Allen Bradley Ultra3000 Servo Motor Replacement Guide

Power only (without braking) 2090-CPWM7DF xaAAxx 2090-CPWM7DF xaAFxx Same as above

Thread DIN (M4) 2090-XXNPMF xaSxx 2090-CPBM4DF xaAFxx for MPS stainless steel motors

Circular plastic (M6) 2090-CPBM6DF-16AAxx - for TLY motor

Note: xa in the cable model indicates wire gauge: 16 AWG is suitable for most MPL motors, 14 AWG is used for larger power motors, and 10 AWG or 8 AWG is used for high-power models such as MPL-A540K.

3.2 Feedback Cable

The choice of feedback cable depends on the type of motor feedback (absolute high-resolution, rotary or incremental) and connector.

Feedback type motor end connector standard cable continuous flexible cable

Absolute/Rotation (CE) SpeedTec DIN (M7) 2090-CFBM7DF-CEAAxx 2090-CFBM7DF-CEAAxx

Absolute value/rotation, 15 pin SpeedTec DIN 2090-CFBM7DD DEAAxx 2090-CFBM7DD DEAFxx driver end

Incremental (CD) SpeedTec DIN 2090-CFBM7DF-CDAFxx 2090-CFBM7DF-CDAFxx

Incremental, thread DIN (M4) M4 2090-XXNFMF-Sxx 2090-CFBM4DF-CDAFxx

Incremental, circular plastic (M6) M6 2090-CFBM6DF CBAAxx or 2090-CFBM6DD CCAAxx-

Special note: For TLY motors, if an incremental encoder is used, the drive end can choose a flying wire (to be paired with a 2090-UBB-DM15 terminal board) or a cable with a pre installed 15 pin connector (2090-CFBM6DD CCAAxx).

3.3 Driver accessories

When using fly wire cables, a driver mounted terminal block must be installed on the driver side:

15 pin (CN2 motor feedback): 2090-UBB-DM15

9-pin (CN3 serial port): 2090-UXB8-DM09

44 pin (CN1 I/O): 2090-U3CBB-DM44 (or 2090-UXBB-DM12 for basic I/O)

In addition, optional panel mounted terminal blocks (2090-UXBK-D15xx and 2090-U3BK-D44xx) are available for connecting overhead cables to DIN rail terminal blocks for easy maintenance.

Performance Verification: Torque/Speed Curve and Motion Analyzer

After replacing the motor, it is necessary to verify whether the continuous and intermittent working areas of the drive motor combination meet the application requirements. The document provides a large number of torque/speed curves, such as:

2098-DSD-005 with MPL-A1510V: Continuous blocking torque of 0.26 N · m, peak value of 0.77 N · m, rated power of 0.16 kW.

2098-DSD-075 with MPL-A4530F: Continuous blocking torque of 8.36 N · m, peak value of 17.5 N · m.

2098-DSD-HV220 with MPL-B880D: Continuous blocking torque of 77.4 N · m, peak value of 144 N · m.

Verification steps:

Create a load model for the current system in Motion Analyzer software (version 4.7 or higher).

Enter the new motor model and driver model, and the software will automatically calculate the continuous/intermittent working area.

Check if the motion curve (speed, acceleration, duty cycle) falls completely within the continuous working zone. If the intermittent workspace occupies too much space, it may be necessary to upgrade the power level of the driver.

Check if the continuous locked rotor current is less than the rated output current of the driver. For example, the continuous current of MPL-A330P on 2098-DSD-030 is 12.0 A (rated 10.6 A for the driver), which has exceeded the limit. Therefore, 2098-DSD-075 should be selected.

Typical error case: Replacing the MPL-A310F (continuous 2.5 A) of the original 2098-DSD-010 with MPL-A320H (continuous 5.0 A) resulted in driver overload. The drive should be upgraded to 2098-DSD-020 at the same time.

Precautions for Replacement of Special Motor Types

5.1 MPM inertia motor

MPM motors are suitable for high inertia loads. For example, MPM-A1151M requires 2098-DSD-030 (continuous 10.3 A, peak 30.5 A), while MPM-A1153F requires 2098-DSD-075. When replacing, in addition to connector compatibility, attention should also be paid to the rated speed (base speed) and maximum speed. For example, MPM-A1153F has a base speed of 3000 rpm and a maximum of 5000 rpm. If the application requires 6000 rpm, it cannot be replaced with MPM-B1153T (base speed of 6000 rpm, but requires a 400V driver).

5.2 Food grade motors (MPF) and stainless steel motors (MPS)

MPF and MPS motors are commonly used in humid or hygienic environments. Their connectors are mostly M4 thread DIN, and cables need to be selected from the 2090-XXNPMF or 2090-CPM4DF series. For example, MPS-A330P can only be equipped with 2098-DSD-010 (continuous 5.0 A) or 2098-DSD-020 (continuous 9.8 A), and cannot be equipped with 2098-DSD-005 (insufficient current). When replacing, it is necessary to confirm the protection level (IP67, etc.) and corrosion resistance.

5.3 Linear motor (LDC/LDL series) and electric cylinder (MPAR/MPAI)

The replacement of linear motors involves the matching of continuous force and peak force. For example, LDC-C050200-DHT with 2098-DSD-020 can output a continuous force of 240... 359 N (depending on the cooling method), with a peak value of 600 N. If the original system uses water cooling, the water cooling circuit should be retained when replacing it; If natural cooling is used, the continuous force will be reduced by about 40%.

Attention should be paid to the type of screw (ball screw vs roller screw) and stroke speed for electric cylinders (MPAR/MPAI). For example, MPAI-A3076CM is a ball screw with a maximum speed of 1305 mm/s and a continuous force of 1624 N (25 ° C) or 1290 N (40 ° C). If replaced with the roller screw model MPAI-A3076RM, the continuous force is slightly lower (1557 N/1237 N), but the lifespan is longer.