Allen-Bradley 2198-S160-ERS3 Replacement for Kinetix 5700

Product Overview

Allen-Bradley 2198-S160-ERS3 Replacement for Kinetix 5700: Smooth Migration from Legacy Servo Systems

The Allen-Bradley 2198-S160-ERS3 is a single-axis servo drive module within the Kinetix 5700 series, designed for high-performance motion control in demanding industrial automation environments. As legacy servo platforms such as the Kinetix 6000 (2094-series) and Kinetix 6500 reach end-of-life or become increasingly difficult to source, the 2198-S160-ERS3 represents the definitive upgrade path — offering backward-compatible wiring strategies, EtherNet/IP-based motion coordination, and a compact dual-axis-ready architecture that fits within existing control cabinet footprints.

Whether your facility is migrating from a 2094-BC07-M05-S Kinetix 6000 multi-axis system or replacing a failed 2198-S086-ERS3 node in an existing Kinetix 5700 bus, the 2198-S160-ERS3 slots into the same 2198-P031 or 2198-P070 DC bus power supply infrastructure without requiring a full cabinet redesign. The drive accepts 460–480V AC three-phase input via the shared DC bus, eliminating the need for individual AC input wiring per axis — a significant advantage when retrofitting multi-axis gantry, conveyor, or press systems.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful migration to the 2198-S160-ERS3 typically involves coordinating several interdependent components across the motion system. The DC bus converter — most commonly the 2198-P031 or 2198-P070 — must be sized to support the aggregate continuous current demand of all axis modules on the shared bus. If your existing cabinet uses a 2094-XL75S-C1 line filter, it can often be retained with appropriate adapter wiring to the new 2198-DBXX-F DC bus filter, reducing retrofit cost.

On the controller side, migrating from a 1756-M08SE SERCOS motion module to native EtherNet/IP CIP Motion eliminates an entire hardware layer. The ControlLogix L83E or L85E processors natively support up to 256 CIP Motion axes without a dedicated motion module, and existing ladder logic and motion function blocks (MAS, MAM, MASD) remain largely compatible in Studio 5000 v30+. For CompactLogix-based systems, the L33ERM or L36ERM controllers provide equivalent CIP Motion support at a lower cost point.

Motor compatibility is a frequent concern during Kinetix 5700 migrations. The 2198-S160-ERS3 is fully compatible with Allen-Bradley MPL, MPM, and VPL servo motor families. If your existing motors use Hiperface or EnDat 2.1 feedback, the 2198-KITCON-DSL feedback conversion kit enables direct reuse without motor replacement — a significant cost saving on large multi-axis installations. For new motor selections, the MPL-B4530F-MK72AA and similar frame-4 motors pair optimally with the 160A drive rating.

I/O integration during the retrofit should account for the 2198-S160-ERS3’s onboard digital I/O (4 inputs, 2 outputs) for local registration, home, and overtravel signals. For applications requiring expanded I/O at the drive level, the 2198-KITCON-IO expansion connector supports additional discrete I/O without routing signals back to the main PLC rack. Safety I/O for STO wiring connects directly to the drive’s 2-channel STO input, replacing the external safety relay previously required by Kinetix 6000 installations.

Communication infrastructure for EtherNet/IP motion requires a managed switch with IGMP snooping and QoS prioritization — the Stratix 5700 (1783-BMS10CGL) is the recommended platform for motion networks with more than four axes. For smaller systems, the Stratix 2000 provides adequate bandwidth at reduced cost. Ensure the motion network is isolated from the plant IT network via a dedicated VLAN or physical separation to maintain deterministic cycle times below 2ms.

Retrofit Guidance FAQ

Q: Can I reuse existing motor power cables from my Kinetix 6000 installation?
A: In most cases, yes. The 2198-S160-ERS3 uses a standard IEC 60034-compliant motor power connector. If your existing cables terminate in the correct pin configuration for MPL/VPL motors, they can be reused. Verify cable shielding continuity and insulation resistance before reconnection.

Q: Do I need to rewrite my motion programs in Studio 5000?
A: Existing motion function blocks (MAM, MAS, MASD, MAFR) are compatible with Kinetix 5700 axis objects. The primary change is replacing AXIS_SERVO (SERCOS) axis type with AXIS_SERVO_DRIVE (CIP Motion) in the controller configuration. Motion parameters such as acceleration, deceleration, and torque limits transfer directly. Tuning (bandwidth, inertia ratio) will require re-commissioning via the Logix Designer Autotune wizard.

Q: How does the shared DC bus affect my cabinet power design?
A: The 2198-P031/P070 DC bus power supply replaces individual AC input sections per axis. Total bus power must be calculated based on the sum of continuous axis loads plus regenerative capacity. The 2198-CAPMOD-2240 capacitor module can be added to the bus to handle regenerative energy from deceleration cycles, reducing the need for a braking resistor in most applications.

Q: What is the physical space requirement compared to Kinetix 6000?
A: The 2198-S160-ERS3 has a narrower profile (approximately 55mm width per axis module) compared to the 2094-series axis modules. In a 6-axis system, this typically results in 80–120mm of recovered horizontal cabinet space, which can be used for additional I/O modules, terminal blocks, or cable management.

Q: Is the STO wiring compatible with my existing safety relay circuit?
A: The 2198-S160-ERS3 integrates a 2-channel STO input (STO-A, STO-B) rated for 24VDC. If your existing safety relay outputs 24VDC dual-channel signals, they can connect directly to the STO terminals without modification. For systems using older 115VAC safety relays, an intermediate 24VDC safety relay (e.g., Pilz PNOZ X2.8P) is required as an interface.

Warranty Assurance

Every 2198-S160-ERS3 unit supplied by TOPNLMS is covered by a 12-month warranty from the date of shipment. Prior to dispatch, each unit undergoes functional verification including DC bus charging, STO channel continuity, feedback interface handshake, and communication port integrity checks. Units are shipped in original or equivalent anti-static packaging with full documentation.

In the event of a confirmed defect within the warranty period, TOPNLMS provides priority replacement dispatch — typically within 2 business days of fault confirmation — to minimize production downtime. Our technical support team is available to assist with installation verification, parameter configuration, and fault code diagnosis via email and phone throughout the warranty period.

For procurement teams requiring documentation, we provide a test report, packing list, and commercial invoice with each shipment. Export compliance documentation (HS Code 8537.10) and country-of-origin certificates are available upon request for customs clearance in all major markets.

Stock is maintained in Xiamen, China, with express shipping options (DHL, FedEx, UPS) available for urgent replacement requirements. Standard lead time for in-stock units is 3–5 business days to most international destinations.