Rockwell Automation Allen-Bradley Kinetix 5100 User manual

Kinetix 300 to Kinetix 5100 Servo Drives Migration Guide
Catalog Numbers 2198-E1004-ERS, 2198-E1007-ERS, 2198-E1015-ERS, 2198-E1020-ERS, 2198-E2030-ERS,
2198-E2055-ERS, 2198-E2075-ERS, 2198-E2150-ERS
Reference Manual
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death.Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 2198-RM004A-EN-P - February 2020 1
Table of Contents
Preface
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1
Migration Options Kinetix 5100 Servo Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . 6
Potential Design Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2
Replacement Considerations Selecting a Replacement Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Nominal Voltage and Output Current Comparison. . . . . . . . . . 10
Dimension Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC Input Power Wiring and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AC Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Input Power Wiring and Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Circuit Breaker and Fuse Considerations . . . . . . . . . . . . . . . . . . . . 13
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
I/O Availability and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control and Auxiliary Power Specifications . . . . . . . . . . . . . . . . . 25
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Feedback Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Required Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Drive Accessories - Shunt Resistors . . . . . . . . . . . . . . . . 27
Optional Drive Accessories - AC Line Filters . . . . . . . . . . . . . . . . 30
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Port for Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Port for Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 3
Connectors Kinetix 300 Servo Drive Connector Locations. . . . . . . . . . . . . . . . . . . 33
Kinetix 5100 Servo Drive Connector Locations. . . . . . . . . . . . . . . . . . 34
I/O Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Motor Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Auxiliary Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Safe Torque Off Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 4
Dimensions, Cables, and Wiring Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Kinetix 5100 Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2Rockwell Automation Publication 2198-RM004A-EN-P - February 2020
Table of Contents
Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor and Feedback Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Kinetix 300 Servo Drive Power Wiring Examples . . . . . . . . . . . . 46
Kinetix 5100 Servo Drives Power Wiring Examples . . . . . . . . . . 47
Chapter 5
System Architecture Kinetix 300 Servo Drive System Architecture. . . . . . . . . . . . . . . . . . . . 53
Kinetix 5100 Servo Drive System Architecture . . . . . . . . . . . . . . . . . . 54
Chapter 6
Application Conversion Scenario 1: Analog Command to Analog Command . . . . . . . . . 57
Scenario 2: Indexing to PR Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Scenario 3: Master / Gearing mode to PT mode. . . . . . . . . . . . . . 61
Scenario 4: EtherNet/IP External Reference to I/O mode. . . . . 64
Appendix A
Feature Comparison

Rockwell Automation Publication 2198-RM004A-EN-P - February 2020 3
Preface
The purpose of this guide is to provide you with the essential information to
determine necessary changes when migrating from a system containing
Kinetix® 300 servo drives to one containing Kinetix 5100 servo drives.
Migrating from a motion control system that uses Kinetix 300 drives to a system
that uses Kinetix 5100 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 used. As a result, this migration
guide is not an all-inclusive document. It does not describe all redesign steps
required, nor 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.
This manual is intended for engineers and technicians that are directly involved
in the installation and wiring of the Kinetix 5100 drives, and programmers who
are directly involved in the operation, field maintenance, and integration of these
drives. You must have previous experience with, and a basic understanding of,
electrical terminology, programming procedures, networking (and required
equipment and software), and safety precautions.
Product compatibility information and release notes are available online within
the Product Compatibility and Download Center at
http://www.rockwellautomation.com/rockwellautomation/support/pcdc.page.
Additional Resources These publication contain additional information concerning related products
from Rockwell Automation.
Table 1 - Additional Resources
Resource Description
Kinetix Rotary Motion Specifications Technical Data,
publication KNX-TD001
Product specifications for Kinetix VP, Kinetix MP, Kinetix TL and TLY, Kinetix RDB, Kinetix TLP, and Kinetix HPK rotary
motors.
Kinetix Servo Drives Specifications Technical Data,
publication KNX-TD003
Product specifications for Kinetix Integrated Motion over the EtherNet/IP network, Integrated Motion over Sercos
interface, EtherNet/IP networking, and component servo drive families.
Kinetix 5100 Drive Systems Design Guide,
publication KNX-RM011.
System design guide to select the required (drive specific) drive module, power accessory, feedback connector kit, and
motor cable catalog numbers for your Kinetix 5100 drive and Kinetix motion control system.
Ethernet Reference Manual, publication ENET-RM002. Provides information on how to design Ethernet and EtherNet/IP networks.
Kinetix Motion Control Selection Guide,
publication KNX-SG001
Overview of Kinetix servo drives, motors, actuators, and motion accessories that are designed to help make initial
decisions for the motion control products best suited for your system requirements.
Kinetix 300 and Kinetix 350 Drive Systems Design Guide,
publication KNX-RM004.
Provides information to help identify the drive system components and accessory items you need for your Kinetix
300/350 drive and motor/actuator combination.
Kinetix 300 EtherNet/IP Indexing Servo Drives User
Manual, publication 2097-UM001
Provides installation instructions to mount, wire, and troubleshoot your Kinetix 300 drive; and system integration for
your drive/motor combination with a Logix controller.
Kinetix 300 EtherNet/IP Indexing Servo Drive Installation
Instructions, publication 2097-IN001
Provides information on how to install your Kinetix 300 drive system.
Kinetix 300 Shunt Resistor Installation Instructions,
publication 2097-IN002
Provides information on how toinstall and wire the Kinetix 300 drive shunt resistors (also compatible with the Kinetix
350 drive).
Kinetix 300 AC Line Filter Installation Instructions,
publication 2097-IN003
Provides information on how to install and wire the Kinetix 300 drive AC line filter (also compatible with the
Kinetix 350 drive).

4Rockwell Automation Publication 2198-RM004A-EN-P - February 2020
Preface
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
Kinetix 300 I/O Terminal Expansion Block Installation
Instructions, publication 2097-IN005
Provides information on how to install and wire the Kinetix 300 drive I/O terminal expansion block (also compatible
with the Kinetix 350 drive).
Industrial AutomationWiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines to install a Rockwell Automation industrial system.
Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.
Table 1 - Additional Resources (continued)
Resource Description

Rockwell Automation Publication 2198-RM004A-EN-P - February 2020 5
Chapter 1
Migration Options
This migration guide provides you with the essential information to determine
hardware design changes that can be necessary when migrating from a motion
system that contains Kinetix 300® servo drives to one that contains Kinetix 5100
servo drives. For each Kinetix 300 drive control mode, there is a suitable solution
with Kinetix 5100 servo drives, Logix 5000™ controller platforms, and the Studio
5000 Logix Designer® application. Table 2 and Table 3 provide some common
considerations and information when migrating from Kinetix 300 drives to
Kinetix 5100 drives.
Table 2 - Kinetix 300 Drive to Kinetix 5100 Drive Control Mode Migrations
Kinetix 300 Drive Kinetix 5100 Drive
Analog Current T mode
Analog Velocity S mode
Indexing PR Mode
Master Gearing, Step, and Direction PT Mode
EtherNet/IP External Reference I/O Mode
Table 3 - Kinetix 5100 Drive Control Modes
Control Mode Short Name Description
Position mode (terminal block
input)
PT This mode is sometimes referred to as PulseTrain Output or Step and Direction. The servo drive receives the Position
command and commands the motor to run to the target position. The Position command is communicated through the
terminal block and the signal type is pulse.
Position mode (register input) PR The servo drive receives the Position command and commands the motor to run to the target position. Position commands
are issued from the program registers (99 sets in total). You can select the register number with binary-weighted DI signals
or through communication.
Speed mode S The servo drive receives the Speed command and commands the motor to run at the target speed. The Speed command is
issued from the internal registers (3 sets in total) or by analog voltage (-10V…+10V) that is communicated through the
terminal block. You can select the command with binary-weighted DI signals.
Speed mode (no analog input) Sz The servo drive receives the Speed command and commands the motor to run at the target speed.The Speed command can
only be issued from the internal registers (4 sets in total, one is fixed at 0). You can select the command with binary-
weighted DI signals.
Torque mode T The servo drive receives the Torque command and commands the motor to run with the target torque. The Torque
commands can be issued from the internal registers (3 sets in total) and by analog voltage (-10V…+10V) that is
communicated through the terminal block.You can select the command with binary-weighted DI signals.
Torque mode (no analog input) Tz The servo drive receives the Torque command and commands the motor to run with the target torque. The Torque
command can only be issued from the internal registers (4 sets in total, one is fixed at 0).You can select the command with
binary-weighted DI signals.
I/O mode IO The servo drive receives commands from the Logix controller through the EtherNet/IP network connection. Commands are
issued through the Add-On Instruction (AOI) instructions in the Logic Designer application.

6Rockwell Automation Publication 2198-RM004A-EN-P - February 2020
Chapter 1 Migration Options
Kinetix 5100 Servo Drive
Catalog Numbers
Table 4 lists the catalog numbers and ratings of the Kinetix 5100 servo drives.
Table 4 - Kinetix 5100 Drive Ratings
For Kinetix 5100 servo drive module specifications not included in this
publication, see the Kinetix Servo Drives Technical Data,
publication KNX-TD003.
Potential Design Changes
The design changes required for converting to the Kinetix 5100 drives depend on
the original/replacement drive combination and the specifics of the application.
The objective is to determine which areas of a design must be changed. This
publicationpublication provides you with knowledge about the type and extent
of work required to change successfully from a Kinetix 300 system to a Kinetix
5100 system.
Dual mode PT-S Switches PT and S mode with DI signals.
PT-T Switches PT andT mode with DI signals.
PR-S Switches PR and S mode with DI signals.
PR-T Switches PR andT mode with DI signals.
S-T Switches S andT mode with DI signals.
–Reserved
PT-PR Switches PT and PR mode with DI signals.
Multi-mode PT-PR-S Switches PT, PR, and S mode with DI signals.
PT-PR-T Switches PT, PR, and T mode with DI signals.
Table 3 - Kinetix 5100 Drive Control Modes (continued)
Control Mode Short Name Description
Cat. No. Input AC
Voltage
(V AC)
Input
Phases
Rated
Power @
230V (kW)
Rated
Power @
120V (kW)
Cont. Output
Current
(A rms)
Peak Output
Current
(A rms)
2198-E1004-ERS 95…132,
170…253
1 PH
1 PH,3 PH
0.4 0.2 2.60 6.5
2198-E1007-ERS 95…132,
170…253
1 PH
1 PH,3 PH
0.75 0.375 5.10 15.41
2198-E1015-ERS 95…132,
170…253
1 PH
1 PH,3 PH
1.5 0.75 7.9 23.7
2198-E1020-ERS 95…132,
170…253
1 PH
1 PH,3 PH
2 1 13.4 53.03
2198-E2030-ERS 170…253 3 PH 3 – 17.9 55.95
2198-E2055-ERS 170…253 3 PH 5.5 – 41.3 91.4
2198-E2075-ERS 170…253 3 PH 7.5 – 49 127.49
2198-E2150-ERS 170…253 3 PH 15 – 78 162

Rockwell Automation Publication 2198-RM004A-EN-P - February 2020 7
Migration Options Chapter 1
Due to the flexibility of drive installation and usage, it is not feasible to cover all
possibilities. In addition to the items described in this publication, pay attention
to unique features and functions of the Kinetix 300 system when considering
replacement with a Kinetix 5100 system. See Appendix A for a comparison of
features. See the Kinetix Servo Drives Specifications Technical Data, publication
KNX-TD003 for complete specifications.

8Rockwell Automation Publication 2198-RM004A-EN-P - February 2020
Chapter 1 Migration Options
Notes: