — — MB- Master encoder B-/Direction- input (1) 4
— — — IN_A_COM Digital input group ACOM terminal 26
— — — IN_A1 Negative travel limit switch 27
— — — IN_A2 Positive travel limit switch 28
— — — IN_A3 Inhibit/enable input 29
— — — IN_A4 Digital input A4 (1) 30
— — — IN_B_COM Digital input group BCOM terminal (1) 31
— — — IN_B1 Digital input B1 32
— — — IN_B2 Digital input B2 (1) 33
— — — IN_B3 Digital input B3 (1) 34
— — — IN_B4 Digital input B4 (1) 35
— — — IN_C_COM Digital input Group CCOM terminal 36
(1)
— — — IN_C1 Digital input C1 37
— — — IN_C2 Digital input C2 (1) 38
— — — IN_C3 Registration input sensor 39
— — — IN_C4 Digital input C4 (1) 40
— — — RDY+ Ready output collector (1) 41
— — — RDY- Ready output emitter (1) 42
— — — OUT1-C Programmable output #1 collector 43
— — — OUT1-E Programmable output #1 emitter (2) 44
— — — OUT2-C Programmable output #2 collector (2) 45
— — — OUT2-E Programmable output #2 emitter (1) 46
— — — OUT3-C Programmable output #3 collector (1) 47
— — — OUT3-E Programmable output #3 emitter (1) 48
— — — OUT4-C Programmable output #4 collector (1) 49
— — — OUT4-E Programmable output #4 emitter (1) 50

(1) Kinetix 300 drive only.


(2) Fixed as Brake Output for Kinetix 350 drive only.

52 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Connectors and Field Connections Appendix A

Mains Power Wiring Table 48, Table 49, and Table 50 define the power terminal connections for
Ultra3000 drives and the comparable connectors on Kinetix 300/350 drives.
Comparison
Table 48 - 2098-DSD-005, 2098-DSD-010, 2098-DSD-020 to Kinetix 300/350 Drive
Power Terminal Connections

Ultra3000 Drives Kinetix 300/350 Drives


(2098-DSD-005, 2098-DSD-010, 2098-DSD-020)
Description Signal Terminal Connector Designator Signal
DC Bus DC Bus+ 1 BC B+ B+
DC Bus- 2 B- B-
100...240V AC L1 3 IPD L1 L1
50/60 Hz
Single-phase L2/N 4 L2 L2
Safety earth ground 5 PE PE
Motor U 6 MP U U
V 7 V V
W 8 W W
Motor case ground 9 PE PE
— — — BP +24V +24V DC
— — -24V Return

Table 49 - 2098-DSD-030 to Kinetix 300/350 Drive Power Terminal Connections

Ultra3000 Drives Kinetix 300/350 Drives


(2098-DSD-030)
Description Signal Terminal Connector Designator Signal
Motor U 1 MP U U
V 2 V V
W 3 W W
Motor case ground 4 PE PE
DC Bus DC Bus+ 5 BC B+ B+
DC Bus- 6 B- B-
100...240V AC L1 7 IPD L1 L1
50/60 Hz
Single-phase L2/N 8 L2 L2
Safety earth ground 9 PE PE
Auxiliary power L1 Aux 10 — — —
100...240V AC
50/60 Hz L2 Aux 11 — —

— — — BP +24V +24V DC
— — -24V Return

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 53


Appendix A Connectors and Field Connections

Table 50 - 2098-DSD-075 and 2098-DSD-150 to Kinetix 300/350 Drive Power Terminal


Connections

Ultra3000 Drives Kinetix 300/350 Drives


(2098-DSD-075 and 2098-DSD-150)
Description Signal Terminal Connector Designator Signal
Motor U 1 MP U U
V 2 V V
W 3 W W
Motor case ground 4 PE PE
DC Bus DC Bus+ 5 BC B+ B+
DC Bus- 6 B- B-
100...240V AC L1 7 IPD L1 L1
50/60 Hz
Three-phase L2/N 8 L2 L2
L3 9 L3 L3
Safety earth ground 10 PE PE
Auxiliary power L1 Aux 11 — — —
100...240V AC
50/60 Hz L2 Aux 12 — —

— — — BP +24V +24V DC
— — -24V Return

54 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Appendix B

Specifications

General Power Comparison Table 51 through Table 54 provide power specifications for the Ultra3000 drives
and the Kinetix 300/350 drives.

Ultra3000 Drives
Table 51 - Ultra3000 Drive Power Specifications
2098-DSD-xxx -005 -010 -020 -030 -075 -150
AC input voltage (1)
Single phase V AC 100...240 100...240 100...240 100...240 — —
Three phase V AC — — — — 100...240 100...240
AC input frequency Hz 47...63 47...63 47...63 47...63 47...63 47...63
AC input current:
Nominal Arms 5 9 18 28 30 46
Max inrush (2) A 100 100 100 50 50 68
Output peak current (3) A 7.5 15 30 30 75 150
Continuous output current (3) A 2.5 5 10 15 35 65
Internal shunt power
Continuous Watts — — — 50 50 180
Peak Watts — — — 6000 10,000 19,000
(1) Specification is for nominal voltage. The absolute limits are 88...265V AC rms.
(2) At 230V AC, 0 to peak.
(3) 0 to peak.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 55


Appendix B Specifications

Kinetix 300/Kinetix 350 Drives

The 2097-V31PRx-xx drives with 120V input are capable of driving 240V
motors at full speed.

Table 52 - Kinetix 300/350 Drives (single-phase) Power Specifications


Attribute 2097-V31PR0-xx 2097-V31PR2-xx 2097-V32PR0-xx 2097-V32PR2-xx 2097-V32PR4-xx
AC input voltage 70…132V rms single-phase (120V nom) 80…264V rms single-phase (240V nom)
80…264V rms single-phase (240V nom)
AC input frequency 48…62 Hz
Main AC input current (1)
Nom (rms) 120V input
(voltage doubler) 9.70 A 15.0 A
Max inrush (0-pk) 120V input 1.15 A 1.15 A
Nom (rms) 120/240V input 5.0 A 8.6 A 15.0 A
5.0 A 8.6 A
Max inrush (0-pk) 240V input 1.1 A 1.1 A 136 A 2.3 A 2.3 A

Integrated AC line filter No No Yes Yes Yes


Control power back-up input voltage 20…26V DC
Control power back-up input current
Nom 500 mA
Max inrush (0-pk) 30 A
Continuous output current (rms) 2.0 A 4.0 A 2.0 A 4.0 A 8.0 A
Continuous output current (0-pk) 2.8 A 5.7 A 2.8 A 5.7 A 11.3 A
Peak output current (rms) (2) 6.0 A 12.0 A 6.0 A 12.0 A 24.0 A
Peak output current (0-pk) 8.5 A 17.0 A 8.5 A 17.0 A 39.9 A
Continuous power output (3) @ 0.40 kW (4) 0.80 kW (4) 0.40 kW 0.80 kW 1.70 kW
240V nom or
120V (Voltage-doubler mode)
Shunt On 390V DC
Shunt Off 375V DC
Overvoltage 430V DC
Short circuit current rating 100,000 A (rms) symmetrical
(1) Kinetix 300/350 drive modules are limited to 1 AC mains power cycling per every 2 minutes.
(2) Peak RMS current allowed for up to 2 seconds with a 50% duty cycle.
(3) Nominal continuous power output (kW) applies to 240V AC drives. Value is approximately one-half of this kW rating when using 120V AC.
(4) The 120V Voltage-doubler mode applies to only the 2097-V31PRx-xx drives.

56 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Specifications Appendix B

Table 53 - Kinetix 300/350 Drives (single-phase and three-phase) Power


Specifications
Attribute 2097-V33PR1-xx 2097-V33PR3-xx 2097-V33PR5-xx 2097-V33PR6-xx
AC input voltage 80…132V rms single-phase (120V nom)
80…264V rms single-phase (240V nom)
80…264V rms three-phase (240V nom)
AC input frequency 48…62 Hz
Main AC input current (1)
Nom (rms) 120V input 5.0 A 8.6 A 15.0 A 24.0 A
Max inrush (0-pk) 120V input 68.0 A 1.15 A 1.15 A 5.65 A

Nom (rms) 240V input 3.0A 5.0A 8.7A 13.9 A


Max inrush (0-pk) 240V input 136 A 2.3 A 2.3 A 11.3 A
Integrated AC line filter No No No No
Control power back-up input voltage 20…26V DC
Control power back-up input current
Nom 500 mA
Max inrush (0-pk) 30 A
Continuous output current (rms) 2.0 A 4.0 A 8.0 A 12.0 A
Continuous output current (0-pk) 2.8 A 5.7 A 11.3 A 17.0 A
Peak output current (rms) (2) 6A 12 A 24 A 36 A
Peak output current (0-pk) 8.5 A 17.0 A 33.9 A 50.9 A
Continuous power output (3) 0.50 kW 1.00 kW 2.00 kW 3.00 kW
@ 240V nom
Shunt On 390 V DC
Shunt Off 375V DC
Overvoltage 430V DC
Short circuit current rating 100,000 A (rms) symmetrical
(1) Kinetix 300/350 drive modules are limited to 1 AC mains power cycling per every 2 minutes.
(2) Peak RMS current allowed for up to 2 seconds with a 50% duty cycle.
(3) Nominal continuous power output (kW) applies to 240V AC drives. Value is approximately one-half of this kW rating when using 120V AC.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 57


Appendix B Specifications

Table 54 - Kinetix 300/350 Drives (three-phase) Power Specifications


Attribute 2097-V34PR3-xx 2097-V34PR5-xx 2097-V34PR6-xx
AC input voltage 320…528V rms three-phase (480V nom)
AC input frequency 48…62 Hz
Main AC input current (1)
Nom (rms) 2.7A 5.5 A 7.9 A
Max inrush (0-pk) 4.5 A 4.5 A 22.6 A
Integrated AC line filter No No No
Control power back-up input voltage 20…26V DC
Control power back-up input current
Nom 500 mA
Max inrush (0-pk) 30 A
Continuous output current (rms) 2.0 A 4.0 A 6.0 A
Continuous output current (0-pk) 2.8 A 5.7 A 8.5 A
Peak output current (rms) (2) 6A 12 A 18 A
Peak output current (0-pk) 8.5 A 17.0 A 25.5 A
Continuous power output 1.00 kW 2.00 kW 3.00 kW
@ 480V nom
Shunt On 780V DC
Shunt Off 750V DC
Overvoltage 850V DC
Short circuit current rating 100,000 A (rms) symmetrical
(1) Kinetix 300/350 drive modules are limited to 1 AC mains power cycling per every 2 minutes.
(2) Peak RMS current allowed for up to 2 seconds with a 50% duty cycle.

58 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Specifications Appendix B

Digital I/O Comparison Table 55 through Table 59 compare the digital input and output specifications
between the Ultra3000 drives and the Kinetix 300/350 drives.

Digital Input Specifications


Table 55 - Ultra3000 Drives Digital Inputs
Parameter Value
ON state voltage 10.8...26.4V
ON state current 3.0...12.0 mA
OFF state voltage -1.0...3.0V
OFF state current mA, not specified

Table 56 - Kinetix 300/350 Drives Digital Inputs

Parameter Value
Scan time 500 µs
Current, max 9 mA, typical
Input impedance 1.2 kΩ, typical
Voltage range 5…24V DC

Digital Output Specifications


Table 57 - Ultra3000 Drives Digital Outputs
Parameter Value
ON state current 0 to 50 mA
OFF state leakage current -0.1...0.1 mA
ON state voltage 0.0...1.5V
OFF state voltage 0...50V

Table 58 - Kinetix 300/350 Drives Digital Outputs

Parameter Value
Scan time 500 µs
Current, max 100 mA
Voltage, max 30V DC

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 59


Appendix B Specifications

Relay Outputs
Table 59 - Ultra3000 Drives Relay Outputs
Attribute Value
ON state current, max 1A
ON state resistance, max 1Ω
OFF state voltage, max 30V
OFF state leakage, max mA, not specified

IMPORTANT Kinetix 300/350 drives do not have relay outputs.

Analog I/O Comparison Table 60 through Table 63 compare the analog input and output specifications
between the Ultra3000 drives and the Kinetix 300 drives.

Analog Input Specifications

IMPORTANT The Ultra3000 SERCOS drive does not have analog input capability
because its command reference comes digitally through communication
networks.

Table 60 - Ultra3000 Drives (non-SERCOS version) Analog Inputs


Parameter Command Limit Input
Input
Resolution 14 bits 10 bits
Input impedance 20 kΩ 10 kΩ
Input signal range -10.0...10.0V 0.0...10.0V
Offset error, max 50 mV 50 mV
Gain error, max 1% 1%
Propagation delay, max 100 µs 100 µs

Table 61 - Kinetix 300 Analog Inputs

IMPORTANT The Kinetix 350 drive does not have analog input capability because its
command reference comes digitally through communication networks.

Parameter Value
Scan time 0.0625 ms
Current, max Depends on load
Input impedance 47 kΩ, typical
Voltage range -10…10V DC

60 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Specifications Appendix B

Analog Output Specifications

IMPORTANT The Ultra3000 SERCOS drive does not have analog output capability.

Table 62 - Ultra3000 Drives (non-SERCOS version) Analog Outputs


Parameter Value
Resolution 8 bits
Output current, max -2.0...2.0 mA
Output signal range -10.0...10.0V
Offset error, max 100 mV
Gain error, max 5%
Bandwidth, min 50 Hz

Table 63 - Kinetix 300 Analog Outputs

IMPORTANT This analog output is not supported on the Kinetix 350 drives.

Parameter Value
Scan time 0.0625 ms
Current, max 10 mA
Voltage range -10…10V DC

Environmental and Safety This section provides environmental and safety feature of the drives.
Feature Comparison
Environmental Specifications
Attribute Ultra3000 Drives Kinetix 300 and
Kinetix 350 Drives
Operating Range Operating Range
Temperature, 0…55 °C (32…131 °F) 0…40 °C (32…104 °F)
operating
Temperature, -40… 70 °C (-40… 158 °F) -10…70 °C (14…158 °F)
nonoperating
Relative humidity 5…95% noncondensing 5…95% noncondensing
Altitude Operation: Derate 3% per 300 m (1000 Operation: Derate by 1% per 300 m
ft) above 1500 m (5000 ft) (1000 ft) above 1500 m (5000 ft)
Storage: 3000 m (9843 ft) during
transport
Vibration 5…2000 Hz @ 2.5 g peak, 0.015 mm 5…2000 Hz @ 2.5 g peak, 0.015
(0.0006 in.) max displacement mm (0.0006 in.) max displacement
Shock 15 g, 11 ms half-sine 15 g, 11 ms half-sine pulse (3 pulses
in each direction of 3 mutually
perpendicular directions)

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 61


Appendix B Specifications

Safety Features

IMPORTANT The Ultra3000 drives do not have the safe torque-off feature.

Table 64 - Kinetix 300/350 Drives Safe Torque-off Signal Specifications

Attribute Value
(1)
Safety inputs Insulated, compatible with single-ended output (+24V DC)
Enable voltage range: 20…24V DC
Disable voltage range: 0…1.0V DC
Input impedance 6.8 k Ω
Safety status Isolated Open Collector (Emitter is grounded.)
Output load capability 100 mA
Digital outputs max voltage 30V DC
(1) Safety inputs are not designed for pulse testing.

62 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Appendix C
Feature Comparison Chart

Feature Comparison Chart Table 65 compares the features of the Ultra3000 drives to the Kinetix 300/350
drives.

Table 65 - Feature Comparison Chart

Features Ultra3000 Drives Kinetix 300/350 Drives Notes


Indexer DeviceNet SERCOS Analog Vel Kinetix 300 Kinetix 350
(-X) (-DN) (-SE) (-LM)
Hardware
Controller used * X X X X X *Not required
120V...460V operation X X X X X X
Internal shunt available X X X X * * *External shunt
Aux 24V operation (converted to 5V) X X X X * * *24V directly
Safe torque-off X X
Digital inputs control indexing X X
Aux encoder input X X * X *Dual loop only
Hardware limits X X X X X
Analog input for current limit X X X
Multiple assignment for inputs X X X
Watch window output assignment X X X
Registration index (index on reg input) X X X
Registration latch (capture position) X X
MicroLogix™/SLC™ compatible X X * X *Stepper mode only
Hardware enable required X
Selectable modes of operation via digital inputs X X X
Buffered encoder outputs (selectable freq) X X X
Holding brake support X X X X X X
Software
Drive software config required X X X X
Able to home servo X X X X X
Rotary mode support X X X X X
Current limit enable X X X X X X
Position mode via analog input X X
Operation mode override X X
Soft limits X X * X X * Via Logix
Slew rate for gearing X X * * * Via Logix
Selectable modes of operation X X X X
Pause index directly X X * * * Via Logix
Offline software X X X X X

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 63


Appendix C Feature Comparison Chart

Notes:

64 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Appendix D

Hardware Layout with Connections

Ultra3000 Drive Power This appendix provides power wiring examples to assist you in comparing the
power wiring for the Ultra3000 drive and the Kinetix 300/350 drive systems.
Wiring
The notes in this table apply to the Ultra3000 drive power interconnect diagrams
(Figure 14, Figure 15, Figure 16, and Figure 17).

Note Information
1 A disconnecting device is required for maintenance and safety. If a grounded neutral is used instead of L2, only L1 may be switched or fused.
2 An isolation transformer is optional. If the transformer secondary has a neutral connection, neutral must be bonded to ground. Multiple drive
modules may be powered from one transformer or other AC supply source.
3 Do not daisy chain drive module power connections. Make separate connections directly to the AC supply.
4 For power wiring specifications, refer to the Ultra3000 Installation Manual, publication 2098-IN003, Power Wiring Requirements in Chapter 3.
5 For input fuse sizes, refer to the Ultra3000 Installation Manual, publication 2098-IN003 Fuse Specifications in Appendix A.
6 May be used to maintain power to logic section of drive and status indicators when main AC input power is removed. A separate AC line source
may be used if voltage is between 88…265V AC (rms) on 2098-DSD-xxx (230V drives) or 207…528V AC (rms) on 2098-DSD-HVxxx (460V drives).
In this configuration, a separate line filter for logic power may be required.
7 Place AC (EMC) line filter as close to the drive as possible and do not route very dirty wires in wireway. If routing in wireway is unavoidable, use
shielded cable with shields grounded to the drive chassis and filter case. For AC line filter specifications, refer to the Ultra3000 Installation
Manual, publication 2098-IN003 AC Line Filter Specifications in Appendix A.
8 Drive Enable input must be opened before main power is removed and auxiliary power is present, or a drive fault will occur. A delay of at least
1.0 second must be observed before attempting to enable the drive after main power is restored.
9 Cable shield clamp must be used in order to meet CE requirements. No external connection to chassis ground required.
10 Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference
international standards EN1050 and EN954 estimation and safety performance categories. For more information refer to
Understanding the Machinery Directive, publication SHB-900.

11 The recommended minimum wire size for wiring the safety circuit is 1.5 mm2 (16 AWG).
12 For motor cable specifications and drive/motor cable combinations, refer to the Kinetix Motion Accessories Technical Data, publication GMC-
TD004.
13 The Ultra3000 drive referenced is either a 2098-DSD-xxx or 2098-DSD-xxxX (Ultra3000 with indexing), 2098-DSD-xxx-SE (SERCOS interface),
2098-DSD-xxx-DN (DeviceNet interface), or 2098-DSD-xxxX-DN (DeviceNet with indexing) 230V drive.
14 The Ultra3000 drive referenced is either a 2098-DSD-HVxxx or 2098-DSD-HVxxxX (Ultra3000 with indexing), 2098-DSD-HVxxx-SE (SERCOS
interface), 2098-DSD-HVxxx-DN (DeviceNet interface), or 2098-DSD-HVxxxX-DN (DeviceNet with indexing) 460V drive.
15 Relay Output (CN1, pins 43 and 44) must be configured as Ready in Ultraware software.
16 The preferred method for supplying auxiliary power is by using the 12-pin or 44-pin drive-mounted breakout board with 24V to 5V auxiliary power
converter (2090-U3CBB-DM12 or -DM44). Auxiliary +5V power is required to maintain encoder position when the main AC power is
disconnected.
17 Refer to the Ultra3000 Digital Servo Drives Integration Manual, publication 2098-IN005, Shunt Module Interconnect Diagrams in Appendix A.

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 65


Appendix D Hardware Layout with Connections

This is the power wiring diagram with 24V DC control string for
2098-DSD-005x-xx, 2098-DSD-010x-xx, and 2098-DSD-020x-xx Ultra3000
drives (non-SERCOS drives only). To avoid a separate 5V DC auxiliary logic
power supply, the 24V to 5V converter breakout board (catalog number
2090-U3CBB-DMxx) is used to wire the control interface (CN1) connector.

For SERCOS drives, input line contactor is part of the PLC program and output
control.

Figure 14 - Typical Power Wiring on Ultra3000 (230V) System

2098-DSD-005x-xx,
2098-DSD-010x-xx, and
2098-DSD-020x-xx
Ultra3000
Digital Servo Drives
Note 13
TB1
DC+ DC Bus Connections
M1* for Active Shunt Module
Note 8 DC- Note 17
Single-phase AC Line
50/60 Hz
L1
Single-phase
AC Input Power
AC Line Filter L2/N Connections
Note 7
Fused Disconnect Input Fusing*
or Circuit Breaker* Note 4, 5
Note 1
U CN1
Bonded Cabinet Three-phase N.O. Relay Output+
Isolation Chassis Ground Bus* Motor Power V Motor Power 43
Transformer* Connections Connections Note 15
N.O. Relay Output- From CN1 Breakout
Note 2 Note 12 W 44 Board with 24V to 5V
Aux Logic Power In +5V Aux Power Converter
L1
3 (2090-U3CBB-DMxx)
Aux +5V Common Note 16

Single-phase Input Cable Shield 2


100...240V AC rms Clamp
Note 9
L2/N

Terminal To additional
Blocks* Ultra3000 drive
Note 3 CN1
43
START* STOP*
CR1*
* Indicates User-supplied Component
CR1* 24V DC
44 M1*
CR1*

Refer to Attention statement (Notes 10, 11)

66 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Hardware Layout with Connections Appendix D

This is the power wiring diagram with 24V DC control string for the
2098-DSD-030x-xx drive (non-SERCOS drives only).

For SERCOS drives, input line contactor is part of the PLC program and output
control.

Figure 15 - Typical Power Wiring on Ultra3000 (230V) System


2098-DSD-030x-xx
Ultra3000
Digital Servo Drive
Note 13

TB1 TB2
U 1 External Passive
Three-phase Shunt Connections
Motor Power V Motor Power 2 Note 17
Connections Connections
Note 12 W 3

DC+
Input Fusing * M1 *
Note 4, 5 Note 8 DC-
L1
Single-phase
AC Line Filter L2/N
Note 7 CN1
AC Input Power
Single-phase AC Line Connections N.O. Relay Output+
50/60 Hz 43
L1 AUX N.O. Relay Output- Note 15
Note 6
44
L2/N AUX
Fused Disconnect Input Fusing *
or Circuit Breaker * Note 4, 5
Note 1
Cable Shield
Bonded Cabinet Clamp
Isolation Chassis Ground Bus * Note 9
Transformer *
Note 2

L1 CN1
Single-phase Input 43
100...240V AC rms START * STOP *
L2/N CR1 *

24V DC
Terminal CR1 *
Blocks * 44 M1 *
Note 3 To additional CR1 *
Ultra3000 drive.

* Indicates User-supplied Component Refer to Attention statement (Notes 10, 11)

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 67


Appendix D Hardware Layout with Connections

This is the power wiring diagram with 24V DC control string for
2098-DSD-075x-xx and 2098-DSD-150x-xx Ultra3000 drives (non-SERCOS
drives only).

For SERCOS drives, input line contactor is part of the PLC program and output
control.

Figure 16 - Typical Power Wiring on Ultra3000 (230V) System

2098-DSD-075x-xx and
2098-DSD-150x-xx
Ultra3000
Digital Servo Drives
Note 13
TB1 TB2
U 1 External Passive
Three-phase Shunt Connections
Motor Power V Motor Power 2 Note 17
Connections Connections
Note 12 W 3

DC+
Input Fusing * M1 *
Note 4, 5 Note 8 DC-
Three-phase AC Line
50/60 Hz L1
Three-phase
AC Line Filter
L2
AC Input Power CN1
Fused Disconnect Note 7
or Circuit Breaker *
L3 Connections N.O. Relay Output+
43
Note 1 N.O. Relay Output- Note 15
44
Note 6 L1 AUX
L2/N AUX
Input Fusing *
Isolation Note 4, 5
Transformer * Neutral
Cable Shield
Note 2 Clamp
Chassis Bonded Cabinet Note 9
Ground Bus *

L1 CN1
43
Three-phase Input L2 START * STOP *
CR1 *
100...240V AC rms
24V DC
CR1 *
L3 44 M1 *
CR1 *

Terminal
Blocks * Refer to Attention statement (Notes 10, 11)
Note 3
To additional
* Indicates User-supplied Component Ultra3000 drive

68 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Hardware Layout with Connections Appendix D

This is the power wiring diagram with 24V DC control string for
2098-DSD-HVxxx-xx and 2098-DSD-HVxxxX-xx Ultra3000 drives.

Figure 17 - Typical Power Wiring on Ultra3000 (460V) System


2098-DSD-HVxxx-xx and
2098-DSD-HVxxxX-xx
Ultra3000
Digital Servo Drives
Note 14
TB1 TB2
DC+ 1 External Passive
Shunt Connections
DC- 2 Note 17

W 3
Three-phase
Motor Power V Motor Power
Connections Connections
Note 12 U

Input Fusing * M1 *
Notes 4 and 5 Note 8

Three-phase AC Line L3
50/60 Hz Three-phase L2
AC Line Filter CN1
AC Input Power
Note 7 L1 Connections N.O. Relay Output+
Fused Disconnect 43
or Circuit Breaker * L1 AUX N.O. Relay Output- Note 15
Note 1 44
L2/N AUX
Note 6

Input Fusing* Cable Shield


Isolation Notes 4 and 5 Clamp
Transformer * Neutral Note 9
Note 2
Chassis Bonded Cabinet
Ground Bus *

L3 CN1

43
Three-phase Input START * STOP *
L2
CR1 *
230...480V AC rms

24V DC
CR1 *
L1 44 M1 *
CR1 *

Terminal Blocks *
Note 3 Refer to Attention statement (Notes 10, 11)

To additional
* Indicates User-supplied Component Ultra3000 drive

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 69


Appendix D Hardware Layout with Connections

Kinetix 300/Kinetix 350 The notes in this table apply to the Kinetix 300/350 drive power interconnect
diagrams (Figure 18, Figure 19, and Figure 20).
Drive Power Wiring
Note Information
1 For power wiring specifications, refer to Power Wiring Requirements in the Kinetix 300 EtherNet/IP Indexing Servo Drives User Manual,
publication 2097-UM001, or the Kinetix 350 EtherNet/IP Indexing Servo Drives User Manual, publication 2097-UM002.
2 For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Specifications in the Kinetix 300 EtherNet/IP Indexing Servo Drives User
Manual, publication 2097-UM001, or the Kinetix 350 EtherNet/IP Indexing Servo Drives User Manual, publication 2097-UM002.
3 Place the AC (EMC) line filters as close to the drive as possible and do not route very dirty wires in the wireway. If routing in wireway is
unavoidable, use shielded cable with shields grounded to the drive chassis and filter case. For AC line filter specifications, refer to AC Line Filter
Specifications in the Kinetix 300 EtherNet/IP Indexing Servo Drives User Manual, publication 2097-UM001, or the Kinetix 350 EtherNet/IP
Indexing Servo Drives User Manual, publication 2097-UM002. This filter DOES NOT apply to 2097-V32PRx-xx drives because they have integrated
AC line filters.
4 Contactor coil (M1) needs integrated surge suppressors for AC coil operation. Refer to Contactor Ratings in the Kinetix 300 EtherNet/IP Indexing
Servo Drives User Manual, publication 2097-UM001, or the Kinetix 350 EtherNet/IP Indexing Servo Drives User Manual, publication 2097-UM002.
5 Drive Enable input must be opened when main power is removed, or a drive fault occurs. A delay of at least 1.0 second must be observed before
attempting to enable the drive after main power is restored.
6 Cable shield clamp must be used to meet CE requirements. No external connection to ground is required.
7 For motor cable specifications, refer to the Kinetix Motion Accessories Technical Data, publication GMC-TD004.

70 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Hardware Layout with Connections Appendix D

You must supply input power components. The single-phase and three-phase line
filters are wired downstream of fusing and the M1 contactor.

In this example, the 2097-V31PRx-xx drives are wired to use the voltage doubling
circuit. The 120V input voltage provides 240V output to motors. The
2097-V33PRx-xx drives are wired for single-phase 120V operation.

Figure 18 - Typical Power Wiring on Kinetix 300/350 Drives


(120V single-phase input power, voltage-doubler mode)

Kinetix 300 Drives: 2097-V31PRx and 2097-V33PR x


Kinetix 350 Drives: 2097-V31PRx-LM and 2097-V33PRx-LM

Ground Stud

Bonded Cabinet
Ground Bus * 2097-V31PRx 2097-V33PRx

PE PE
AC Line Filter Mains
L2/N (Optional)
Single-phase AC Input N L2 Single-phase
Note 3
120V rms AC, 50/60 Hz L1 AC Input
L1 L1
Notes 1, 2 (IPD) Connector
Fuse Disconnect Input Fusing * M1 * L2/N L3
or Circuit Breakers Notes 4, 5

Shunt Resistor B+ Shunt Resistor


B+
and DC Bus Connections
BR
(BC) Connector B-
B-

Back-up Power +24V DC User-supplied


(BP) Connector Return +24V DC

U Three-phase
Motor Power Motor Power
V
(MP) Connector W Connections
PE Note 7

29
EN
Use discrete logic or 26
PLC to control ACOM Cable Shield
ENABLE to drive and I/O (IOD) Clamp
monitor RDY signal 41 Connector Note 6
RDY +
back from drive. 42
RDY -

* Indicates User-supplied Component

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 71


Appendix D Hardware Layout with Connections

In this example, single-phase 240V AC is applied to 2097-V31PRx-xx and


2097-V32PRx-xx drives.

Figure 19 - Typical Power Wiring on Kinetix 300/350 Drives

IMPORTANT The 2097-V32PR x-xx models have integrated AC line filters and do not
require the AC line filter shown in this diagram.

(240V single-phase input power)

Kinetix 300 Drives: 2097-V31PRx and 2097-V32PR x


Kinetix 350 Drives: 2097-V31PRx-LM and 2097-V32PRx-LM

Ground Stud

Bonded Cabinet
Ground Bus * 2097-V31PRx 2097-V32PRx

PE PE Mains
AC Line Filter
Single-phase
(Optional) N
Note 3
AC Input
L1
Single-phase AC Input L1 L1 (IPD) Connector
120/240V rms AC, 50/60 Hz L2/N
L2
L2/N
Notes 1, 2
Input Fusing * M1 *
Fuse Disconnect Shunt Resistor B+ Shunt Resistor
or Circuit Breakers Notes 4, 5 B+
and DC Bus Connections
BR
(BC) Connector B-
B-

Back-up Power +24V DC User-supplied


(BP) Connector Return +24V DC

U Three-phase
Motor Power
V Motor Power
(MP) Connector
W Connections
PE Note 7
29
EN
Use discrete logic or 26
PLC to control ACOM
I/O (IOD) Cable Shield
ENABLE to drive and
monitor RDY signal 41 Connector Clamp
RDY + Note 6
back from drive. 42
RDY -

* Indicates User-supplied Component

72 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Hardware Layout with Connections Appendix D

In this example, three-phase 240V AC is applied to 2097-V33PRx-xx drives and


480V AC is applied to 2097-V34PRx-xx drives.

Figure 20 - Typical Power Wiring on Kinetix 300/350 Drives

IMPORTANT For the 480V Kinetix 300/350 drives to meet ISO 13849-1 (PLd) spacing
requirements, each phase voltage to ground must be less than or equal to
300V AC rms. This means that the power system must use center
grounded wye secondary configuration for 400/480V AC mains.

(240/480V three-phase input power)


Kinetix 300 Drives: 2097-V33PRx and 2097-V34PR x
Kinetix 350 Drives: 2097-V33PRx-LM and 2097-V34PRx-LM

B+ Shunt
Shunt Resistor
Ground Stud B+ Resistor
and DC Bus BR Connections
(BC) Connector B-
B-
Bonded Cabinet
Ground Bus *

PE
Mains
L1 AC Line Filter
(optional) L1 Three-phase Input
Three-phase AC Input Note 3 (IPD) Connector
L2
240/480V rms AC, 50/60 Hz L2
Notes 1, 2 L3
L3
Back-up Power +24V DC User-supplied
Input Fusing * M1 *
Fuse Disconnect (BP) Connector Return +24V DC
or Circuit Breakers Notes 4, 5

U Three-phase
29
EN
Motor Power V Motor Power
Use discrete logic or 26 (MP) Connector W Connections
PLC to control ENABLE ACOM
PE Note 7
to drive and monitor
RDY signal back from 41 I/O (IOD)
RDY +
drive. 42 Connector Cable Shield
RDY -
Clamp
Note 6
* Indicates User-supplied Component

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 73


Appendix D Hardware Layout with Connections

N o te s :

74 Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


Appendix E

Topology/Architecture Layouts

This section compares the typical Ultra3000 drive architecture and materials to
the typical Kinetix 300/Kinetix 350 drive architectures and materials.

For comparison examples, see the following:

• Ultra3000 (Analog) to Kinetix 300 Architecture on page 76

• Ultra3000 (Indexing) to Kinetix 350 Architecture on page 77

• Ultra3000 (SERCOS) to Kinetix 350 Architecture on page 78

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011 75


76
Ultra3000 (Analog) to
Kinetix 300 Architecture
Appendix E

Typical Configuration - Ultra3000 (Analog) Servo Drive System Typical Configuration - Kinetix 300 Servo Drive System
CompactLogix L23E

Commissioning and Communication 1783-EMS08T


Ultra3000 Drive Stratix 6000 CompactLogix Controller Platform
(2098-DSD-xxxxxx-xx) Switch 1769-L23E-QB1B Shown
Input Output
Logix Controller Logix Interface Module RSLogix 5000
Software
Motor Feedback
1585J-M8CBJM-x
I/O and Commands Logix Platform Ultraware Ethernet (shielded) Cable
(ControlLogix is shown)
Software
Topology/Architecture Layouts

2097-Rx
2097-V3xxxx Shunt Resistor
Other compatible motors/actuators include: Bulletin 2090 or 2097-Fx (optional equipment)
Kinetix 300 Drive
Motor Power AC Line Filter (optional equipment)
• MP-Series Integrated Linear Stages 3 0000
2097-F1 Filter Shown
• MP-Series Electric Cylinders 24V DC Control
MP-Series and TL-Series Rotary Motors Back-up Power Supply
(MPL-Axxxx motors shown) • LDC-Series and LDL-Series Linear Motors 2097-TB1 Terminal
(optional equipment)
Expansion Block

MP-Series Integrated Linear Stages


2090-K2CK-D15M
(MPAS-B9xxx ballscrew shown)
Low-profile Connector Kit

Bulletin 2090
Bulletin 2090 Motor Power Cables
Motor Feedback Cables
MP-Series and TL-Series Electric Cylinders
(MPAR-Bxxxx electric cylinders shown)
MP-Series and TL-Series
Rotary Motors MP-Series Heavy Duty Electric Cylinders
(MPL-Bxxxx motors shown) (MPAI-Bxxxx electric cylinders shown)

Ultra3000 (Analog) System Bill of Materials Kinetix 300 System Bill of Materials
Qty Description Qty Description
1 Ultra3000 servo drive 1 Kinetix 300 servo drive

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


1 per axis Rotary servo motor or linear motor/actuator (MP-series, 1 per axis Rotary servo motor or linear motor/actuator
TL-series, or LDL-series) (MP-series, TL-series, or LDL-series)
1 per axis Motor power cable 1 per axis Motor power cable
1 per axis Motor feedback cable 1 per axis Motor feedback cable
1 per axis Low profile connector kit for motor feedback
1 per axis DM44 I/O breakout board 1 per axis I/O terminal block expansion
1 Compact Logix and IF8, or 1 Compact Logix
Control Logix and M02AE
1 Stratix switch
1 24V DC control for I/O and Aux power (optional) 1 24V DC control for I/O and Aux power (optional)
77
Ultra3000 (Indexing) to
Kinetix 350 Architecture
Appendix E

Typical Configuration - Ultra3000 (Indexing) Servo Drive System Typical Configuration - Kinetix 350 Servo Drive System
CompactLogix L23E
Ultra3000 Drive Commissioning and Communication 1783-EMS08T
Stratix 6000 CompactLogix Controller Platform
(2098-DSD-xxxxxX-xx) Switch 1769-L23E-QB1B Shown
Input Output
Logix Controller RSLogix 5000
Software
Motor Feedback
1585J-M8CBJM-x
Logix Platform Ultraware Ethernet (shielded) Cable
(ControlLogix is shown) Software
Topology/Architecture Layouts

2097-Rx
I/O and Commands Shunt Resistor
2097-V3xxxx-LM Bulletin 2090 or 2097-Fx (optional equipment)
Kinetix 350 Drive AC Line Filter (optional equipment)
3 0000
2097-F1 Filter Shown
Other compatible motors/actuators include:
Motor Power 24V DC Control
• MP-Series Integrated Linear Stages Back-up Power Supply
2097-TB1 Terminal
(optional equipment)
• MP-Series Electric Cylinders Expansion Block
MP-Series and TL-Series Rotary Motors
(MPL-Axxxx motors shown) • LDC-Series and LDL-Series Linear Motors

MP-Series Integrated Linear Stages


2090-K2CK-D15M
(MPAS-B9xxx ballscrew shown)
Low-profile Connector Kit

Bulletin 2090
Bulletin 2090 Motor Power Cables
Motor Feedback Cables
MP-Series and TL-Series Electric Cylinders
(MPAR-Bxxxx electric cylinders shown)
MP-Series and TL-Series
Rotary Motors MP-Series Heavy Duty Electric Cylinders
(MPL-Bxxxx motors shown) (MPAI-Bxxxx electric cylinders shown)

Ultra3000 (Indexing) System Bill of Materials Kinetix 350 System Bill of Materials
Qty Description Qty Description
1 Ultra3000 servo drive (-X) 1 Kinetix 350 servo drive

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


1 per axis Rotary servo motor or linear motor/actuator 1 per axis Rotary servo motor or linear motor/actuator
(MP-series, TL-series, or LDL-series) (MP-series, TL-series, or LDL-series)
1 per axis Motor power cable 1 per axis Motor power cable
1 per axis Motor feedback cable 1 per axis Motor feedback cable
1 per axis Low profile connector kit for motor feedback
1 per axis DM44 I/O breakout board 1 per axis I/O terminal block expansion
1 Compact Logix and IF8, or 1 Compact Logix
Control Logix and M02AE
1 Stratix switch
1 24V DC control for I/O and Aux power (optional) 1 24V DC control for I/O and Aux power (optional)
78
Ultra3000 (SERCOS) to
Kinetix 350 Architecture
Appendix E

Typical Configuration - Ultra3000 (SERCOS) Servo Drive System Typical Configuration - Kinetix 350 Servo Drive System

CompactLogix L23E
1783-EMS08T
Logix Controller Programming Network Logix SERCOS Stratix 6000 CompactLogix Controller Platform
Interface Module Switch 1769-L23E-QB1B Shown

Logix Platform
(ControlLogix is shown) RSLogix 5000
RSLogix 5000 Software
Software
1585J-M8CBJM-x
SERCOS Fiber-optic Ring Ethernet (shielded) Cable
Topology/Architecture Layouts

Ultra3000
Ultra3000 Servo Drive Servo Drive 2097-Rx
(2098-DSD-xxxxxx-SE) Shunt Resistor
2097-V3xxxx-LM Bulletin 2090 or 2097-Fx (optional equipment)
Kinetix 350 Drive AC Line Filter (optional equipment)
Motor 2097-F1 Filter Shown
3 0000
SERCOS Fiber-optic Ring Feedback
24V DC Control
Back-up Power Supply
Motor Feedback Motor Power 2097-TB1 Terminal
Motor Power (optional equipment)
Expansion Block

MP-Series or TL-Series Rotary Motors


(MPL-Axxxx motors shown)
MP-Series Integrated Linear Stages
(MPAS-A9xx ballscrew shown)
MP-Series Integrated Linear Stages
2090-K2CK-D15M
(MPAS-B9xxx ballscrew shown)
LDC-Series Linear Motors Low-profile Connector Kit
(LDC-Cxxxxxxx linear motor shown)
Bulletin 2090
Bulletin 2090 Motor Power Cables
USA
www.ab.com
IN
MADE

00
X XXXX
LDC-M0755
NO. XXXX
CAT. NO.
SERIAL
A
SERIES

MP-Series Electric Cylinders Motor Feedback Cables


LDL-Series Linear Motors
MP-Series and TL-Series Electric Cylinders
(MPAR-Axxxx electric cylinder shown)
(LDL-xxxxxxx linear motor shown) (MPAR-Bxxxx electric cylinders shown)
MP-Series and TL-Series
Rotary Motors MP-Series Heavy Duty Electric Cylinders
MP-Series Heavy Duty Electric Cylinders (MPL-Bxxxx motors shown) (MPAI-Bxxxx electric cylinders shown)
(MPAI-Bxxxx electric cylinders shown)

Ultra3000 (SERCOS) System Bill of Materials Kinetix 350 System Bill of Materials
Qty Description Qty Description
1 Ultra3000 servo drive (-SE) 1 Kinetix 350 servo drive

Rockwell Automation Publication 2098-AP001A-EN-P - October 2011


1 per axis Rotary servo motor or linear motor/actuator 1 per axis Rotary servo motor or linear motor/actuator
(MP-series, TL-series, or LDL-series) (MP-series, TL-series, or LDL-series)
1 per axis Motor power cable 1 per axis Motor power cable
1 per axis Motor feedback cable 1 per axis Motor feedback cable
1 per axis Low profile connector kit for motor feedback
1 per axis DM44 I/O breakout board 1 per axis I/O terminal block expansion
1 CompactLogix: L23/32/35 + 1769-IF8, or 1 Compact Logix
L43, L45 and 1768-M04SE;
ControlLogix L6X, L7X+M0XSE (X=3,8,16)
1 Stratix switch
1 24V DC control for I/O and Aux power (optional) 1 24V DC control for I/O and Aux power (optional)
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