Kinetix 300, 350, 6000 and Ultra3000 Servo Drive Migration to Kinetix 5100, 5300 and 5700: Paths and Changes

Kinetix 300, Kinetix 350, Kinetix 2000, Kinetix 6000/6200/6500, Kinetix 7000 and Ultra3000 are all discontinued. Per Rockwell's product pages (read 27 October 2026): Ultra3000 was discontinued during 2022 (last date 31 December 2022), Kinetix 2000 on 31 December 2022, Kinetix 6000 and Kinetix 7000 on 31 December 2023 (2094-BC07-M05-S on 5 August 2025), Kinetix 300 and Kinetix 350 between 17 July 2023 and 31 July 2024, and the Kinetix 6200/6500 modules between 31 December 2023 and 31 December 2025. A running machine keeps running; the problem is that a failed drive can no longer be replaced with new genuine stock.

Rockwell publishes five migration guides for the main upgrade paths. This article summarises them: which old family goes to which new one, what changes, and what to prepare before a replacement. The replacement for each old catalog number is in the end-of-life lookup.

Old family to new family

2198-RM006A states that it covers only Ultra3000 SERCOS drives; analog, indexing and DeviceNet drives are pointed to Kinetix 5100 under 2198-RM003 (2198-RM006A p. 6). Figure 1 on the same page also shows Kinetix 5500, but the body of the guide describes only the path to Kinetix 5300.

For Kinetix 2000, Kinetix 7000 and Kinetix 6200/6500, the publications cited here include no dedicated migration guide. Replacements follow the Rockwell product pages: Kinetix 2000 to Kinetix 5300, Kinetix 7000 to Kinetix 5700. The Kinetix 6200/6500 2094-…-M power modules have inverter ratings of 4, 9, 15, 30 and 49 A 0-pk (2094-UM002I p. 23), equivalent to the 2.8–34.6 A rms Kinetix 6000 modules in Table 9 of 2198-RM002B (p. 24), so that output-current table serves as a reference. The 2094-SE02F and 2094-EN02D control modules have no separate replacement on the Rockwell pages.

Changes that come up on almost every replacement

• 24 V DC control power. Kinetix 6000 takes its control power from AC; Kinetix 5700 needs a customer-supplied 24 V DC supply for control power, digital inputs and motor brakes (2198-RM002B pp. 12, 19). Kinetix 5300 uses 24 V DC (21.6…26.4 V) at 400 mA, 900 mA or 1.7 A depending on frame, plus brake current (2198-RM005B p. 23). Kinetix 5100 200 V-class drives take control power from one incoming AC phase; 400 V-class drives use 24 V DC (2198-RM004C pp. 16, 28–29).
• Fewer digital inputs, each assigned a function. Kinetix 6000 has six dedicated inputs; each Kinetix 5700 inverter has four configurable inputs (2198-RM002B p. 20). Kinetix 350 has five fixed inputs; Kinetix 5300 has four configurable sinking inputs (2198-RM005B pp. 19, 21). A machine that uses ENABLE, HOME, both registration inputs and both overtravel inputs needs its wiring reviewed.
• Dual-port EtherNet/IP. SERCOS moves to EtherNet/IP; the existing controller may be reusable, but the communication module and switches must support EtherNet/IP (2198-RM002B p. 16). Kinetix 5300 has two ports; any external switch must support IEEE-1588 (2198-RM005B p. 27).
• Software versions. Kinetix 5700 needs Studio 5000 v26.00 or later (2198-RM002B p. 13); Kinetix 5300 needs Studio 5000 v33.00 or later (2198-RM005B p. 46; 2198-RM006A p. 13). Kinetix 5100 is configured in KNX5100C over a mini-USB port, replacing MotionView OnBoard on Kinetix 300 and Ultraware on Ultra3000 (2198-RM004C pp. 34–35; 2198-RM003B p. 41).
• AC input. Kinetix 5100 and Kinetix 5300 support only a center-grounded wye secondary (2198-RM004C p. 13; 2198-RM005B p. 11; 2198-RM003B p. 13).
• Safe Torque Off. STO connectors and pinouts differ between old and new drives (2198-RM004C p. 44; 2198-RM005B pp. 33–34). Ultra3000 has no STO; Kinetix 5300 has hardwired STO and needs jumpers when STO is not used (2198-RM006A pp. 17, 53).

Kinetix 6000 to Kinetix 5700 (2198-RM002B)

• A different bus architecture. The 2094 power rail, slot fillers and LIM are not used; they are replaced by a 2198-Pxxx DC-bus power supply plus inverters (2198-RM002B pp. 13, 16). The contactor enable relay moves from the IAM to the DC-bus supply (CED connector) and must be wired (pp. 28–29).
• Shunts. The 2094-BSP2 module is replaced by 2198-Rxxx resistors wired to the DC-bus supply; only the 2198-R004 may be mounted inside the enclosure (pp. 15, 29).
• Inverter sizing by output current. Table 9 (p. 24) pairs each Kinetix 6000 module with a Kinetix 5700 inverter, for example 2094-BM01-S (6.1 A rms) with 2198-D020-ERS3 (8.0 A rms) and 2094-BM05-S (34.6 A rms) with 2198-S086-ERS3 (43.0 A rms). Kinetix 5700 inverters need a properly sized DC-bus power supply (p. 24, note 2).
• Motors can stay, with conditions. 1326AB, MPL/MPM/MPF/MPS and RDB motors, LDC linear motors and MPAS/MPAR/MPAI/LDAT actuators remain usable, but feedback compatibility restrictions apply (p. 11). 1326AB resolver motors need a third-party resolver converter and a custom motor file (p. 14).
• Feedback kits. The 2198-K57CK-D15M kit accepts Hiperface, EnDat, AqB and sin/cos (p. 17). The 2198-H2DCK kit converts Hiperface to DSL when a dual position loop is needed (p. 18).
• Cables. Only the 2090-CxBM7DF motor cables — 2090-CPBM7DF power and 2090-CFBM7DF feedback — are shared between the two systems (pp. 18, 22). Feedback cables are limited to 90 m with absolute encoders, 30 m with incremental encoders and 75 m with EnDat (p. 18); Ethernet cables to 100 m, and shielded cable is required (p. 19).
• Size. In most cases Kinetix 5700 needs less panel space and fits the Kinetix 6000 space (p. 19).
• Logix Designer. The DC-bus supply has to be added to the I/O Configuration (p. 41).

The guide includes a ten-item checklist (Table 1, pp. 11–12): rotary motor compatibility, linear motor and actuator compatibility, 24 V DC for brakes, power for digital and registration inputs, I/O terminations, hardware enable inputs, STO, input power components, precharge protection relays, and DC common-bus capability.

Kinetix 300 to Kinetix 5100 (2198-RM004C)

Each Kinetix 300 operating mode has a Kinetix 5100 counterpart (p. 7):

• Digital I/O. Twelve inputs in three isolated groups become ten inputs (eight standard, two high-speed) on one common; registration is only on inputs 9 and 10. Indexes increase from 32 to 99 (pp. 20, 22). Digital outputs go from five to six (p. 23).
• Motors and cables. Only Kinetix MP and TL motors run on both drives; MP motors with resolver feedback do not run on Kinetix 5100 (p. 29). MP and TL/TLY cables are reusable; for TL/TLY, remove the 2090-DANFCT drive-end connector and use the 2198-K51CK-D15M kit (pp. 49–50).
• Short-circuit current rating drops from 100,000 A on Kinetix 300 to 5,000 A on Kinetix 5100 (pp. 16–18); review the upstream protection.
• Network. Kinetix 300 supports star topology only (a 1783-ETAP is needed for linear or ring); Kinetix 5100 has two ports for linear, ring and star (p. 35).
• Control from the PLC. Kinetix 5100 can be controlled through AOIs in I/O mode, by explicit messaging from MicroLogix, Micro800 or third-party controllers, or standalone by pulse train, analog or digital I/O (pp. 60–62). The guide gives four conversion scenarios: analog to analog, indexing to PR, gearing/step-direction to PT (maximum pulse frequency up from 2 MHz to 4 MHz), and External Reference to I/O mode (pp. 64–70).

Kinetix 350 to Kinetix 5300 (2198-RM005B)

• Both are configured and programmed in Studio 5000 (pp. 5–6); Kinetix 5300 needs v33.00 or later (p. 46).
• Brake. Kinetix 5300 powers brakes up to 2.25 A directly; do not wire a customer supply to this brake circuit, and the external relay can often be removed (p. 22).
• STO. The 6-pin plug becomes a 10-pin connector with different pinouts (pp. 33–34).
• Cables and feedback. MP power and feedback cables are reusable (pp. 25, 39); where flying-lead cables were used, replace the kit with the 2198-K53CK-D15M (p. 39).
• Similar size, for example 2097-V31PR0-LM (238 × 68 × 185 mm) to 2198-C1004-ERS (215 × 50 × 200 mm) (p. 10). Motor power moves from the front to the bottom of the drive (p. 11).

Ultra3000 to Kinetix 5100 or Kinetix 5300

To Kinetix 5100 (2198-RM003B). Analog Current, Analog Velocity, Analog Position, Preset, Follower and Indexing modes all have counterparts (T, S, PT, PR…); Host Command moves to explicit messaging and DeviceNet to I/O mode with AOIs (p. 9).

• Serial or DeviceNet communication becomes USB for configuration and EtherNet/IP for control; RSNetWorx for DeviceNet is no longer needed (pp. 13, 40, 88).
• Inputs go from eight (sinking only) to ten, sinking or sourcing; outputs from four to six (pp. 13–14).
• 1326AB and F/H/N/Y-series motors are not supported on Kinetix 5100; MP motors (except resolver types) and TLY-A…-H motors run on both; Ultra3000 does not run TL motors (p. 34).
• Maximum cable length drops from 90 m to 50 m (MP Hiperface, TLP) or 30 m (TL/TLY, MP incremental) (p. 14). Maximum ambient temperature drops from 55 °C to 50 °C (p. 11).
• Breakout boards, the resistive brake module (RBM) and auxiliary encoders are not shared (p. 35).

To Kinetix 5300 (2198-RM006A), for SERCOS drives. Fiber-optic SERCOS becomes dual-port EtherNet/IP; Studio 5000 v33.00 or later is required (p. 13). The Ultra3000's optional 5 V or auxiliary supply is replaced by a required 24 V DC supply (pp. 15–16). Six dedicated inputs become four configurable inputs (p. 16). Existing feedback cables work with the 2198-K53CK-D15M kit (p. 35). In most cases Kinetix 5300 is smaller and fits the Ultra3000 space (p. 15).

Where the drive size needs a second look

The replacement on a Rockwell product page does not always match the output-current table in the migration guide. Examples from the end-of-life lookup:

• 2094-AM05-S: the product page lists 2198-D012-ERS3; Table 9 of 2198-RM002B pairs it with 2198-S086-ERS3 by its 34.6 A rms output.
• 2098-DSD-075: the product page lists 2198-E2075-ERS; Table 8 of 2198-RM003B pairs it with 2198-E2055-ERS.
• 2099-BM09-S (96 A rms continuous, 2099-UM001G p. 150): the page lists 2198-S160-ERS3, rated 85 A rms (2198-RM002B p. 24).
• 2098-DSD-HV220-SE (33.2 A rms): the page lists 2198-C4075-ERS, rated 27.5 A rms (2198-RM006A p. 20).

2198-RM002B recommends sizing the drive, the DC-bus supply and the shunt in Motion Analyzer against the real load (pp. 6, 24, 37).

A TDL case: P&G Dong An packing lines

From 2024 to 2026 TDL replaced 24 discontinued servo drives with Kinetix 5300 on five packing machines at P&G Vietnam's Dong An plant:

Parameters of the old drives were backed up before removal, and the axes were set up again as integrated motion on EtherNet/IP axes in the new program. Kinetix 350 and Ultra3000 follow the Kinetix 5300 path of 2198-RM005B and 2198-RM006A; the Kinetix 300 and Ultra3000i drives also went to Kinetix 5300 rather than Kinetix 5100, controlled by integrated motion. Details: P&G Dong An packing line project.

Before replacing the drive

1. Upload and save the controller program and the current network configuration files; if no current copy exists, upload it first (2198-RM002B p. 6; 2198-RM005B p. 7).
2. Record the drive and motor catalog numbers, feedback type, cable lengths and the I/O, STO and brake wiring of every axis; label every connection before disconnecting (2198-RM004C p. 11; 2198-RM005B p. 7).
3. Size the new drive in Motion Analyzer; check which motors can stay and which feedback kits are needed.
4. Check the Studio 5000 version, EtherNet/IP modules and switches against the new drive's requirements.
5. Add the 24 V DC supply, relays, shunt resistors and line filters required by the new drive family to the bill of materials.
6. For SERCOS systems: plan the axis reconfiguration in Logix Designer and review the tuning (2198-RM002B pp. 41–42).