Allen-Bradley 20D-DL2-CKE1 Retrofit-Compatible DriveLogix Kit

Allen-Bradley 20D-DL2-CKE1 Retrofit-Compatible DriveLogix Kit for Legacy Systems

The Allen-Bradley 20D-DL2-CKE1 is a DriveLogix Controller Kit designed for integration with the PowerFlex 700S AC drive platform. As legacy DriveLogix-based systems approach end-of-life or require modernization, the 20D-DL2-CKE1 serves as a critical retrofit and replacement component — enabling engineers to restore full drive-integrated control logic without replacing the entire drive chassis or rewriting the control architecture from scratch.

For facilities running aging PowerFlex 700S drives in continuous production lines, paper mills, metal processing, water treatment, or mining conveyor systems, sourcing a verified replacement 20D-DL2-CKE1 kit is often the fastest path to restoring uptime. This kit includes the DriveLogix processor module and associated hardware required to re-establish embedded PLC functionality within the drive — eliminating the need for an external controller in many retrofit scenarios.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Replacing a failed or obsolete 20D-DL2-CKE1 DriveLogix kit requires careful pre-migration planning to avoid extended downtime and configuration errors. Before removing the existing module, engineers should back up the current program using RSLogix 5000 or Studio 5000 Logix Designer and document all I/O tag assignments, motion axis configurations, and drive parameter settings stored in the PowerFlex 700S non-volatile memory.

The 20D-DL2-CKE1 kit interfaces directly with the drive’s internal backplane — meaning terminal wiring to external I/O racks, such as 1756 ControlLogix I/O modules or 1734 POINT I/O distributed blocks, remains unchanged during the swap. However, if the system uses 20-COMM-E EtherNet/IP adapter modules or 20-COMM-C ControlNet adapters for network communication, firmware compatibility between the new DriveLogix processor and the communication adapter must be verified before going live.

In systems where the PowerFlex 700S drive is coordinated with a 1756-L71 ControlLogix controller via a 1756-EN2T EtherNet/IP bridge module, the replacement DriveLogix kit must be re-commissioned with matching produced/consumed tag configurations to restore coordinated motion and process interlocks. If the original system used 1756-DNB DeviceNet scanner modules for field device communication, those network node addresses and I/O mapping tables must be re-verified post-installation.

For facilities where the 20D-DL2-CKE1 controls a multi-axis motion system, re-establishing axis configurations through the Logix Designer Motion Axis Properties dialog is essential. Any 20D-P2-series PowerFlex 700S power structures paired with this DriveLogix kit should also be inspected for firmware alignment. Additionally, if a PanelView Plus 7 HMI terminal is connected to the drive controller via EtherNet/IP, the HMI application tags referencing the DriveLogix controller path must be updated to reflect the new module’s slot address and controller name.

Signal isolation between the DriveLogix analog outputs and field instrumentation — particularly in environments with high-frequency VFD switching noise — may require signal isolator modules or shielded cable re-termination at the 1492 terminal block level to prevent reference drift after the retrofit.

Downtime Control During System Migration

Minimizing production interruption during a 20D-DL2-CKE1 retrofit begins with pre-staging. Before the planned maintenance window, the replacement kit should be bench-tested, firmware-loaded, and program-restored from a verified backup. This allows the physical swap to be completed within a single shift rather than requiring extended troubleshooting on the production floor.

Where possible, the original PowerFlex 700S drive parameters — including speed references, torque limits, ramp rates, and fault response configurations — should be exported using DriveExecutive or Connected Components Workbench and re-imported to the replacement unit prior to installation. This eliminates the need for manual parameter re-entry under time pressure during the cutover window.

For critical continuous processes such as chemical dosing, kiln rotation, or compressor control, a parallel run strategy — where the replacement DriveLogix kit is validated in a test rack before field installation — significantly reduces the risk of logic errors causing process upsets. Once the new 20D-DL2-CKE1 is installed and the program is confirmed running, a controlled handover from manual bypass to automatic drive control should be executed step-by-step, with process engineers monitoring key variables throughout.

All replacement units supplied by NINERMAS undergo pre-shipment functional testing to confirm processor boot, communication link establishment, and I/O response — reducing the risk of receiving a non-functional unit during a time-critical retrofit. With in-stock inventory and same-week dispatch capability, the 20D-DL2-CKE1 is available to support both planned upgrades and emergency breakdown recovery scenarios.

Retrofit Support FAQ

Q1: Is the 20D-DL2-CKE1 a direct drop-in replacement for the original DriveLogix kit in my PowerFlex 700S?
Yes. The 20D-DL2-CKE1 is designed as a direct replacement kit for the DriveLogix processor assembly within compatible PowerFlex 700S drives. Physical mounting, backplane interface, and connector positions are identical to the original configuration. Firmware version alignment and program restoration are required after installation.

Q2: What pre-shipment testing does NINERMAS perform on the 20D-DL2-CKE1?
Each unit undergoes functional power-on testing, processor initialization verification, and communication port response checks before dispatch. Units are shipped with protective packaging to prevent ESD damage and physical shock during transit. A 12-month warranty is included from the date of shipment.

Q3: Can the 20D-DL2-CKE1 work with my existing RSLogix 5000 program without modification?
In most cases, yes — provided the firmware version of the replacement DriveLogix processor is compatible with the program revision. If the original program was created on an older firmware version, a minor revision upgrade or controller properties update in Studio 5000 may be required. NINERMAS technical support can advise on firmware compatibility before shipment.

Q4: Does NINERMAS maintain long-term stock of the 20D-DL2-CKE1 for ongoing maintenance contracts?
Yes. NINERMAS maintains inventory of the 20D-DL2-CKE1 and related PowerFlex 700S components to support both one-time emergency replacements and long-term maintenance agreements. Customers with multi-site operations or scheduled maintenance programs are encouraged to contact us to discuss volume pricing and reserved stock arrangements.