Allen-Bradley 2198-P031, 2198-P208, 2198-S160-ERS3, 2198-P070, 2198-D006-ERS3 User Manual

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Page 1

User Manual

Original Instructions

Kinetix 5700 Servo Drives

Catalog Numbers 2198-P031, 2198-P070, 2198-P141, 2198-P208, 2198-RP088, 2198-RP200, 2198-RP263, 2198-RP312, 2198-D006-ERS3, 2198-D012-ERS3, 2198-D020-ERS3, 2198-D032-ERS3, 2198-D057-ERS3, 2198-S086-ERS3, 2198-S130-ERS3, 2198-S160-ERS3, 2198-S263-ERS3, 2198-S312-ERS3, 2198-D006-ERS4, 2198-D012-ERS4, 2198-D020-ERS4, 2198-D032-ERS4, 2198-D057-ERS4, 2198-S086-ERS4, 2198-S130-ERS4, 2198-S160-ERS4, 2198-S263-ERS4, 2198-S312-ERS4, 2198T-W25K-ER, 2198-CAPMOD-2240, 2198-CAPMOD-DCBUS-IO, 2198-DCBUSCOND-RP312

Page 2

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.

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.

Labels may also be on or inside the equipment to provide specific precautions.

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).

Page 3

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Access the Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1

Start Kinetix 5700 Servo Drives Series Change. . . . . . . . . . . . . . . . . . . . . . . . 16

About the Kinetix 5700 Servo Drive System . . . . . . . . . . . . . . . . . . . . . 17

DC-bus Power Supply Input Power Configurations. . . . . . . . . . . . . . 19

Typical DC-bus Power Supply Configuration Example . . . . . . . 19

Multiple DC-Bus Power Supply Configuration Example. . . . . . 20

Extended DC-bus Configuration Example. . . . . . . . . . . . . . . . . . . 21

iTRAK Power Supply Configuration Example . . . . . . . . . . . . . . . 22

Regenerative Bus Supply Input Power Configurations. . . . . . . . . . . . 23

Typical Regenerative Bus Configuration Examples . . . . . . . . . . . 23

Extended Regenerative Bus Configuration Example . . . . . . . . . . 26

iTRAK Power Supply Configuration Example . . . . . . . . . . . . . . . 27

8720MC-RPS Power Supply Input Power Configuration. . . . . . . . . 28

Motor and Auxiliary Feedback Configurations . . . . . . . . . . . . . . . . . . 29

Typical Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . 30

Linear Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Ring Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Star Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Functional Safety Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Hardwired Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Integrated Safety Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Safe Stop and Safe Monitor Configurations. . . . . . . . . . . . . . . . . . 36

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Plan the Kinetix 5700 Drive System Installation

Chapter 2

System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DC-bus Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

AC Line Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

AC Line Impedance Considerations . . . . . . . . . . . . . . . . . . . . . . . . 45

Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

24V Control Power Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Contactor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Passive Shunt Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Active Shunt Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 56

Multi-axis Shared DC-Bus Configurations. . . . . . . . . . . . . . . . . . . 57

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 3

Page 4

Table of Contents

Accessory Module Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

DC-bus Power Supply Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Regenerative Bus Supply Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8720MC-RPS or Other Regenerative Power Supply . . . . . . . . . . 64

Accessory Module Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Electrical Noise Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Bonding Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Bonding Multiple Subpanels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Establishing Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Cable Categories for Kinetix 5700 Systems . . . . . . . . . . . . . . . . . . 72

Noise Reduction Guidelines for Drive System Accessories. . . . . 73

Chapter 3

Mount the Kinetix 5700 Drive System

Connector Data and Feature Descriptions

Determine Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Mount Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Zero-stack Tab and Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Install Shared-bus Connection Systems . . . . . . . . . . . . . . . . . . . . . . . . . 84

DC-bus Connection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

24V Input Power Connection System . . . . . . . . . . . . . . . . . . . . . . . 85

Drill-hole Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Drill-hole Pattern Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Drill-hole Patterns by Using the System Mounting Toolkit . . . 90

Mount Your Kinetix 5700 Drive Modules. . . . . . . . . . . . . . . . . . . . . . . 90

Chapter 4

Kinetix 5700 Connector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Safe Torque-off Connector Pinout. . . . . . . . . . . . . . . . . . . . . . . . . 102

Input Power Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

DC Bus and Shunt Resistor Connector Pinouts . . . . . . . . . . . . . 103

Digital Inputs Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . 103

Ethernet Communication Connector Pinout . . . . . . . . . . . . . . . 105

Motor Power, Brake, and Feedback Connector Pinouts. . . . . . 105

Motor Feedback Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . 106

Universal Feedback Connector Pinouts . . . . . . . . . . . . . . . . . . . . 107

Accessory Module Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Understand Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . 108

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Ethernet Communication Specifications . . . . . . . . . . . . . . . . . . . 109

Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Converter OK Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Motor Brake Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Feedback Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Encoder Feedback Supported on the

DSL Feedback Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

4 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Table of Contents

Encoder Feedback Supported on the

UFB Feedback Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Encoder Phasing Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Functional Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Hardwired STO Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Integrated Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Chapter 5

Connect the Kinetix 5700 Drive System

Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . 128

Input Power Configurations for Kinetix 5700 Power Supplies . . . 129

DC-bus Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Regenerative Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Ground Screw/Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Kinetix 5700 Drive System Power Supply. . . . . . . . . . . . . . . . . . . 135

Kinetix 5700 Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Kinetix 5700 iTRAK Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 137

Remove/Install the Ground Screw/Jumper . . . . . . . . . . . . . . . . . . . . . 137

Ground the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Ground the System Subpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Wire the Power Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Wire the 24V Control Power Input Connector . . . . . . . . . . . . . 145

Wire the Input Power Connector. . . . . . . . . . . . . . . . . . . . . . . . . . 147

Wire the Contactor Enable Connector . . . . . . . . . . . . . . . . . . . . . 148

Wire the Digital Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

2198-xxxx-ERS3 (series A) Connector Plugs. . . . . . . . . . . . . . . . 149

2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B)

Connector Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Wire the Safe Torque-off Connector. . . . . . . . . . . . . . . . . . . . . . . 150

Wire the Digital Inputs Connector . . . . . . . . . . . . . . . . . . . . . . . . 151

Wire Motor Power and Brake Connectors . . . . . . . . . . . . . . . . . . . . . 152

Maximum Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Wiring Single Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Apply the Single Motor Cable Shield Clamp. . . . . . . . . . . . . . . . 161

Wiring Power/Brake and Feedback Cables . . . . . . . . . . . . . . . . . . . . . 163

Motor Power and Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Motor Power/Brake Cable Series Change. . . . . . . . . . . . . . . . . . . 164

Dual-axis Inverter Power/Brake Cable Installation . . . . . . . . . . 165

Single-axis Inverter Power/Brake Cable Installation . . . . . . . . . 168

Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Customer-supplied Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . 178

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 5

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Table of Contents

Configure and Start the Kinetix 5700 Drive System

Accessory Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

External Passive-shunt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

External Active-shunt Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

DC-bus Power Supply Active Shunt Connections. . . . . . . . . . . 183

Regenerative Bus Supply Active Shunt Connections . . . . . . . . . 183

Wire the External DC-bus Connections. . . . . . . . . . . . . . . . . . . . 184

Bulletin VPC Motors and the Extended Speed Feature . . . . . . 185

Considerations for Powerohm Shunt Installation . . . . . . . . . . . 185

Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Chapter 6

Understand the Kinetix 5700 Display. . . . . . . . . . . . . . . . . . . . . . . . . . 188

Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Set the Network Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Studio 5000 Logix Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Version History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Install the Kinetix 5700 Add-On Profile. . . . . . . . . . . . . . . . . . . . 199

Configure the Logix 5000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Configure the Kinetix 5700 Drive Modules . . . . . . . . . . . . . . . . . . . . 203

Configure the DC-bus Power Supply. . . . . . . . . . . . . . . . . . . . . . . 203

Configure the Regenerative Bus Supply. . . . . . . . . . . . . . . . . . . . . 207

Configure the Inverter Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Continue Inverter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Configure Regenerative Bus Supply Axis Properties . . . . . . . . . . . . . 224

Configure Vertical Load Control Axis Properties . . . . . . . . . . . . . . . 229

Configure Feedback-only Axis Properties . . . . . . . . . . . . . . . . . . . . . . 230

Configure Induction-motor Frequency-control Axis Properties . . 232

General and Motor Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Basic Volts/Hertz Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Sensorless Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Fan/Pump Volts/Hertz Method. . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Configure IPM Motor Closed-loop Control Axis Properties . . . . . 241

Configure SPM Motor Closed-loop Control Axis Properties. . . . . 245

Configure Induction-motor Closed-loop Control Axis Properties 249

Configure Feedback Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Configure Module Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Apply Power to the Kinetix 5700 Drive System . . . . . . . . . . . . . . . . . 262

Understand Bus-sharing Group Configuration . . . . . . . . . . . . . . . . . 263

Bus-sharing Group Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Configure Bus-sharing Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

6 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Table of Contents

Test the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Chapter 7

Troubleshoot the Kinetix 5700 Drive System

Remove and Replace Drive Modules

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Display Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Fault Code Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

SAFE FLT Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Kinetix 5700 Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Kinetix 5700 Accessory Module Status Indicators . . . . . . . . . . . 279

Axis Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Regenerative Bus Supply Troubleshooting. . . . . . . . . . . . . . . . . . . . . . 281

Logix 5000 Controller and Drive Module Behavior . . . . . . . . . . . . . 283

DC-bus Power Supply Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

Regenerative Bus Supply Behavior . . . . . . . . . . . . . . . . . . . . . . . . . 286

iTRAK Power Supply Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Inverter Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Chapter 8

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Remove and Replace Kinetix 5700 Drive Modules . . . . . . . . . . . . . . 296

Remove Power and All Connections . . . . . . . . . . . . . . . . . . . . . . . 296

Remove the Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Replace the Drive Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Start and Configure the Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . 302

Replacing 2198-xxxx-ERS3 (series A) Drives with

Series B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Kinetix 5700 Safe Torque-off Function

Chapter 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Average Frequency of a Dangerous Failure . . . . . . . . . . . . . . . . . . 307

Safe Torque-off Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Out of Box State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Safe Torque-off Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Hardwired Safe Torque-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Compatible Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Troubleshoot the Safe Torque-off Function . . . . . . . . . . . . . . . . 316

Safe Torque-off Connector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Wire the Safe Torque-off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Safe Torque-off Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . 320

Safe Torque-off Feature Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 7

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Table of Contents

Cascade the Safe Torque-off Signal. . . . . . . . . . . . . . . . . . . . . . . . . 321

Hardwired Safe Torque-off Electrical Specifications . . . . . . . . . 323

Integrated Safe Torque-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Compatible Safety Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Safe Torque-off Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

STO Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Troubleshoot the Safe Torque-off Function . . . . . . . . . . . . . . . . 329

Understand Integrated Safety Drive Replacement . . . . . . . . . . . 330

Replace an Integrated Safety Drive in a GuardLogix System . . 331

Motion Direct Commands in Motion Control Systems. . . . . . 332

Integrated Safe Torque-off Specifications. . . . . . . . . . . . . . . . . . . 339

Appendix A

Interconnect Diagrams Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Power Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Capacitor Module Status Wiring Example. . . . . . . . . . . . . . . . . . . . . . 357

DC-bus Conditioner Module Status Wiring Example . . . . . . . . . . . 357

Contactor Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Passive Shunt Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Active Shunt Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Kinetix 5700 Servo Drive and Rotary Motor Wiring Examples. . . 362 Kinetix 5700 Servo Drive and Linear Actuator Wiring Examples . 367

System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Appendix B

Upgrade the Drive Firmware Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Configure Logix 5000 Controller Communication. . . . . . . . . . 383

Inhibit Feedback Only Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Upgrade Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Appendix C

Size Multi-axis Shared-bus Configurations

Shared DC-bus Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Shared DC-bus Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

General Sizing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

System Sizing Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

Select Drive/Motor Combinations. . . . . . . . . . . . . . . . . . . . . . . . . 394

Select the Power Supply and Define the DC-bus Groups. . . . . 394

Calculate System and External-bus Capacitance . . . . . . . . . . . . . 394

Calculate the Total Motor Power Cable Length. . . . . . . . . . . . . 395

Calculate 24V DC Control Power Current Demand . . . . . . . . 396

24V DC Voltage Drop Calculation Example. . . . . . . . . . . . . . . . 397

System Sizing Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

System Sizing Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

8 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 9

Appendix D

Table of Contents

Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

DC-bus Power Supply Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 402

Regenerative Bus Supply Configurations . . . . . . . . . . . . . . . . . . . . . . . 404

Appendix E

Motor Control Feature Support Frequency Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

Basic Volts/Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

Basic Volts/Hertz for Fan/Pump Applications . . . . . . . . . . . . . . 408

Sensorless Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

Current Limiting for Frequency Control. . . . . . . . . . . . . . . . . . . . . . . 410

The Effects of Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

Enable the Current Limiting Feature. . . . . . . . . . . . . . . . . . . . . . . 412

Set the CurrentVectorLimit Attribute Value. . . . . . . . . . . . . . . . 412

Stability Control for Frequency Control . . . . . . . . . . . . . . . . . . . . . . . 413

Enable the Stability Control Feature . . . . . . . . . . . . . . . . . . . . . . . 414

Skip Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

Multiple Skip Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

Flux Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

Flux Up Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

Configure the Flux Up Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . 419

Current Regulator Loop Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420

Motor Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420

Motor Tests and Autotune Procedure . . . . . . . . . . . . . . . . . . . . . . 422

Motor Analyzer Category Troubleshooting. . . . . . . . . . . . . . . . . 423

Selection of Motor Thermal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

Generic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

Thermally Characterized Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 427

Speed Limited Adjustable Torque (SLAT) . . . . . . . . . . . . . . . . . . . . . 428

Motion Polarity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

SLAT Min Speed/Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

SLAT Max Speed/Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

SLAT Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Configure the Axis for SLAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

Motion Drive Start (MDS) Instruction. . . . . . . . . . . . . . . . . . . . . 434

Motor Overload Retention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

Phase-loss Detection Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

Phase-loss Detection Configuration. . . . . . . . . . . . . . . . . . . . . . . . 441

Phase Loss Detection Current Example . . . . . . . . . . . . . . . . . . . . 442

Velocity Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Velocity Droop Attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Velocity Droop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Commutation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

Adaptive Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 9

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Table of Contents

Field Weakening Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Extended Speed Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Configure Extended Speed Operation . . . . . . . . . . . . . . . . . . . . . . 447

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449

10 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 11

Preface

This manual provides detailed installation instructions for mounting and wiring your Kinetix® 5700 power supplies, single-axis inverters, dual-axis inverters, and accessory modules. Also included is system configuration with the Studio 5000 Logix Designer® application, integration of your drive modules with a Logix 5000™ controller, system startup, and troubleshooting.

Also provided in this manual are installation instructions for mounting and wiring input power for your iTRAK® power supply. For wiring iTRAK digital inputs, outputs to the motor modules, and startup, troubleshooting, and commissioning with the AOI, see the iTRAK System User Manual, publication 2198T-UM001

This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 5700 drive modules, and programmers directly involved in the operation, field maintenance, and integration of these modules with the EtherNet/IP™ communication module or controller.

If you do not have a basic understanding of Kinetix 5700 drive modules, contact your local Rockwell Automation sales representative for information on available training courses.

Summary of Changes

This manual contains new and updated information as indicated in the following table.

Table 1 - Summary of Changes

Top ic Page

Added the following drive module catalog numbers, specifications, features, pinouts, mounting, wiring, configuration in the Logix Designer application, and troubleshooting information:

• 2198-RPxxx regenerative bus supplies

• 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters

• 2198-DCBUSCOND-RP312 DC-bus conditioner module

Added Kinetix VP (Bulletin VPAR) electric cylinders as another compatible linear actuator with Kinetix 5700 servo drives.

Updated the maximum current rating (40 A) for the 24V input power shared-bus connection system.

Moved fault code tables (FLT Sxx, FLT Mxx, and INIT FLT for example), previously in Troubleshoot the Kinetix 5700 Drive System (chapter 7), to the attached spreadsheet.

Added 2198-DBRxx-F AC line filters. 18

Added the 2198-BARCON-220DC200 DC-bus link to support the 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters. 24

Added the following DC-bus links to support the 2198-RPxxx regenerative bus supplies:

• 2198-BARCON-165DC200

• 2198-BARCON-275DC200

• 2198-BARCON-440DC200

Added the 842E-CM integrated motion encoder to the star communication topology diagram. 32

Added DC-bus Voltage Regulation that explains how the regenerative bus supply can be configured to operate as a DC-bus power supply. 42

Added AC Line Filter Selection that matches line filter catalog numbers to Kinetix 5700 power supplies. 44

Added AC Line Impedance Considerations that provides guidelines for transformer and line reactor selection. 45

Added 24V Control Power Evaluation that provides guidelines to minimize 24V control power voltage drop. 49

Added Passive Shunt Considerations and Active Shunt Considerations that provide guidelines for shunt module selection. 51, 52

Added Multi-axis Shared DC-bus Configurations that provides guidelines for system sizing. 57

Throughout

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 11

Page 12

Preface

Table 1 - Summary of Changes (continued)

Top ic Page

• Added Accessory Module Selection with DC-bus power supply configurations that moved from chapter 3.

• Added regenerative bus supply system configurations illustrating the minimum number of accessory modules required.

Updated the 8720MC-RPS or Other Regenerative Power Supply example configurations with a DC-bus conditioner module. 64

Added accessory module flowcharts designed to help determine the minimum number of accessory modules required. 65

Added the 2198-S312-P-T control power T-connector and bus bar to support 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters. 87

Added Converter OK Relay that explains how the circuitry is used to support applications that migrate from 8720MC-RPS units to the 2198-RPxxx regenerative bus supply.

Added footnotes (1) and (2) that further specify wire size to meet CE requirements for 2198-P070 DC-bus power supplies. 141

Updated Maximum Cable Lengths with examples for 2198-RPxxx regenerative bus supplies. 155

Added Customer-supplied Motor Power Cables to support wiring 2198-S263-ERSx and 2198-S312-ERSx single-axis inverter applications that require conductors larger than 2 AWG.

Updated External Active-shu nt Connections with Powerohm catalog numbers that apply to regenerative bus supplies and added information for wiring regenerative bus supplies to the Active Shunt (RC) connector.

Added Hardware Fault Tolerance (HFT) specifications to the table. 307

Added Active Shunt Wiring Examples. 360

Added external-bus capacitance calculations and updated the System Sizing Example with the external-bus capacitance value. 399

Added the Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies (Appendix D). 401

Updated Motor Analyzer Category Troubleshooting with rated slip-speed information. 423

111

172

183

Conventions Used in This Manual

These conventions are used throughout this manual:

• Bulleted lists such as this one provide information, not procedural steps

• Numbered lists provide sequential steps or hierarchical information

• When catalog number 2198-xxxx-ERS3 appears in this publication without series designation, the topic applies to series A and B drives

IMPORTANT Throughout this publication, when the Kinetix 5700 inverter catalog

number ends in -ERSx, for example 2198-D057-ERSx, the variable (x) indicates that the inverter (using this example) can be 2198-D057-ERS3 or 2198-D057-ERS4.

• The 2198-CAPMOD-2240 capacitor module, 2198-CAPMODDCBUS-IO extension module, and 2198-DCBUSCOND-RP312 DC-bus conditioner module are collectively referred to as accessory modules

12 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 13

Preface

Access the Attachments

Additional Resources

Table 2 - Additional Resources

The Microsoft Excel spreadsheet that is attached to this publication contains fault code descriptions. To use the spreadsheet file, click the Attachments link

, right-click the spreadsheet file, and save the file to your computer.

If the PDF file opens in a browser and you don't see the Attachments link , download the PDF file and reopen the file with the Adobe Acrobat Reader

application.

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001

Kinetix Linear Motion Specifications Technical Data, publication KNX-TD002

Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003

Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004

AC Line Filter Installation Instructions, publication 2198-IN003

Kinetix 5700 Regenerative Bus Supply Installation Instructions, publication 2198-IN014

Kinetix 5700 Capacitor Modules Installation Instructions, publication 2198-IN008 Provides information on installing and wiring the Kinetix 5700 capacitor modules.

Replacement Fan Kit Installation Instructions, publication 2198-IN015

Kinetix 5700 DC-bus Conditioner Module Installation Instructions, publication 2198-IN016

Kinetix 5700 Shunt Passive Modules Installation Instructions, publication 2198-IN011 Provides information on installing and wiring Kinetix 5700 passive shunts.

Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001

iTRAK System User Manual, publication 2198T-UM001

Provides product specifications for Kinetix VP (Bulletin VPL, VPC, VPF, and VPS), MP-Series™ (Bulletin MPL, MPM, MPF, and MPS), and HPK-Series™ rotary motors.

Provides product specifications for Bulletin MPAS and MPMA linear stages, Bulletin VPAR, MPAR, and MPAI electric cylinders, LDAT-Series linear thrusters, and LDC-Series™ linear motors.

Provides product specifications for Kinetix Integrated Motion over the EtherNet/IP network, Integrated Motion over sercos interface, EtherNet/IP networking, and component servo drive families.

Provides product specifications for Bulletin 2090 motor and interface cables, lowprofile connector kits, drive power components, and other servo drive accessory items.

Provides information on installing and wiring the Kinetix 5500 and Kinetix 5700 AC line filters.

Provides information on installing and wiring the Kinetix 5700 regenerative bus supply.

Provides information on removal and replacement of cooling fans used in 2198RPxxx regenerative bus supplies and 2198-S263-ERSx and 2198-S312-ERSx single- axis inverters.

Provides information on installing and wiring the Kinetix 5700 DC-bus conditioner module.

Provides a description of integrated stopping functions and safe monitoring functions with a GuardLogix® controller and Kinetix 5700 servo drives.

Provides information on installing the Kinetix 5700 iTRAK power supply with an iTRAK system and programming the iTRAK system.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 13

Page 14

Preface

Table 2 - Additional Resources (continued)

Resource Description

1321 Power Conditioning Products Technical Data, publication 1321-TD001

8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Kinetix Motion Control Selection Guide, publication KNX-SG001

Kinetix 5700 Drive Systems Design Guide, publication KNX-RM010

Rockwell Automation Product Selection website http://www.rockwellautomation.com/global/support/selection.page

Motion Analyzer System Sizing and Selection Tool website https://motionanalyzer.rockwellautomation.com/

Product Certifications website, rok.auto/certifications

Motor Nameplate Datasheet Entry for Custom Motor Applications Application Technique, publication 2198-AT002

Vertical Load and Holding Brake Management Application Technique, publication MOTION-AT003

Motion System Tuning Application Technique, publication MOTION-AT005 Provides information on tuning a Kinetix drive system.

Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual, publication MOTION-UM003

Integrated Motion on the EtherNet/IP Network Reference Manual, publication MOTION-RM003

GuardLogix 5570 Controllers User Manual, publication 1756-UM022

GuardLogix 5580 Controllers User Manual, publication 1756-UM543

Compact GuardLogix 5370 Controllers User Manual, publication 1769-UM022

Compact GuardLogix 5380 Controllers User Manual, publication 5069-UM001

GuardLogix 5570 and Compact GuardLogix 5370 Controller Systems Safety Reference Manual, publication 1756-RM099

GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Reference Manual, publication 1756-RM012

ControlFL ASH Firmware Upgrade Software User Manual, publication 1756-UM105 For ControlFLASH™ information not specific to any drive family.

Rockwell Automatio n Industrial Automation Glossary, publication AG-7 .1

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Provides information on typical use cases, specifications, terminations, and dimensions of Bulletin 1321 line reactors.

Provides information on installing, wiring, and startup for the 8720MC regenerative power supply with 380…460V AC operation.

Provides information, examples, and techniques designed to minimize system failures caused by electrical noise.

Overview of Kinetix ser vo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements.

System design guide to select the required (drive specific) drive module, power accessory, feedback connector kit, and motor cable catalog numbers for your Kinetix 5700 drive system.

Online product selection and system configuration tools, including AutoCAD (DXF) drawings.

Comprehensive motion application sizing tool used for analysis, optimization, selection, and validation of your Kinetix Motion Control system.

Provides declarations of conformity, certificates, and other certification details.

Provides information on the use of nameplate data entry for custom induction motors and permanent-magnet motors that are used in applications with Kinetix 5700 servo drives.

Provides information on vertical loads and how the servo motor holding-brake option can be used to help keep a load from falling.

Provides information on configuring and troubleshooting your ControlLogix® and CompactLogix™ EtherNet/IP network modules.

Provides information on the AXIS_CIP_DRIVE attributes and the Studio 5000 Logix Designer application Control Modes and Methods.

Provides information on how to install, configure, program, and use ControlLogix controllers and GuardLogix controllers in Studio 5000 Logix Designer projects.

Provides information on how to install, configure, program, and use CompactLogix and Compact GuardLogix controllers.

Provides information on how to achieve and maintain Safety Integrity Level (SIL) and Performance Level (PL) safety application requirements for GuardLogix and Compact GuardLogix controllers.

A glossary of industrial automation terms and abbreviations.

Provides general guidelines for installing a Rockwell Automation industrial system.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

14 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 15

Chapter 1

Start

Use this chapter to become familiar with the Kinetix® 5700 drive system and obtain an overview of installation configurations.

Top ic Pa ge

Kinetix 5700 Servo Drives Series Change 16

About the Kinetix 5700 Servo Drive System 17

DC-bus Power Supply Input Power Configurations 19

Regenerative Bus Supply Input Power Configurations 23

8720MC-RPS Power Supply Input Power Configuration 28

Motor and Auxiliary Feedback Configurations 29

Typical Communication Configurations 30

Functional Safety Configurations 33

Catalog Number Explanation 37

Agenc y Compliance 39

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 15

Page 16

Chapter 1 Start

Kinetix 5700 Servo Drives Series Change

Single-axis and dual-axis inverters, catalog numbers 2198-xxxx-ERS3 (series B), include an enhancement that is not included in series A drives, but that is included in 2198-xxxx-ERS4 drives.

• The drive-based (Monitored SS1 and Timed SS1) stopping functions and controller-based monitoring functions apply to the 2198-xxxx-ERS4 drives

• The drive-based Timed SS1 stopping function and STO with configurable delay applies to the 2198-xxxx-ERS3 (series B) drives

• When catalog number 2198-xxxx-ERS3 appears in this publication without series designation, the topic applies to series A and B drives

Table 3 - Integrated Functional Safety Support

Integrated Safety Over the EtherNet/IP™ Network

Drive-based stopping functions

Controller-based stopping functions

Controller-based monitoring functions

Safety feedback function Safety Feedback Interface (SFX)

Integrated STO mode Safe Torque-off (STO)

(1) Where a ControlLogix or CompactLogix (non-safety) controller is specified, a GuardLogix or Compact GuardLogix controller is backwards compatible. Also, GuardLogix 5580 and Compact GuardLogix

5380 controllers are backwards compatible with GuardLogix 5570 and Compact GuardLogix 5370 controllers.

Safety Func tion

Timed Safe Stop 1 (SS1)

Monitored Safe Stop 1 (SS1)

• Monitored Safe Stop 1 (SS1)

• Safe Stop 2 (SS2)

• Safe Operational Stop (SOS)

• Safely Limited Speed (SLS)

• Safety Limited Position (SLP)

• Safe Direction (SDI)

Dual-axis Inverters Cat. No.

2198-Dxxx-ERS3 (series B) 2198-Dxxx-ERS4

2198-Dxxx-ERS4 2198-Sxxx-ERS4

2198-Dxxx-ERS3 2198-Sxxx-ERS3

Single-axis Inverters Cat. No.

2198-Sxxx-ERS3 (series B) 2198-Sxxx-ERS4

Minimum Controller Required

• GuardLogix® 5580

• CompactLogix™ 5380

• ControlLogix® 5570

• CompactLogix 5370

(1)

16 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 17

Start Chapter 1

About the Kinetix 5700 Servo Drive System

Table 4 - Kinetix 5700 Drive System Overview

Drive System Component

Kinetix 5700 DC-bus Power Sup ply

Kinetix 5700 Regenerative Bus Supply

Kinetix 5700 Singleaxis Servo Drives

Kinetix 5700 Dualaxis Servo Drives

Kinetix 5700 iTRAK Power Sup ply

Kinetix 5700 Capacitor Module

Kinetix 5700 Extension Module

Kinetix 5700 DC-bus Conditioner Module

8720MC Regenerative Power Sup ply

Shared-bus Connector Kits

DSL Feedback Connector Kit

Universal Feedback Connector Kit

Hiperface to DSL Converter Kit

Cat. No. Description

2198-Pxxx

2198-RPxxx

2198-Sxxx-ERS3

2198-Sxxx-ERS4

2198-Dxxx-ERS3

2198-Dxxx-ERS4

2198T-W25K-ER DC-DC converter that generates DC-bus power for iTRAK® systems.

2198-CAPMOD-2240

2198-CAPMOD-DCBUS-IO

2198-DCBUSCOND-RP312

8720MC-RPSxxx

2198-TCON-24VDCIN36 2198-xxxx-P-T 2198-BARCON-xxDCAC100

2198T-W25K-P-IN 2198T-W25K-P-T

2198-BARCON-xxDC200 2198-KITCON-ENDCAP200

2198-KITCON-DSL

2198-K57CK-D15M

2198-H2DCK (series B or later)

The Kinetix 5700 drive modules are zero-stacked and use the shared-bus connection system to extend power from one drive module to another. Systems are designed to support Integrated Motion over the EtherNet/IP network.

Converter power supply with 400V-class (three-phase) AC input. Provides power in a range of 7…46 kW and

10.5…69.2 A output current. Systems typically consist of one module, however, up to three modules in parallel is possible. Parallel modules increase available power for Bulletin 2198 single-axis and dual-axis inverters.

Regenerative bus supply with 400V-class (three-phase) AC input provides continuous output power and current to Bulletin 2198 single-axis and dual-axis inverters for applications with requirements in the range of 24…140 kW and 35…207 A, output current.

Single-axis inverters with current ratings up to 192 A rms. Drives feature TÜV Rheinland certified safe torque-off function with hardwired and integrated safety connection options, PL e and SIL 3 safety ratings, and support for DSL, Hiperface, and Heidenhain EnDat encoder feedback. 2198-Sxxx-ERS3 (series B) drives also support Timed SS1 drivebased stopping functions.

Single-axis inverters with the same power structure and encoder feedback support as -ERS3 inverters, plus support for Monitored SS1 and Timed SS1 drive-based stopping functions. Also, support for controller-based safe stop and safe monitor functions over the EtherNet/IP network.

Dual-axis inverters with current ratings up to 23 A rms. Drives feature TÜV Rheinland certified safe torque-off function with hardwired and integrated safety connection option s, PL e and SIL 3 safety ratings, and support for DSL, Hiperface, and Heidenhain EnDat encoder feedback. 2198-Dxxx-ERS3 (series B) drives also support Timed SS1 drive-based stopping functions.

Dual-axis inverters with the same power struc ture and encoder feedback support as -ERS3 inverters, plus support for Monitored SS1 and Timed SS1 drive-based stopping functions. Also, support for controller-based safe stop and safe monitor functions over the EtherNet/IP network.

Use for energy storage, external active-shunt connection, and to extend the DC-bus voltage to another inver ter cluster. Modules are zero-stacked with servo drives and use the shared-bus connection system to extend the ex ternal DC-bus voltage in applications up to 104 A. Can parallel with itself or with another accessory module for up to 208 A with required 2198-KITCON-CAPMOD2240 kit that includes flexible bus-bars.

The extension module, paired with a capacitor module or DC-bus conditioner module, is used to extend the DC-bus voltage to another inverter cluster in systems with ≥104 A current and up to 208 A.

Decreases the voltage stress on insulation components in an inverter system and used to extend the DC-bus voltage to another inverter cluster. Modules are zero-stacked with servo drives and use the shared-bus connection system to extend the external DC-bus voltage in applications up to 104 A. Can parallel with itself or with another accessory module for up to 208 A with required 2198-KITCON-DCBUSCOND kit that includes flexible bus-bars.

Sinusoidal PWM converter that can control the increase of DC-bus voltage and perform continuous power generation for one or more servo drives in multi-axis DC common-bus configurations.

24V input wiring connectors, T-connectors, and bus-bars for most Kinetix 5700 drive modules that use the 24V sharedbus connection system (optional).

24V input wiring connector, T-connector, and bus-bar for the iTRAK motor module and other select Kinetix 5700 drive modules that use the 24V shared-bus connection system (optional).

DC-bus links (55, 85, 100, and 220 mm) and end caps for the DC-bus shared-bus connection system (required and included with each respective drive module). DC-bus links (165, 275, and 440 mm) are optional and do not ship with any modules.

Replacement DSL motor feedback connector kit with 2-pin connector plug and grounding plate inside the connector housing. Supports 400V-class Kinetix VP rotary motors. Included with 2090-CSxM1DE motor cables. Must be purchased separately when used with 2090-CSxM1DG motor cables.

Universal feedback connector kit for motor and auxiliary feedback connections with the 15-pin connector plug and grounding plate inside the connector housing. Supports 400V-class MP-Series™ and HPK-Series™ rotary motors, MPSeries linear actuators, LDAT-Series linear thrusters, and LDC-Series™ linear motors.

Provides Hiperface-to-DSL feedback conversion for use with compatible 400V-class motors and actuators.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 17

Page 18

Chapter 1 Start

Table 4 - Kinetix 5700 Drive System Overview (continued)

Drive System Component

Kinetix 5700 System Mounting Toolkit

Kinetix 5700 Cable Clamp Spacer Kit

Encoder Output Module

Logix 5000™ Controller Platform

Studio 5000® Environment

Rotary Servo Motors

Linear Actuators

Linear Motors LDC-Series Compatible motors include LDC-Series iron-core (400V-class) linear motors.

Induction Motors N/A Induction motors with open-loop frequency control and closed-loop control are supported.

Cables

AC Line Filters

Line Reactors 1321-3Rxx-x

AC Contac tor

24V DC Power Supply 1606-XLxxx Bulletin 1606 24V DC power supply for control circuitry, digital inputs, safety, and motor brake.

External Passive Shunt Resistors

External Active Shunts

Cat. No. Description

2198-K5700-MOUNTKIT Use to position the drive modules and identify drill-holes for mounting your Kinetix 5700 servo drive system.

2198-K5700-CLAMPSPACER Replacement cable clamp spacers for 2198-Dxxx-ERSx dual-axis inverters.

2198-ABQE

Bulletin 1769 Bulletin 5069

1756-EN2T module 1756-EN2TR module 1756-EN3TR module

N/A

Kinetix VP Compatible motors include 400V-class Bulletin VPL, VPC, VPF, and VPS ser vo motors.

MP-Series Compatible motors include 400V-class Bulletin MPL, MPM, MPF, and MPS servo motors.

HPK-Series Compatible motors include 460V and 400V-class HPK-Series asynchronous servo motors.

Kinetix VP, MP-Series, LDAT-Series

2090-CSxM1DE-xxAxxx

2090-CSxM1DG-xxAxxx

2090-CFBM7DF-CEAxxx Bulletin 2090 motor feedback cables for MP-Series motors and actuators with Stegmann Hiperface encoders.

2090-CPxM7DF-xxAxxx Bulletin 2090 motor power/brake cables for MP-Series motors and actuators.

2090-XXNFMF-Sxx 2090-CFBM7DF-CDAFxx

2198T-CHBFLS8-12AAxx Bulletin 2198T power cables for iTRAK power supply to iTRAK motor modules.

1585J-M8CBJM-x Ethernet cables are available in standard lengths. Shielded cable is required to meet EMC specifications.

2198-DB20-F, 2198-DB42-F, 2198-DB80-F, 2198-DB290-F

2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, 2198-DBR200-F

100-Cxxxxx 100-Dxxxxx 100-Exxxxx

2198-R014, 2198-R031, 2198-R127, 2198-R004

N/A

The Allen-Bradley® encoder output module is a DIN-rail mounted EtherNet/IP network-based standalone module capable of outputting encoder pulses to a customer-supplied peripheral device (cameras, for example, used in linescan vision systems).

Integrated Motion on the EtherNet/IP network in CompactLogix 5370 and CompactLogix 5380 controllers and Integrated Safety in Compact GuardLogix 5370 and Compact GuardLogix 5380 controllers. Linear, device-level ring (DLR), and star topology is supported.

EtherNet/IP network communication modules for use with ControlLogix 5570, ControlLogix 5580, GuardLogix 5570, and GuardLogix 5580 controllers. Linear, device-level ring (DLR), and star topology is supported.

Studio 5000 Logix Designer® application, version 26.00 or later, provides support for programming, commissioning, and maintaining the CompactLogix, ControlLogix, and GuardLogix controller families.

Compatible actuators include 400V-class Bulletin MPAS linear stages, Bulletin VPAR, MPAR, and MPAI electric cylinders, and LDAT-Series linear thrusters.

Bulletin 2090 single cable for motor power, feedback, and 24V DC brake power with Kinetix VP motors. Feedback conductors are wired to the 2198-KITCON-DSL feedback connector kit.

Bulletin 2090 single cable for motor power, feedback, and 24V DC brake power with Kinetix VP motors. 2090-CSxM1DG cables have flying-lead feedback conductors for connection to a customer-supplied 2198-KITCON-DSL feedback connector kit.

Bulletin 2090 standard and continuous-flex feedback cables that include additional conductors for use with incremental and EnDat encoders.

Bulletin 2198 three-phase AC line filters are required to meet CE and are available for use with DC-bus power supplies. Use 2198-DBxx-F filters as field replacements in existing installations that use DC-bus power supplies with inverter ground jumpers installed. Select 2198-DBRxx-F filters for all new systems and remove all inverter ground jumpers.

Bulletin 2198 three-phase AC line filters are required to meet CE and available for use with DC-bus power supplies and regenerative bus supplies. Select 2198-DBRxx-F filters for all new systems and remove all inverter ground jumpers.

Bulletin 1321 line reactors help keep equipment running longer by absorbing many of the power line disturbances that can shut down your power supply. For 2198-RPxxx regenerative bus supplies, line reactors can significantly reduce the amount of circulating currents between the integrated LC filter and other devices on the common AC power source.

The AC three-phase contactor control string must be wired in series with the contactor-enable relay at the CED connector to make sure that three-phase power is removed under various fault conditions to protect the power supply.

Bulletin 2198 external passive-shunt resistors for use when the DC-bus power supply internal shunt capability is exceeded. Not for use with regenerative bus supplies.

External active shunts from Rockwell Automation Encompass™ partner, Powerohm Resistors, Inc., are available for connecting to Bulletin 2198 DC-bus power supplies and regenerative bus supplies. See External Active-shunt

Connections on page 183 for catalog numbers.

18 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 19

Start Chapter 1

Bulletin 2198

Shunt Module

(optional component)

Magnetic Contactor (M1) Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power (customer-supplied)

AC Input Power

Kinetix 5700 Servo Drive System

(front view)

Bulletin 2198 shared-bus connection system for DC-bus and 24V DC control power.

Kinetix 5700 Servo Drive System (top view)

Line Disconnect

Device

324…528V AC

Three-phase Input Power

Circuit

Protection

Magnetic (M1)

Contac tor

Bonded Cabinet Ground Bus

2198-DBRxx-F

AC Line Filter

(required for CE)

Converter Digital Inputs

Inverter Digital Inputs

Shared DC-bus Power

Shared 24V Control Power (24V shared-bus connection system is optional)

DC-bus

Power Supply

Single-axis

Inverter

Dual-axis Inverters

Capacitor

Module

DC-bus Power Supply Input Power Configurations

A single 2198-Pxxx DC-bus (converter) power supply can supply the Kinetix 5700 drive system with 458…747V shared DC-bus power (7…46 kW). For additional output power (kW) you can install two or three 2198-P208 DC-bus power supplies. You can also extend the DC-bus to additional inverter clusters via accessory modules.

Typical DC-bus Power Supply Configuration Example

In this multi-axis example, AC input power is fed to the DC-bus (converter) power supply. One single-axis (inverter) module and two dual-axis (inverter) modules support five axes of motion. The DC-bus power supply is mounted on the far left and the inverters are positioned on the right, but the reverse mounting order (right to left) is also possible.

Digital inputs are wired to sensors and the control circuitry at the IOD connectors. The contactor-enable relay protects the DC-bus power supply in the event of shutdown fault conditions.

Figure 1 - Typical DC-bus Power Supply Installation

DC+

Allen-Bradley

1606-XL

Power Supply

Input

SB+/NC S1A SCA S2A SBNC NC

SB+/NC

S1A

SCA

S2A

SB-

MOD

NET

MOD

NET

MOD

NET

MOD

NET

DC BUS

I/O

UFB

D+ D-

MBRK

I/O

I/O-A

I/O-B

I/O-A

I/O-B

MODULE

D+ D-

510

UFB-A UFB-B

510

D+ D-

STATUS

510

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B MF-A MF-B

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 19

Page 20

Chapter 1 Start

DC+

1606-XL

Power Supply

Input

Allen-Bradley

MOD

NET

MOD

NET

MOD

NET

I/O

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

DC+

MOD

NET

I/O

MOD

NET

I/O

MOD

DC BUS

MODULE

STATUS

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

MOD

NET

I/O

MBRK

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

W V U

SB+/NC

S1A SCA S2A SBNC NC

Bulletin 2198

Shunt Module

(optional component)

1606-XLxxx

24V DC Control Power

(customer-supplied)

AC Input Power

Kinetix 5700 Ser vo Drive System

(front view)

Kinetix 5700 Servo Drive System (top view)

Circuit

Protection

Bonded Cabinet

Ground Bus

1321-3R80-B Line Reactors

(required components)

2198-P208 DC-bus Power Supplies

Single-axis Inverter

Dual-axis Inverters

Capacitor

Module

Bulletin 2198 shared-bus connection system for DC-bus and 24V DC control power.

Shared DC-bus Power

Shared 24V Control Power (24V shared-bus connection system is optional)

Magnetic Contactor

(M1) Control String

Line Disconnect

Device

324…528V AC

Three-phase Input Power

Magnetic (M1)

Contac tor

2198-DBR200-F

AC Line Filter

(required for CE)

Circuit

Protection

Multiple DC-Bus Power Supply Configuration Example

In this example, three DC-bus (converter) power supplies all receive AC input power and feed the inverter modules for increased output power.

Contactor enable relays from each of the DC-bus power supplies are wired in series to protect the DC-bus power supply in the event of shutdown fault conditions.

Figure 2 - Multiple DC-bus Power Supply Installation

IMPORTANT When two or three DC-bus power supplies are wired together in the same

drive cluster, they must all be catalog number 2198-P208.

20 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 21

Start Chapter 1

Kinetix 5700 Servo Drives

Cluster 1 (front view)

Bonded Cabinet

Ground Bus

Kinetix 5700 Extended Servo Drives

Cluster 2 (front view)

DC-bus Extension

Shared DC-bus and 24V DC Control Power

Circuit

Protection

1321-3R80-B Line Reactors

(required components)

2198-P208 DC-bus Power Supplies

Single-axis

Inverter

Dual-axis

Inverters

Capacitor

Module

Extension

Module

Capacitor

Module

Extension

Module

Dual-axis Inverters

Bulletin 2198 Shared-bus

Connection System

(24V shared-bus connection

system is optional)

Magnetic Contactor

(M1) Control String

Line Disconnect

Device

324…528V AC

Three-phase Input Power

Magnetic (M1)

Contac tor

2198-DBR200-F

AC Lin e Filter

(required for CE)

DC-bus Extension

ATT EN TI ON : Circuit protection can

be added after the power supply cluster to help protect converters and inverters from damage in the event of

a DC-bus cable short-circuit.

Circuit

Protection

Extended DC-bus Configuration Example

In this example, two drive clusters in the same cabinet are connected by the same 458…747V DC bus voltage. Kinetix 5700 accessory modules provide connection points for the DC-bus at the end of cluster 1 and the beginning of cluster 2. The Kinetix 5700 servo drive system is capable of up to 208 A DC-bus current. Two accessory modules are needed when the DC-bus system current exceeds 104 A. See Accessory Module Selection information on the when accessory modules are required.

Figure 3 - Extended DC-bus Installation

MOD

NET

DC BUS

NET

MOD

NET

on page 59 for more

MOD

NET

MOD

NET

I/O

MOD

NET

I/O

I/O-A

I/O-B

I/O-A

MODULE

510

STATUS

UFB-A UFB-B

D+

D-

MF-A MF-B

MF-A MF-B MF-A MF-B

MOD

NET

I/O

I/O-B

510

D+ D-

I/O-A

I/O-B

I/O-A

510

UFB-A UFB-B

D+

D-

MF-A MF-B

I/O-B

I/O-A

I/O-B

510

UFB-A UFB-B

D+D-D+

D+

D-

MF-A MF-B MF-A MF-B

510

I/O-A

UFB-A UFB-B

I/O-B

I/O-A

I/O-B

510

UFB-A UFB-B

D+

D-

MF-A MF-B

MOD

NET

I/O-A

I/O-B

510

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B MF-A MF-B

D+ D-

510

I/O-A

UFB-A UFB-B

MOD

NET

I/O-B

510

D+ D-

MOD

DC BUS

MODULE

STATUS

MOD

NET

I/O

UFB

D+ D-

MBRK

IMPORTANT When two or three DC-bus power supplies are wired together in the same

drive cluster, they must all be catalog number 2198-P208.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 21

Page 22

Chapter 1 Start

I/O

510

–

iPS RDY

MOD–

NET–

1 2 3 4 5

6 7 8 9 10

MOD

NET

I/O

510

–

iPS RDY

MOD–

NET–

1 2 3 4 5

6 7 8 9 10

DC+

1606-XL

Power Supply

Input

Allen-Bradley

Bulletin 2198

Shunt Module

(optional component)

Magnetic Contactor

(M1) Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and iTRAK Motor Module Control Power

(customer-supplied)

AC Input Power

Kinetix 5700 iTRAK System

(front view)

Kinetix 5700 iTRAK System (top view)

Line Disconnect

Device

324…528V AC

Three-phase

Input Power

Circuit

Protection

Magnetic (M1)

Contac tor

Bonded Cabinet

Ground Bus

2198-DBRxx-F

AC Lin e Filter

(can be required for CE)

Converter Digital Inputs

iTRAK Motor Modules

DC-bus

Power Supply

iTRAK

Power Supply

iTRAK

Power Supp ly

iTRAK Motor Modules

iTRAK Power Supply Digital Inputs

Shared-bus connection system for DC-bus and 24V DC control power.

Shared DC-bus Power

Shared 24V Control Power

(1)

(24V shared-bus connection system is optional)

2198T-CHBFLS8

Motor Power

Cables

iTRAK Power Supply Configuration Example

In this example, AC input power is fed to the DC-bus (converter) power supply. Two iTRAK power supplies support up to 40 iTRAK motor modules, depending on cable lengths and iTRAK motor-module power consumption.

Digital inputs are wired to sensors and the control circuitry at the IOD connectors. The contactor-enable relay protects the DC-bus power supply in the event of shutdown fault conditions.

Figure 4 - Typical iTRAK Power Supply Installation

(1) If total control power current exceeds 16 A, a second input connector (catalog number 2198T-W25K-P-IN) can be added to the

leftmost iTRAK power supply.

22 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 23

Start Chapter 1

1606-XL

Power Supply

Input

Allen-Bradley

MOD

NET

MOD

NET

MOD

NET

I/O

I/O-A

510

I/O-B

510

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

DC+

D+ D-

SB+/NC

I/O-A

510

I/O-B

510

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

MOD

NET

I/O

OK+

OK–

EN–

EN+

DC–

MOD

DC BUS

MODULE

STATUS

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

I/O-A

510

I/O-B

510

SB+/NC

S1A SCA S2A SBNC NC

Active Shunt (optional component)

See External Active-shunt Connections

on page 183

for more information.

Magnetic Contactor (M1) Control String

1606-XLxxx

24V DC Control, Digital Inputs, and

Motor Brake Power (customer-supplied)

AC Input Power

Kinetix 5700 Servo Drive System

(front view)

Shared-bus connection system for DC-bus and 24V DC control power.

Kinetix 5700 Ser vo Drive System (top view)

Line Disconnect

Device

324…506V AC

Three-phase Input Power

Circuit

Protection

Magnetic (M1)

Contac tor

Bonded Cabinet Ground Bus

Converter Digital Inputs

Inverter Digital Inputs

Shared DC-bus Power

Shared 24V Control Power (24V shared-bus connection system is optional)

Single-axis

Inverter

Dual-axis Inverters

Regenerative Bus Supply

(1)

DC-bus Conditioner Module

2198-DBRxx-F

AC Lin e Filter

(required for CE)

Regenerative Bus Supply Input Power Configurations

The 2198-RPxxx regenerative bus supply (24…140 kW) provides full-line motoring and regenerative power to and from the Kinetix 5700 drive system. In addition, you can extend the DC-bus voltage to additional inverter clusters via accessory modules.

Typical Regenerative Bus Configuration Examples

In this example, the inverter modules are mounted to the right of the regenerative bus supply. One single-axis (inverter) module and three dual-axis (inverter) modules support seven axes of motion. Other features include:

• Digital inputs are wired to sensors and the control circuitry at the IOD connectors.

• The contactor enable relay protects the regenerative bus supply in the event of shutdown fault conditions.

• The DC-bus conditioner module is required when the combined motor cable length exceeds 400 m (1312 ft). See Accessory Module Selection on page 59

Figure 5 - Typical Shared DC-bus Installation (mounted left to right)

for more information on accessory module requirements.

(1) The regenerative bus supply can be left or right of the inverters. Further, we recommend that the highest inverter power ratings

are positioned closest to the regenerative bus supply and in decreasing order leading away from the regenerative bus supply.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 23

Page 24

Chapter 1 Start

SB+/NC

S1A SCA S2A SBNC NC

1606-XL

Power Supply

Input

Allen-Bradley

MOD

NET

I/O

MBRK

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

W V U

MOD

NET

I/O

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MODULE STATUS

MOD

DC BUS

I/O-A

510

I/O-B

510

SB+/NC

S1A SCA S2A SBNC NC

L1 L2 L3

SB+/NC

S1A SCA S2A SBNC NC

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

I/O-A

6101

I/O-B

510

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

1606-XLxxx

24V DC Control Power

(customer-supplied)

AC Input Power

Kinetix 5700 Servo Drive System

(front view)

Kinetix 5700 Servo Drive System (top view)

Line Disconnect Device

324…506V AC

Three-phase

Input Power

Circuit Protection

Magnetic (M1)

Contactor

Bonded Cabinet

Ground Bus

2198-DBRxx-F

AC Line Filter

(required for CE)

Shared DC-bus Power

Shared 24V Control Power

Dual-axis Inverters

Regenerative Bus Supply

(1)

DC-bus Conditioner

Module

24V DC Control Power Connector Plug

Single-axis Inverter

Magnetic Contactor (M1) Control String

1321-3Rxx-x Line Reactor

(recommended)

In this example, the 2198-RP312 regenerative bus supply is mounted on the far right and followed by the 2198-S312-ERSx single-axis inverter, and two 2198-D020-ERSx dual-axis inverters.

• The 2198-BARCON-440DC200 DC-bus link extends the DC-bus from the regenerative bus supply to the single-axis inverter.

• The 2198-BARCON-220DC200 DC-bus link extends the DC-bus from the single-axis inverter to the dual-axis inverter.

• The regenerative bus supply has 24V DC wired to the connector plug

• The 2198-xxxx-P-T bus-bar connector extends 24V control power from the input wire connector to the dual-axis and single-axis inverters.

• The DC-bus conditioner module is required when the combined motor cable length exceeds 400 m (1312 ft). See Accessory Module Selection on page 59

Figure 6 - Typical Shared DC-bus Installation (mounted right to left)

for more information on accessory module requirements.

24 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

(1) The regenerative bus supply can be left or right of the inverters. Further, we recommend that the highest inverter power ratings

are positioned closest to the regenerative bus supply and in decreasing order leading away from the regenerative bus supply.

Page 25

Start Chapter 1

MOD

NET

I/O-A

510

I/O-B

510

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B

MOD

NET

I/O

OK+

OK–

EN–

EN+

MOD

NET

I/O-A

510

I/O-B

510

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B

MOD

NET

I/O

OK+

OK–

EN–

EN+

MOD

NET

I/O

MOD

NET

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B

I/O-A

510

I/O-B

510

Kinetix 5700 Servo Drive Systems

(front view)

Line Disconnect

Device

324…506V AC

Three-phase Input Power

Circuit

Protection

Magnetic (M1)

Contac tors

Bonded Cabinet

Ground Bus

2198-DBRxx-F

AC Line Filter

(required for CE)

Dual-axis

Inverter

Regenerative Bus Supply

DC-bus

Power Supply

Dual-axis

Inverter

Regenerative Bus Supply

Dual-axis

Inverter

Bulletin 1321 Line Reactors

Additional

Inverters

Additional

Inverters

Additional

Inverters

M1 Control

String

Magnetic Contactor (M1)

Control S tring

M1 Control

String

Circuit

Protection

2198-DBRxx-F AC Line Filter

(required for CE)

2198-DBRxx-F

AC Line Filter

(required for CE)

In this example, three-phase input power feeds two 2198-RPxxx regenerative power supplies and one 2198-Pxxx DC-bus power supply.

IMPORTANT We recommend that Bulletin 1321 line reactors be used in any system with

multiple regenerative bus supplies sharing the same AC input-power source.

Bulletin 1321 line reactors are used in the regenerative power supply input power circuits to help do the following:

• Reduce circulating currents between different systems

• Prevent all power supplies on the same input power source from nuisance thermal overload faults

Figure 7 - Input Power to Multiple Kinetix 5700 Drive Systems

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 25

Page 26

Chapter 1 Start

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

D+ D-

MF-A MF-B

D+ D-

MOD

NET

MOD

NET

MOD

NET

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

MOD

NET

D+ D-

MODULE

STATUS

MOD

NET

MODULE

STATUS

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

MODULE

STATUS

I/O-A

510

I/O-B

510

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

MOD

NET

I/O

OK+

OK–

EN–

EN+

Kinetix 5700 Drive System

Cluster 1 (front view)

Kinetix 5700 Extended Drive System

Cluster 2 (front view)

DC-bus Extension

Shared DC-bus and 24V DC Control Power

Magnetic Contactor

(M1) Control String

Dual-axis Inverters

Line Disconnect Device

324…506V AC

Three-phase Input Power

Circuit Protection

Magnetic (M1) Contac tor

Bonded Cabinet

Ground Bus

2198-DBRxx-F

AC Line Filter

(required for CE)

Regenerative Bus Supply

2198-CAPMOD-DCBUS-IO Extension Module

2198-CAPMOD-2240 Capacitor Module

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

Combin ed motor

cable lengths equal

300 m (984 ft).

Combined motor

cable lengths equal

480 m (1575 ft).

Single-axis

Inverter

ATTENTION: Circuit protection can

be added after the power supply cluster to help protec t converters and inverters from damage in the event of

a DC-bus cable short-circuit.

Bulletin 1321

Line Reactor

(recommended)

Extended Regenerative Bus Configuration Example

In this example, two drive clusters in the same cabinet are connected by the same 458…747V DC bus voltage.

• Kinetix 5700 accessory modules provide connection points for the DC bus at the end of cluster 1 and the beginning of cluster 2.

• The Kinetix 5700 servo drive system is capable of up to 208 A DC-bus current. Two parallel accessory modules are needed when the DC-bus system current exceeds 104 A.

• The DC-bus conditioner module is required when the combined motor cable length exceeds 400 m (1312 ft). See Accessory Module

Selection on page 59 for more information on accessory module

requirements.

Figure 8 - Extended DC-bus Installation

26 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 27

I/O

510

–

iPS RDY

MOD–

NET–

1 2 3 4 5

6 7 8 9

I/O

510

–

iPS RDY

MOD–

NET–

1 2 3 4 5

6 7 8 9

1606-XL

Power Supply

Input

Allen-Bradley

DC+

MOD

NET

I/O

OK+

OK–

EN–

EN+

DC–

Magnetic Contactor

(M1) Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and iTRAK Motor Module Control Power

(customer-supplied)

AC Input Power

Kinetix 5700 iTRAK System

(front view)

Kinetix 5700 iTRAK System (top view)

Line Disconnect Device

324…506V AC

Three-phase Input Power

Circuit Protection

Magnetic (M1) Contac tor

Bonded Cabinet

Ground Bus

Converter Digital Inputs

iTRAK Motor Modules

Regenerative Bus Supply

iTRAK

Power S upply

iTRAK

Power S upply

iTRAK Motor Modules

iTRAK Power Supply Digital Inputs

Bulletin 2198 shared-bus connection system for DC-bus and 24V DC control power.

Shared DC-bus Power Input

Shared 24V Control Power Input (24V shared-bus connection system is optional)

2198T-CHBFLS8

Motor Power

Cables

Active Shunt (optional component)

See External Active-shunt Connections

on page 183

for more information.

Bulletin 1321

Line Reactor

(recommended)

2198-DBRxx-F

AC Lin e Filter

(can be required for CE)

Start Chapter 1

iTRAK Power Supply Configuration Example

In this example, AC input power is fed to the regenerative bus supply. Two iTRAK power supplies support up to 40 iTRAK motor modules, depending on cable lengths and iTRAK motor-module power consumption.

Digital inputs are wired to sensors and the control circuitry at the IOD connectors. The contactor-enable relay protects the regenerative bus supply in the event of shutdown fault conditions.

Figure 9 - Typical iTRAK Power Supply Installation

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 27

Page 28

Chapter 1 Start

1606-XL

Power Supply

Input

Allen-Bradley

MOD

NET

MOD

NET

MOD

NET

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

87208720

MCMC

RST

PRG

ENT

READYREADY

FAULTFAULT

PROGRAMPROGRAM kWkW

MOD

NET

UFB-A UFB-B

D+ D-

MF-B

D+ D-

MOD

DC BUS

MODULE STATUS

D+ D-

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

MOD

DC BUS

MODULE STATUS

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power (customer-supplied)

AC Input Power

Kinetix 5700 Servo Drive System (front view)

Kinetix 5700 Servo Drive System (top view)

324…506V AC

Three-phase Input Power

Circuit Protection

Magnetic

(1)

(M1) Contactor

Bonded Cabinet Ground Bus

8720MC-RFI80

AC Lin e Filter

(required for CE)

8720MC-LRxx

Line Reactor

8720MC-RPS065-BM-HV2

Regenerative Power Supply

Single-axis

Inverter

Dual-axis Inverters

Capacitor

Module

8720MC-HF-B2 Harmonic Filter

8720MC-VA-B

Vari sto r

Bulletin 2198 shared-bus connection system for DC-bus and 24V DC control power.

Shared DC-bus Power Input

Shared 24V Control Power Input (24V shared-bus connection system is optional)

DC-bus

Conditioner

Module

8720MC-RPS Power Supply Input Power Configuration

In this example, three-phase AC input power is fed to the Bulletin 8720MC regenerative power supply. The 8720MC-RPS DC-bus voltage supplies the Kinetix 5700 DC-bus via the capacitor module.

• The 8720MC-RPS065 provides 65 A of DC-bus current. The 2198CAPMOD-2240 capacitor module and 2198-DCBUSCOND-RP312 DC-bus conditioner are required to reduce voltage stress on the system components.

• If the 8720MC-RPS190 is used, the capacitor module and DC-bus conditioner module provide up to 208 A of DC input current. DC-bus full-regeneration is possible with this configuration.

• The DC-bus conditioner module is required when the combined motor cable length exceeds 400 m (1312 ft). See Accessory Module Selection on page 59

for more information on accessory module requirements.

IMPORTANT The 8720MC-RPS power supply is not compatible with the iTRAK power

supply.

Figure 10 - 8720MC-RPS Power Supply Installations

28 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

(1) This M1 contactor is controlled by the 8720MC regenerative power supply.

Page 29

Start Chapter 1

2090-CSBM1DE Single Motor Cables

2198-KITCON-DSL Connector Kit

Accepts DSL motor feedback from VPC-Bxxxxx-Q and (Bulletin VPL, VPF, VPS) rotary motors and Kinetix VP electric cylinders.

Bulletin 2090 Motor Power and Feedback Cables

2198-K57CK-D15M Universal Connector Kit

Accepts multiple encoder feedback types:

• Hiperface high-resolution absolute multi-turn and single-turn encoders – VPC-Bxxxxx-S rotary motors – MP-Series (Bulletin MPL, MPM, MPF, MPS) rotary motors – HPK-Series asynchronous rotary motors – MP-Series (Bulletin MPAS, MPAR, MPAI) linear actuators – LDAT-Series linear thrusters, LDC-Series linear motors

• Heidenhain EnDat high-resolution absolute encoders – VPC-Bxxxxx-Y rota ry motors – RDD-Series direct-drive motors

• Feedback-only, master feedback, or load feedback

(absolute single-turn/multi-turn Hiper face)

• Feedback-only, master feedback, or load feedback (incremental)

MP-Series Rotary Motors (MPL-Bxxxx motor is shown)

LDAT-Series Linear Thrusters

2198-H2DCK Converter Kit

Converts 15-pin Hiperface feedback into 2-pin DSL feedback for:

• VPC-Bxxxxx-S rotary motors

• MP-Series rotary motors and linear actuators

• HPK-Se ries asynchro nous rotary motor s

• LDAT-Series linear thrusters

• Feedback-only, master feedback, or load feedback (absolute single-turn/multi-turn Hiperface)

15-pin Universal Feedback (UFB) Connectors

2-pin Motor Feedback (MF) Connectors

2198-Dxxx-ERSx

or 2198-Sxxx-ERSx Inverters

(2198-Dxxx-ERSx dual-axis

inverter is shown)

Kinetix VP Rotary Motors (Bulletin VPL, VPF, VPS and Catalog Number VPC-Bxxxxx-Q)

HPK-Series Asynchronous Rotary Motors

and Induction Rotary Motors

(closed-loop control)

2090-CSBM1DG Single Motor Cables

RDD-Series Direct Drive Rotary Motors

Kinetix VP Rotary Motors

Catalog Numbers

VPC-Bxxxxx-S and VPC-Bxxxxx-Y

Kinetix VP Electric Cylinders (Bulletin VPAR)

MP-Series (Bulletin MPAS)

Integrated Linear Stages

MP-Series (Bulletin MPAI) Heavy-duty Electric Cylinders

LDC-Series

Linear Motors

MP-Series (Bulletin MPAR)

Electric Cylinders

Motor and Auxiliary Feedback Configurations

UFB-A

D+D-D+

MF-A

UFB-A

D+D-D+

MF-A

Feedback connections are made at the 2-pin motor feedback (MF) connector and the 15-pin universal feedback (UFB) connector. These examples illustrate how you can use the Bulletin 2198 connector kits for making these connections. To see motor power and brake connections, refer to Chapter 5

page 127

Figure 11 - Feedback Configuration Example

UFB-A

MOD–

NET–

I/O-B

I/O-A

510

UFB-A

UFB-B

D+D-D+

D-

MF-B

MF-A

D+D-D+

MF-A

UFB-B

D-

MF-B

UFB-B

D-

MF-B

UFB-B

D+D-D+

D-

MF-B

MF-A

UFB-A

UFB-B

D-

MF-B

o c . b a . w

S w U w N I E D A M

0 0 5

X 5

X 7

X 0 X M

. X O . N O .

I R E S

ES I R E S

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 29

Page 30

Chapter 1 Start

ControlLogix 5570 Controller with Bulletin 1756 EtherNet/IP Module

Studio 5000 Logix Designer Application

1585J-M8CBJM-x

Ethernet (shielded) Cable

1734-AENTR POINT I/O™ EtherNet/IP Adapter

ControlLogix Controller Programming Network

PanelView™ Plus

Display Terminal

1585J-M8CBJM-OM15

0.15 m (6 in.) Ethernet cables for drive-to-drive connections.

Kinetix 5700 Servo Drive System

2198-ABQE

Encoder Output Module

Line Scan Cameras

Typical Communication Configurations

The Kinetix 5700 drives support any Ethernet topology including linear, ring, and star by using ControlLogix, GuardLogix, or CompactLogix controllers.

These examples feature the ControlLogix 5570 programmable automation controllers with support for integrated motion and integrated safety over the EtherNet/IP network. Other Allen-Bradley controllers are also compatible with the Kinetix 5700 servo drives.

Refer to ControlLogix Communication Module Specifications Technical Data, publication 1756-TD003

, for more information on ControlLogix

1756-EN2T, 1756-EN2TR, and 1756-EN3TR communication modules.

TIP These example configurations use the 2198-Pxxx DC-bus power supply.

However, 2198-RPxxx regenerative bus supply can be used instead.

Linear Topology

In this example, all devices are connected by using linear topology. The Kinetix 5700 drive modules include dual-port connectivity, however, if any device becomes disconnected, all devices downstream of that device lose communication. Devices without dual ports must include the 1783-ETAP module or be connected at the end of the line.

Figure 12 - Kinetix 5700 Linear Communication Installation

EtherNet/IP

LNK1LNK2NET OK

MOD

NET

OUTPUT-A OUTPUT-B

NET

I/O

MOD

NET

MOD

NET

I/O

UFB

MBRK

I/O-A

I/O-B

I/O-A

510

UFB-A UFB-B

D+

D+D-D+

D+

D-

MF-A MF-B MF-A MF-B

I/O-B

I/O-A

I/O-B

510

D+ D-

UFB-A UFB-B

MF-A MF-B

510

D+ D-

1734-AENTR

POINT I O

Module Status

Network Activity

Network Status

Point Bus Status

Link 1 Activity/

System

Status

Power

Field Power

Link 2 Activity/ Status

30 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 31

Start Chapter 1

1734-AENTR

Module Status

Network Activity

Network Status

Point Bus Status

System Power

Field Power

POINT I O

Link 1 Activity/ Status

Link 2 Activity/ Status

MOD

NET

MOD

NET

MOD

NET

MOD

NET

I/O

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

LNK1LNK2NET OK

EtherNet/IP

MOD

NET

OUTPUT-A OUTPUT-B

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

1734-AENTR POINT I/O EtherNet/IP Adapter

ControlLogix Controller Programming Network

1783-ETAP

Module

1585J-M8CBJM-OM15

0.15 m (6 in.) Ethernet cable for drive-to-drive connections.

Panel View Plus Display Terminal

Kinetix 5700 Servo Drive System

Studio 5000 Logix Designer

Application

1585J-M8CBJM-x Ethernet

(shielded) Cable

ControlLogix 5570 Controller with Bulletin 1756 EtherNet/IP Module

2198-ABQE

Encoder Output Module

Line Scan

Cameras

Ring Topology

In this example, the devices are connected by using ring topology. If only one device in the ring is disconnected, the rest of the devices continue to communicate. For ring topology to work correctly, a device level ring (DLR) supervisor is required (for example, the Bulletin 1783 ETAP device). DLR is an ODVA standard. For more information, refer to the EtherNet/IP Embedded Switch Technology Application Guide, publication ENET-AP005

Devices without dual ports, for example the display terminal, require a 1783-ETAP module to complete the network ring.

Figure 13 - Kinetix 5700 Ring Communication Installation

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 31

Page 32

Chapter 1 Start

MOD

NET

MOD

NET

MOD

NET

MOD

NET

I/O

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

LNK1LNK2NET OK

EtherNet/IP

MOD

NET

OUTPUT-A OUTPUT-B

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

1585J-M8CBJM-x

Ethernet (shielded) Cable

1734-AENTR POINT I/O EtherNet/IP Adapter

ControlLogix Controller Programming Network

Panel View Plus Display Terminal

1783-BMS

Stratix® 5700

Switch

1585J-M8CBJM-OM15

0.15 m (6 in.) Ethernet cable

for drive-to-drive connections.

Kinetix 5700 Servo Drive System

Studio 5000 Logix Designer

Application

ControlLogix 5570 Controller with Bulletin 1756 EtherNet/IP Module

2198-ABQE

Encoder Output Module

Line Scan

Cameras

842E-CM Integrated

Motion Encoder

Star Topology

In this example, the devices are connected by using star topology. Each device is connected directly to the switch.

Kinetix 5700 drive modules have dual ports, so linear topology is maintained from one module to another, but the Kinetix 5700 system and other devices operate independently. The loss of one device does not impact the operation of other devices.

Figure 14 - Kinetix 5700 Star Communication Installation

You can use the 842E-CM integrated motion encoder for applications requiring an external encoder for gearing or camming to the Kinetix 5700 drive. By providing auxiliary feedback directly through the EtherNet/IP network, the 842E-CM encoder helps eliminate the need for point-to-point wiring while letting customers use the encoder in a variety of network topologies. For more information, see the 842E-CM Integrated Motion on EtherNet/IP Product Profile, publication 842ECM-PP001

32 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 33

Start Chapter 1

1585J-M8CBJM-x

Ethernet (shielded) Cable

Any Logix 5000 Controller

(ControlLogix 5570 controller is shown)

Studio 5000 Logix Designer

Application

AC Input Power

Safety Device

Kinetix 5700 Servo Drive System

(top view)

Kinetix 5700 Servo Drive System

(front view)

Digital Inputs to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

Kinetix VP

Servo Motors

Module Definition

Configured with

Motion Only

Connection

Safe Torque-off (STO) Connectors

ControlLogix 5570 Controllers or GuardLogix 5570 Safety Controllers

ControlLogix 5580 Controllers or GuardLogix 5580 Safety Controllers

CompactLogix 5370 Controllers or Compact GuardLogix 5370 Safety Controllers

CompactLogix 5380 Controllers or Compact GuardLogix 5380 Safety Controllers

Functional Safety Configurations

EtherNet/IP

LNK1LNK2NET OK

Kinetix 5700 servo drives are capable of safe torque-off (STO) and safe stop 1 (SS1) drive-based safety functions via hardwired connections or integrated over the EtherNet/IP network. In addition, safely limited speed (SLS) and other controller-based safety instructions are also possible. These examples illustrate the functional safety configuration options.

TIP These example configurations use the 2198-Pxxx DC-bus power supply.

However, 2198-RPxxx regenerative bus supply can be used instead.

Hardwired Configuration

Kinetix 5700 servo drives use the safe torque-off (STO) connector for wiring external safety-devices and cascading hardwired safety-connections from one drive to another.

Figure 15 - Safe Torque-off (hardwired) Configuration

DC+

DC INPUT

Logix5585

0000

SAFETY ON

NET

LINK

OKFORCESDRUN

AC OUTPUT

SB+/NC S1A SCA S2A SBNC NC

Allen-Bradley

1606-XL

Power Supply

Input

MOD

NET

I/O

MOD

NET

I/O

UFB

MBRK

SB+/NC S1A SCA S2A SBNC NC NC

MOD

NET

I/O-A

I/O-B

510

UFB-A UFB-B

D+D-D+

D+

D-

MF-A MF-B MF-A MF-B

I/O-A

510

UFB-A UFB-B

SB+/NC S1A SCA S2A SBNC NC

MOD

NET

I/O-B

510

D+ D-

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 33

Page 34

Chapter 1 Start

1606-XL

Power Supply

Input

Allen-Bradley

LNK1LNK2NET OK

EtherNet/IP

MOD

NET

MOD

NET

MOD

NET

MOD

NET

I/O

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

DC+

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

1585J-M8CBJM-x Ethernet (shielded) Cable

Compact GuardLogix 5370 Controller, Compact GuardLogix 5380 Safety Controller or

GuardLogix 5570 Controller, GuardLogix 5580 Safety Controller (GuardLogix 5570 Safety Controller is shown)

Studio 5000 Logix Designer

Application

AC Input Po wer

Kinetix 5700 Servo Drive System

(top view)

Kinetix 5700 Servo Drive System

(front view)

Digital Inputs to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

Kinetix VP

Servo Motors

1783-BMS Stratix 5700 Switch

Module Definition

Configured with

Motion and Safety

Conne ction

1734-AENTR POINT Guard I/O™ EtherNet/IP Adap ter

Safety Device

Integrated Safety Configurations

The GuardLogix or Compact GuardLogix safety controller issues the safe torque-off (STO) or safe stop (SS1) command over the EtherNet/IP network and the Kinetix 5700 servo drive executes the command.

In this example, a single GuardLogix safety controller makes the Motion and Safety connections.

IMPORTANT If only one controller is used in an application with Motion and Safety

connections, it must be a GuardLogix or Compact GuardLogix safety controller. For more information, see the Integrated Functional Safety

Support table on page 16.

Figure 16 - Motion and Safety Configuration (single controller)

34 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 35

Start Chapter 1

LNK1LNK2NET OK

EtherNet/IP

LNK1LNK2NET OK

EtherNet/IP

1606-XL

Power Supply

Input

Allen-Bradley

MOD

NET

MOD

NET

MOD

NET

MOD

NET

I/O

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

DC+

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

1585J-M8CBJM-x Ethernet (shielded) Cable

Compact GuardLogix 5370 Controller,

Compact GuardLogix 5380 Safety Controller or

GuardLogix 5570 Controller,

GuardLogix 5580 Safety Controller

(GuardLogix 5570 Safety Controller is shown)

Studio 5000 Logix Designer

Application

AC Input Power

Kinetix 5700 Servo Drive System

(top view)

Kinetix 5700 Servo Drive System

(front view)

Digital Inputs to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

Kinetix VP

Servo Motors

1734-AENTR POINT Guard I/O EtherNet/IP Adapter

1783-BMS Stratix 5700 Switch

Motion Program

Module Definition

Configured with

Motion Only

Connection

Safety Program

Module Definition

Configured with

Safety Only Connect ion

Safety Device

Any Logix 5000 Controller

(ControlLogix 5570 controller is shown)

In this example, a non-safety controller makes the Motion-only connection and a separate GuardLogix safety controller makes the Safety-only connection.

IMPORTANT If two controllers are used in an application with Motion Only and Safety

Only connections, the Safety Only connection must be a GuardLogix or Compact GuardLogix safety controller and the Motion Only connection must be any Logix 5000 controller. For more information, see the Integrated

Functional Safety Support table on page 16.

Figure 17 - Motion and Safety Configuration (multi-controller)

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 35

Page 36

Chapter 1 Start

LNK1LNK2NET OK

EtherNet/IP

MOD

NET

I/O

MOD

NET

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B

I/O-A

510

I/O-B

510

Controller-based Instruction Example

Compact GuardLogix 5380 or

GuardLogix 5580 Safety Controller

(GuardLogix 5580 Safety Controller is shown)

Kinetix 5700 Servo Drive System

with Integrated Safety Functions

Position feedba ck is se nt

separately to the drive for

safety and for motion control.

Primary Feedback

• Kinetix VP (Bulletin VPL/VPF) Servo Motors with -W or -Q encoders

• Kinetix VP (Bulletin VPC) Servo Motors with -Q encoders

Secondary Feedback

Bulletin 842HR SIN/COS Encoder for

Dual Feedback Monitoring

Applications

DSL feedback connector kit with primary

feedback from the motor is hidden behind the

universal feedback connector kit with

secondary feedback from the external encoder.

1585J-M8CBJM-x Ethernet (shielded) Cable

Studio 5000 Logix Designer

Application

1734-AENTR POINT Guard I/O EtherNet/IP Adap ter

1783-BMS Stratix 5700 Switch

Safety Device

Secondary Feedback to UFB Connector

Primary Feedback to MF Connector

Safe Stop and Safe Monitor Configurations

Kinetix 5700 servo drives are capable of safe stop and safe monitor functions via drive-based and controller-based integrated safety over the EtherNet/IP network.

IMPORTANT For applications with safe stop and safe monitor safety functions, the

GuardLogix 5580 or Compact GuardLogix 5380 controllers must be used. For more information, see the Integrated Functional Safety Support

page 16

In this example, the SS1 stopping function is used in a motion and safety controller-based configuration with dual-feedback monitoring.

Figure 18 - Safe Motion-monitoring Configuration

table on

36 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Start Chapter 1

Catalog Number Explanation

Kinetix 5700 drive module catalog numbers and performance descriptions.

Table 5 - Kinetix 5700 Drive Module Catalog Numbers

Kinetix 5700 Drive Modules

DC-bus Power Supply

Regenerative Power Supply

Single-axis Inverters

Dual-axis Inverters

Module

Cat. No.

Width

Input Voltage

2198-P031 2198-P070

2198-P141 2198-P208

324…528V AC rms, three-phase

2198-RP088 165

2198-RP200 275 67 100

2198-RP263

2198-RP312 140 207

2198-S086-ERS3 2198-S130-ERS3

2198-S086-ERS4 2198-S130-ERS4

440

2198-S160-ERS3 2198-S160-ERS4 100 60.1 120.2

2198-S263-ERS3 2198-S312-ERS3

2198-D006-ERS3 2198-D012-ERS3 2198-D020-ERS3 2198-D032-ERS3

2198-S263-ERS4 2198-S312-ERS4

2198-D006-ERS4 2198-D012-ERS4 2198-D020-ERS4 2198-D032-ERS4

220

324…506V AC rms, three-phase

–

Continuous Output Power

7 17

31 46

24 35

(1)

119 176

29.7

44.9

90 112

1.7

3.4

5.5

8.9

Continuous Output Current to Bus

rms

10.5

25.5

46.9

69.2

–

2198-D057-ERS3 2198-D057-ERS4 85 15.9 32.5

iTRAK Power Supply 2198T-W25K-ER 100 – – – 2x12.5

(1) Applies when DC-bus voltage regulation is enabled. If DC-bus voltage regulation is not enabled, the input voltage range is 324….528V AC. For more information on these two modes of operation, see

DC-bus Voltage Regulation

on page 42.

Continuous Output Current

A 0-pk

–

60.8

91.9

212.1

271.5

3.5

7.0

11.3

18.3

Table 6 - Accessory Module Catalog Numbers

Accessory Modules

(1)

Cat. No.

Capacitor Module 2198-CAPMOD-2240

Extension Module 2198-CAPMOD-DCBUS-IO

DC-bus Conditioner Module 2198-DCBUSCOND-RP312

(1) Combination of any two accessory modules increases system current up to 208 A. However, modules must be mounted side-by-side and joined by two flexible bus-bars. (2) Flexible bus-bars are included with only the 2198-CAPMOD-DCBUS-IO extension module. So, if you have two capacitor modules, two DC-bus conditioner modules, or a capacitor module and DC-bus

conditioner module mounted side by side, you must order the 2198-KITCON-CAPMOD2240 or 2198-KITCON-DCBUSCOND connector set separately.

Module Width

System Current

(2)

Rated Voltage Capacitance

55 104 A 458…747V DC, nom

2240 μF

–

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 37

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Chapter 1 Start

Table 7 - Shared-bus Connector Kit Catalog Numbers

Shared-bus Connector Kits Cat. No.

Drive Module Cat. No.

Application Description

2198-P031, 2198-P070, 2198-P141, 2198-P208

(1) (2)

2198-TCON-24VDCIN36

2198-CAPMOD-2240

24V DC input power to control bus 24V DC input wiring connector2198-RP088, 2198-RP200, 2198-DCBUSCOND-RP312

2198T-W25K-P-IN

(1) (2)

2198T-W25K-ER, 2198-RP263, 2198-RP312, 2198-S263-ERSx, 2198-S312-ERSx

2198-D006-ERSx, 2198-D012-ERSx

2198-H040-P-T

2198-D020-ERSx, 2198-D032-ERSx

Control power sharing Control power T-connector with bus bars, 55 mm

2198-CAPMOD-2240, 2198-DCBUSCOND-RP312

2198-H070-P-T 2198-D057-ERSx, 2198-S086-ERSx, 2198-S130-ERSx Control power sharing Control power T-connector with bus bars, 85 mm

2198-S160-P-T 2198-S160-ERSx

2198T-W25K-P-T 2198T-W25K-ER

Control power sharing Control power T-connector with bus bars, 100 mm

2198-S312-P-T 2198-S263-ERSx, 2198-S312-ERSx Control power sharing Control power T-connector with bus bars, 220 mm

(1) The input wiring connector can be inserted into any drive module (mid-stream in the drive system) to begin a new 24V control bus when the maximum current value is reached. However, the input

connector must always extend the 24V DC-bus from left to right. The 2198T-W25K-P-IN male plug is physically larger than the male plug on 2198-TCON-24VDCIN36.

(2) For drive module amp ratings and connector wire size information, see Control Power

on page 113, and CP Connector Plug Wiring Specifications table on page 146, respectively.

38 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Start Chapter 1

Agency Compliance

If this product is installed within the European Union and has the CE mark, the following regulations apply.

ATT EN TI ON : Meeting CE requires a grounded system, and the method of grounding the AC line filter and drive module must match. Failure to do this renders the filter ineffective and can cause damage to the filter. For grounding examples, refer to Grounded Power Configurations

on page 129.

For more information on electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

To meet CE requirements, these requirements apply:

• Install an AC line filter (catalog number 2198-DBRxx-F) for input power as close to the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply as possible.

• Bond DC-bus power supplies, regenerative bus supplies, inverter modules, capacitor modules, and line filter grounding screws by using a braided ground strap as shown in Figure 91 on page 139

• When using the 2198-P070 DC-bus power supply above 45 °C (113 °F) with stranded input power wiring, conductors must be single-core

6mm

stranded copper with 90 °C minimum rating.

• When using the 2198-RP088 regenerative power supply above 40 °C (104 °F) with stranded input power wiring, conductors must be singlecore 6 mm

stranded copper with 90 °C minimum rating.

• Use Bulletin 2090 single motor cables with Kinetix VP servo motors. Use Bulletin 2090 motor power/brake and feedback cables for other compatible Allen-Bradley motors and actuators. Motor cable shieldclamp on the drive must be used.

• Combined motor power cable length for all axes on the same DC bus must not exceed:

– 1200 m (3937 ft) for 2198-Pxxx DC-bus power supplies and

2198-RPxxx regenerative bus supplies when paired with 2198-DBRxx-F line filters.

– 400 m (1312 ft) for 2198-Pxxx DC-bus power supplies when paired

with 2198-DBxx-F line filters.

Drive-to-motor feedback cables must not exceed 90 m (295 ft), depending on system components.

• Motor cable length for the iTRAK power supply to iTRAK motor modules must be at least 3 m (9.8 ft), not to exceed 30 m (98.4 ft).

• Use Bulletin 2198T power cables with iTRAK systems.

• Install the Kinetix 5700 system inside an approved enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure. Separate signal and power cables.

• Segregate input power wiring from control wiring and motor cables.

Refer to Appendix A on page 341

for input power wiring and drive/motor

interconnect diagrams.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 39

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Chapter 1 Start

Notes:

40 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 41

Chapter 2

Plan the Kinetix 5700 Drive System Installation

This chapter describes system installation guidelines used in preparation for mounting your Kinetix® 5700 drive system components.

Top ic Pa ge

System Design Guidelines 41

Accessory Module Selection 59

Electrical Noise Reduction 67

ATT EN TI ON : Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry and result in damage to the components.

System Design Guidelines

Use the information in this section when planning to mount your system components on the panel.

For on-line product selection and system configuration tools, including AutoCAD (DXF) drawings of the product, refer to

https://www.rockwellautomation.com/global/support/selection.page

System Mounting Requirements

• To comply with UL and CE requirements, the Kinetix 5700 drive system must be mounted in a grounded conductive enclosure offering protection as defined in standard IEC 60529 to IP20 such that they are not accessible to an operator or unskilled person.

To maintain the functional safety rating of the Kinetix 5700 drive system, this enclosure must be appropriate for the environmental conditions of the industrial location and provide a protection class of IP54 or higher.

• The panel you install inside the enclosure for mounting your system components must be on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors in accordance with pollution degree 2 (EN 61800-5-1) because the product is rated to protection class IP20 (EN 60529).

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 41

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

• Size the system enclosure so as not to exceed the maximum ambient temperature rating. Consider heat dissipation specifications for all system components.

• Use high-frequency (HF) bonding techniques to connect the modules, enclosure, machine frame, and motor housing, and to provide a lowimpedance return path for high-frequency (HF) energy and reduce electrical noise.

Bond the Kinetix 5700 system power supply, inverter modules, iTRAK® power supply, accessory modules, and line filter grounding screws by using a braided ground strap as shown in Figure 91 on page 139

Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 reduction.

, to better understand the concept of electrical noise

DC-bus Voltage Regulation

The 2198-Pxxx DC-bus power supply does not regulate DC-bus voltage. As a result, the DC-bus power supply always has DC-bus voltage regulation disabled. The 2198-RPxxx regenerative bus supply can be configured to provide active DC-bus voltage regulation or passive AC rectification like the 2198-Pxxx DC-bus (converter) power supply.

IMPORTANT Active or passive DC-bus voltage regulation must be determined during

system configuration in the Studio 5000 Logix Designer® application.

IMPORTANT Regeneration back to the AC source is only possible when the DC-bus voltage

regulation is enabled.

Converter Startup Method

The Converter Startup Method (Axis Properties>General category) specifies the method to be used to initiate transition of the regenerative converter axis from the STOPPED state to the STARTING state.

ATT EN TI ON : To help prevent permanent inverter damage, make sure that all inverter ground jumpers are removed before enabling DC-bus voltage regulation.

Set the Converter Startup Method to one of these two settings:

• Automatic (default): After applying AC, the converter automatically transitions to the RUNNING state with active DC-bus voltage regulation loops operational

• Enable Request: After applying AC, the converter stays in the STOPPED state and performs passive AC rectification. Once it receives an Enable Request from the controller, the converter transitions to the RUNNING state with active DC-bus voltage control loops operational

42 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 43

Plan the Kinetix 5700 Drive System Installation Chapter 2

• 1.05

Bus Voltage Set Point (V )

AC Input Voltage (V ) •

RMS

–

Boost Voltage = Bus Voltage Set Point (V )

AC Input Voltage (V ) •

RMS

In Enable Request mode, you must issue an MSO instruction (after AC is applied and CIP_Axis_State = STOPPED) to enable voltage regulation on the regenerative bus supply and an MSF instruction to disable voltage regulation.

Bus Voltage Loop Parameters

The regenerative bus supply uses an active control loop to maintain the DC bus voltage at a specified level (or reference) and has two settings for the Bus Voltage Reference Source (Axis Properties>Bus Voltage Loop category> Parameters):

• Automatic (default) setting: The converter optimizes the BusVoltageReference for the best converter performance

• Manual setting: You configure the desired BusVoltageSetPoint value for the BusVoltageReference signal

In Manual mode, the BusVoltageSetPoint must be greater than 5% of the peak input AC voltage (or it is clamped automatically) with a maximum of 747V DC.

Boost voltage is the difference between the rectified AC voltage and the BusVoltageSetPoint.

IMPORTANT Setting a manual fixed DC-bus voltage sets peak motor output power

performance regardless of the variance of the input AC rms. Higher boost voltage increases Total Harmonic Distortion (THD), reduces efficiency, and increases acoustic noise, but this is normal and expected. For example, optimal operation is best achieved for 460V AC motors when the input AC rms is also at 460V AC nominal, Automatic mode is selected, and the DC-bus voltage regulates at approximately 683V DC.

Refer to Configure Regenerative Bus Supply Axis Properties

on page 224 for

more information.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 43

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

AC Line Filter Selection

An AC line filter is required to meet CE requirements. Install an AC line filter for input power as close to the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply as possible.

IMPORTANT AC line filters are only recommended with grounded WYE power

configurations. For facility power configuration examples, see Input Power

Configurations for Kinetix 5700 Power Supplies on page 129.

Table 8 - AC Line Filter Selection

DC-bus Power Supply Cat. No.

2198-P031

2198-P070

2198-P141 2198-P208

2198-P208 (2 in parallel) 2198-P208 (3 in parallel)

(1) The use of 2198-DBRxx-F line filters provide a maximum motor-power cable length of up to 1200 m (3937 ft). Maximum motor-power cable length with 2198-DBxx-F line filters is 400 m (1312 ft). (2) See Chapter 5

Specifications Technical Data, publication KNX-TD003 (3) When using 2198-DBRxx-F line filters with DC-bus power supplies, remove all inverter ground jumpers to reduce overall system leakage-inductance current. (4) When using 2198-DBRxx-F line filters with regenerative bus supplies, remove all inverter ground jumpers to prevent permanent damage to the inverters.

beginning on page 127, for more information on maximum cable lengths and how the use of 2198-DBRxx-F line filters affe ct ground screw/jumper settings. See Kinetix Servo Drive

AC Line Filter Cat. No.

• 2198-DBR20-F or

• 2198-DB20-F

• 2198-DBR40-F or

• 2198-DB42-F

• 2198-DBR90-F or

• 2198-DB80-F

• 2198-DBR200-F or

• 2198-DB290-F

(1) (2) (3)

, for AC line filter specifications.

Regenerative Bus Supply Cat. No.

2198-RP088 2198-DBR40-F

2198-RP200 2198-DBR90-F

2198-RP263 2198-RP312

AC Line Filter Cat. No.

2198-DBR200-F

(1) (2) (4)

IMPORTANT Use 2198-DBxx-F line filters only as field replacements in existing installations that use DC-bus power supplies and have

inverter ground jumpers installed. Select 2198-DBRxx-F line filters for all new systems and remove inverter ground jumpers. 2198-DBRxx-F line filters can also be used to replace existing 2198-DBxx-F line filters, but you must remove the inverter ground jumpers.

44 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

AC Line Impedance Considerations

DC-bus power supplies do not require an isolation transformer for three-phase input power. Regenerative bus supplies also do not require an isolation transformer for three-phase input power unless they are connected to cornergrounded or ungrounded facility power. See Input Power Configurations for

Kinetix 5700 Power Supplies on page 129 for example configurations.

IMPORTANT These recommendations are advisory and do not address all situations.

Site-specific conditions must be considered for proper installation.

A transformer can be required to match the voltage requirements of the power supply to the available service. For the AC input voltage requirements, refer to the Kinetix 5700 power specifications in the Kinetix Servo Drives Technical Data, publication KNX-TD003

IMPORTANT When using an autotransformer, make sure that the phase to neutral/

ground voltage does not exceed the input voltage ratings of the power supply.

Use a safety factor of 1.5 for three-phase power (where safety factor is used to compensate for transformer, drive modules, motor losses, and to account for utilization in the intermittent operating area of the torque speed curve).

EXAMPLE Sizing a transformer to the voltage requirements of this power supply:

2198-P141: 31kW x 1.5 = 46.5 kVA transformer.

In the following use cases, an additional transformer or line reactor is required due to faults or potential damage associated with AC line disturbances:

• Installation site has switched power-factor correction capacitors.

• Installation site has lightning strikes or voltage spikes in excess of 6000V peak.

• Installation site has power interruptions or voltage dips in excess of 200VAC.

• The transformer kVA is more than 10 times larger than the drive kVA, or the percent source impedance relative to each converter is less than 0.5%.

In the following use cases, a line reactor is required due to faults associated with sharing AC line-input on multiple converters:

• Repetitive AC input line-voltage notching is present. For example, if silicon controlled rectifier drive is connected to the same AC inputpower source.

– In drive systems that include the regenerative bus supply, repetitive

AC line voltage notching can cause the integrated AC line filter to overheat and result in FLT S18 converter overtemperature fault.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 45

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

% impedance is the nameplate impedance of the transformer.

xfmr

line-line

)

* % Impedance

% impedance is the nameplate impedance of the transformer.

• Powering multiple (two or more) regenerative bus supplies from the same AC input-power source.

– Switching ripple from each regenerative bus supply can interfere with

other regenerative bus supplies on the same AC input power source.

• Powering 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus supply from the same AC input-power source.

– Switching ripple from the regenerative bus supply can impact the

temperature of DC-bus capacitors in the DC-bus power supply. In this use case, a line reactor is required in the AC input-power string leading to the regenerative bus supply.

– Line reactor in the AC input-power string is not required for the

DC-bus power supply in this use case, but is recommended for the prevention of issues caused by other use cases.

• Powering two or three 2198-P208 DC-bus power supplies from the same AC input-power source that share the same DC-bus.

– In this use case, a line reactor is required for each 2198-P208 DC-bus

power supply to make sure that they share current more evenly.

Use these equations to calculate the impedance of the DC-bus power supply, regenerative bus supply, or transformer to check the percent source-impedance relative to the power supply to make sure it is not less than 0.5%. An additional transformer or line reactor is required in this use case.

DC-bus Power Supply or Regenerative Bus Supply Impedance (in ohms)

drive

3 * I

line-line

input-rating

Transformer Impedance (in ohms)

line-line

xfmr

3 * I

* % Impedance

xfmr-rated

Transformer Impedance (in ohms)

line-line

xfmr

3 * I

* % Impedance

xfmr-rated

46 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

xfmr

drive

0.2304

102.6

= 0.00224 = 0.22%=

EXAMPLE The DC-bus power supply or regenerative bus supply is rated 1 Hp, 480V,

2.7 A input. The supply transformer is rated 50,000VA (50 kVA), 5% impedance.

drive

3 * I

line-line

input-rating

480V

= = 102.6 Ohms

3 * 2.7

Kinetix 5700 Power Supply

DC-bus Power Supply

Regenerative Bus Supply

)

line-line

xfmr

* % Impedance =

480

* 0.05 = 0.2304 Ohms

50,000

The percent (%) impedance has to be in per unit (5% becomes 0.05) for the formula.

0.22% is less than 0.5%. Therefore, this transformer is too large for the DC-bus power supply or regenerative bus supply. Consider adding either a line reactor or isolation transformer.

Bulletin 1321 Line Reactor Selection

Power Supply Cat. No.

2198-P031 1 1321-3R12-B Recommended

2198-P070 1 1321-3R35-B Recommended

2198-P141 1 1321-3R55-B Recommended

2198-P208

2198-RP088 1 1321-3R35-A Recommended

2198-RP200 1 1321-3R100-A Recommended

2198-RP263 1 1321-3R160-B Recommended

2198-RP312 1 1321-3R200-A Recommended

Number of Power Supplies in a Bus Group

2Required

3Required

Bulletin 1321 Line Reactor Cat. No.

1321-3R80-B

Status

Recommended

See Power Wiring Examples on page 343 for AC input-power interconnect diagrams. For Bulletin 1321 line reactor specifications, see the 1321 Power Conditioning Products Technical Data, publication 1321-TD001

IMPORTANT You can group multiple 2198-Pxxx DC-bus power supplies on one line

reactor if they do not share same DC bus. However, the line reactor percent impedance must be large enough when evaluated for each DC-bus power supply separately, not evaluated for all loads connected at once.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 47

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Circuit Breaker/Fuse Selection

The Kinetix 5700 power supplies use internal solid-state motor short-circuit protection and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 200,000 A (fuses) and 65,000 A (circuit breakers).

Refer to Power Wiring Examples

, on page 343, for the wiring diagram.

ATT EN TI ON : Do not use circuit protection devices on the output of an AC drive as an isolating disconnect switch or motor overload device. These devices are designed to operate on sine wave voltage and the drive’s PWM waveform does not allow it to operate properly. As a result, damage to the device occurs.

Table 9 - DC-bus Power Supply UL/CSA Circuit-protection Specifications

DC-bus Power Supply Cat. No.

2198-P031

2198-P070 LPJ-40SP (40A) N/A 140M-F8E-C45 140G-G6C3-C50

2198-P141 LPJ-70SP (70A) N/A N/A 140G-G6C3-C90

2198-P208 LPJ-100SP (100A) N/A N/A 140G-G6C3-D12

(1) For applications requiring CSA certification, fuses (Bussmann catalog number 170M1760) must be added to the DC link between the two drive clusters when circuit breakers are used for branch circuit

protection. The DC bus fuses are not required when AC line fuses are used for branch circuit protection.

(2) These Bulletin 140M circuit breakers, when used as self-protected (Type E) devices, and Bulletin 1489 circuit breakers can be used on only WYE power systems (480Y/277V).

Input Voltage (three-phase) nom

324…528V AC

Bussmann Fuses Cat. No.

LPJ-15SP (15A) 1489-M3D250 140M-D8E-C25 140G-G6C3-C25

(1)

Miniature CB Cat. No.

(2)

Motor Protection CB, Self Protected CMC Cat. No.

Table 10 - Regenerative Bus Supply UL/CSA Circuit-protection Specifications

Regenerative Bus Supply Cat. No.

2198-RP088

2198-RP200 LPJ-125SP (125A) AJT125 (125A) – 140G-J6F3-D15

2198-RP263 LPJ-200SP (200A) AJT200 (200A) – 140G-K6F3-D30

2198-RP312 LPJ-250SP (250A) AJT250 (250A) – 140G-K6F3-D40

(1) Applies when DC-bus voltage regulation is enabled. If DC-bus voltage regulation is not enabled, then the input voltage range is 324….528V AC. For more information on these two modes of

operation, see DC-bus Voltage Regulation

(2) For applications requiring CSA certification, fuses (Bussmann catalog number 170M1760) must be added to the DC link between the two drive clusters when circuit breakers are used for branch circuit

protection. The DC bus fuses are not required when AC line fuses are used for branch circuit protection.

Input Voltage (three-phase) nom

324…506V AC rms

(1)

on page 42.

Bussmann Fuses Cat. No.

LPJ-45SP (45A) AJT45 (45A) – 140G-G6C3-C60

(2)

Mersen Fuses Cat. No.

Miniature CB Cat. No.

(2)

Molded Case CB Cat. No.

Table 11 - DC-bus Power Supply IEC (non-UL/CSA) Circuit-protection Specifications

DC-bus Power Supply Cat. No.

2198-P031

2198-P070 40 N/A 1492-SPM3D400 140M-F8E-C45 140G-G6C3-C50

2198-P141 75 N/A 1492-SPM3D630 140MG-H8E-C60 140G-G6C3-C90

2198-P208 110 N/A N/A 140MG-H8E-D10 140G-G6C3-D12

48 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Drive Voltage (three-phase) nom

324…528V AC

DIN gG Fuses

Amps, max

16 1489-M3D250 N/A 140M-D8E-C25 140G-G6C3-C25

Miniature CB

Cat. No.

Motor Protection CB Cat. No.

Molded Case CB Cat. No.

Page 49

Plan the Kinetix 5700 Drive System Installation Chapter 2

Table 12 - Regenerative Bus Supply IEC (non-UL/CSA) Circuit-protection Specifications

Regenerative Bus Supply Cat. No.

2198-RP088

2198-RP200 125 – – 140MG-J8E-D15 140G-J6F3-D15

2198-RP263 200 – – – 140G-K6F3-D30

2198-RP312 250 – – – 140G-K6F3-D40

(1) Applies when DC-bus voltage regulation is enabled. If DC-bus voltage regulation is not enabled, then the input voltage range is 324….528V AC. For more information on these two modes of

operation, see DC-bus Voltage Regulation

Input Voltage (three-phase) nom

324…506V AC rms

(1)

on page 42.

DIN gG Fuses

Amps, max

50 1489-M3C600 1492-SPM3C630 140MG-H8E-C60 140G-G6C3-C60

Miniature CB Cat. No.

Motor Protection CB Cat. No.

Molded Case CB Cat. No.

Refer to the Kinetix Servo Drives Technical Data, publication KNX-TD003, for additional power specifications for your 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus supply.

24V Control Power Evaluation

The Kinetix 5700 drive system requires 24V DC input for its control circuitry. Due to the 24V shared-bus connection system and the 24V current requirements of the Kinetix 5700 drives, a thorough evaluation of control power is required prior to implementation. Consider the following when sizing such a system:

• Verify that the 24V DC power supply is capable of supplying the 24V current requirements of your Kinetix 5700 drive system. See Calculate

24V DC Control Power Current Demand on page 396 to determine the

24V current requirements. For systems with a high 24V current demand, consider the following:

– Install separate 24V power supplies for each cluster or change the

cluster configuration to more evenly divide the 24V current demand.

– Install separate 24V power supplies for each Bulletin 2198 power

supply and inverter.

• Verify that the wiring being used is capable of supplying the Kinetix 5700 drive system with a voltage within the 24V input-voltage range; 24V ±10% (21.6…26.4V DC). Consider the following:

– Mount the 24V power supply as close to the Kinetix 5700 drive

system as possible to minimize input voltage drop.

– Install larger gauge wire, up to 4 mm

AWG) for 24V control power when using the CP connectors included with the module; or use the 24V shared-bus connection system to lower the DC wire resistance with up to 10 mm and result in a lower voltage drop.

(12 AWG) and 6 mm2 (10

(6 AWG)

IMPORTANT The 24V current demand, wire gauge, and wire length all impact the voltage

drop across the wiring being used. For an example, see 24V DC Voltage Drop

Calculation Example on page 397.

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Contactor Selection

The AC three-phase contactor control string must be wired in series with the contactor-enable relay at the CED connector. The contactor-enable relay (applies to 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus supply) is rated at 24V DC (28V, max) and 1.0 A, max.

IMPORTANT Applying more than 28V DC control voltage or more than 1.0 A control

current to the contactor can cause permanent damage to the DC-bus power supply or regenerative bus supply.

ATT EN TI ON : Wiring the contactor-enable relay is required. To avoid personal injury or damage to the system, wire the contactor-enable relay into your control string so that:

• three-phase power is removed and the power supply is protected under various fault conditions.

• three-phase power is never applied to the Kinetix 5700 drive system before control power is applied.

Contactor with auxiliary contacts is strongly recommended when used with 2198-RPxxx regenerative bus supply. Wire auxiliary contact to digital input #2 (default setting) to monitor the three-phase input power. See Contactor

Wiring Examples on page 358 for wiring examples.

Table 13 - DC-bus Power Supply Contactor Specifications

DC-bus Power Supply Cat. No.

2198-P031 100-C16EJ10

2198-P070 100-C37EJ10

2198-P141 100-C72DJ10

2198-P208 100-C97DJ10

2198-P208 (2 in parallel) 100-E190KJ11

2198-P208 (3 in parallel) 100-E305KJ11

(1) Auxiliary contact configuration 10 indicates there is 1 N.O. and 0 N.C. contacts. Other configurations are available. (2) For contactors that are not Bulletin 100-E type, the integrated diode is required with the contactor coil. See Knowledgebase document 19362 (3) These DC-bus power supplies require an additional intermediate relay used with the contacto r.

Contactor Cat. No.

Table 14 - Regenerative Bus Supply Contactor Specifications

Regenerative Bus Supply Cat. No.

2198-RP088 100-C43EJ10

2198-RP200 100-E116KJ11

2198-RP263 100-E205KJ11

2198-RP312 100-E265KJ11

(1) Auxiliary contact configuration 10 indicates there is 1 N.O. and 0 N.C. contacts. 11 indicates there is 1 N.O. and 1 N.C. contact. Other config urations are available. (2) These contactor catalog numbers include a 24V DC coil. For contactors that are not Bulletin 100-E type, see Knowledgebase document 19362

Contactor Cat. No.

(1) (2)

Intermediate Relay Cat. No.

N/A

700-HB32Z24 (relay) 700-HN153 (socket)

for more information.

Intermediate Relay Cat. No.

N/A

for more information.

(3)

50 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

2198-R014, 2198-R031,

and 2198-R127

Shunt Modules

2198-R004 Shunt Resistor

Passive Shunt Considerations

The 2198-Pxxx DC-bus power supplies all include an internal shunt that is wired to the shunt resistor (RC) connector at the factory. Bulletin 2198-Rxxx external passive shunts are available to provide additional shunt capacity for applications where the internal shunt capacity is exceeded.

IMPORTANT Keep the DC-bus power supply internal shunt wires connected unless you

have an external passive shunt to connect.

IMPORTANT 2198-RPxxx regenerative bus supplies do not support passive shunts. The

active shunt (RC) connector is used for making active shunt connections.

Table 15 - DC-bus Power Supply Passive-shunt Options

DC-bus Power Supply Cat. No.

2198-P031

2198-P070 – – X X

2198-P141

2198-P208 XXXX

(1) Shunt resistor selection is based on the needs of your actual hardware configuration.

Internal Shunt Specifications

ΩW2198-R127 2198-R031 2198-R014 2198-R004

37.5 75

13.5 200

External Shunt Module Compatibility Cat. No.

––XX

XXXX

(1)

Catalog numbers 2198-R014, 2198-R031, and 2198-R127 are composed of resistor coils that are housed inside an enclosure. Catalog number 2198-R004 is a shunt resistor without an enclosure.

Figure 19 - External Passive Shunts

External Shunt Module Specifications

Shunt Module Cat. No.

2198-R004 33 400 1.8 (4.0)

2198-R014 9.4 1400 9.1 (20)

2198-R031 33 3100 16.8 (37)

2198-R127

(1) This product presents a lift hazard. To avoid personal injury, use care when lifting the product.

(1)

Resistance

13 12,700 22.2 (49)

Continuous Power

Weight, a pprox

kg (lb)

How the Bulletin 2198-Rxxx shunts connect to the 2198-Pxxx DC-bus power supply is explained in External Passive-shunt Connections illustrated with interconnect diagrams in Passive Shunt Wiring Examples

page 359

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Active Shunt Considerations

External active shunts are required in the following use cases:

• The 2198-RPxxx regenerative bus supply provides DC-bus power while DC-bus regulation is not enabled.

• One permanent magnet motor runs above its bus overvoltage speed. See

Field Weakening Mode

• One permanent magnet motor drives a vertical load that could make the motor accelerate above the bus overvoltage speed during a fault condition.

• Any condition where total shared DC-bus regenerative power is greater than the 2198-RPxxx regenerative bus supply capacity. For example, consider a peak-power stopping condition.

• The 2198-RPxxx regenerative bus supply is operating with DC-bus regulation enabled and the regenerative bus supply loses three-phase AC input power, 24V DC input power, or has a fault condition.

ATT EN TI ON : To avoid damage to the Kinetix 5700 drive system, wire the active shunt thermal switch to a digital input on the power supply and configure the Shunt Thermal Switch OK function in the Logix Designer application.

on page 446 for a description of this feature.

ATT EN TI ON : DC-bus failure can cause damage to all drive modules in the bus group, not just the inverter connected to the motor.

Active shunts are available from the Rockwell Automation Encompass™ partner Powerohm Resistors, Inc. See http://www.powerohm.com

for more

information on Powerohm active shunts.

IMPORTANT Powerohm Bulletin PKBxxx active shunt modules use built-in internal brake

resistors. Bulletin PWBxxx active shunt modules require appropriately sized external brake resistors.

Table 16 - Compatible Active Shunt Specifications (internal brake resistor)

Kinetix 5700 Power Supply

2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply when DC-bus regulation is not enabled.

2198-RPxxx regenerative bus supply when DC-bus regulation is enabled.

(1) How the Powerohm PKBxxx shunts connect to the 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus supply is explained in External Active-shunt Connections on page 183 and

illustrated with interconnect diagrams in Active Shunt Wiring Examples

Powerohm Resistors Cat. No.

PKB005

PKB010 2.06 52.7 – 2.75 14.2

PKB050 7.00 10.5 – 9.30 71.4

PKB005-800

PKB010-800 2.06 52.7 – 2.58 15.2

PKB050-800 7.00 10.5 – 8.72 76.2

(1)

Input Voltage, nom

480V AC

on page 360.

Turn -on Bus Voltage

750V DC

800V DC

Continuous Power

1.50 108 – 2.00 6.9

1.50 108 – 1.88 7.4

Resistance (internal)

Resistance (minimum)

Continuous Current

Amps

Peak Current

Amps

52 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Table 17 - Compatible Active Shunt Specifications (no internal brake resistor)

Kinetix 5700 Power Supply

2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply when DC-bus regulation is not enabled.

2198-RPxxx regenerative bus supply when DC-bus regulation is enabled.

(1) How the Powerohm PWBxxx shunts connect to the 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus supply is explained in External Active-shunt Connections on page 183 and

illustrated with interconnect diagrams in Active Shunt Wiring Examples

Powerohm Resistors Cat. No.

PWB035

PWB110 82.5 – 2.5 110 300

PWB035-800

PWB110-800 82.5 – 2.7 110 300

(1)

Input Voltage, nom

480V AC

on page 360.

Turn -on Bus Voltage

750V DC

800V DC

Continuous Power

26.25 – 7.5 35 100

26.25 – 8.0 35 100

Resistance (internal)

Resistance (minimum)

Continuous Current

Amps

Peak Current

Amps

ATT EN TI ON : Do not use Powerohm active-shunt modules at input line voltages that exceed 528V AC. Active-shunt thermal-overload shutdown can occur if input line voltage exceeds 528V AC.

See External Active-shunt Connections on page 183, when making active shunt connections.

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

A =

0.38 (416)

1.8 (30) - 1.1

= 2.99 m

Enclosure Selection

This example is provided to assist you in sizing an enclosure for your Kinetix 5700 drive system. You need heat dissipation data from all components planned for your enclosure to calculate the enclosure size (refer to Ta b l e 1 8

With no active method of heat dissipation (such as fans or air conditioning) either of the following approximate equations can be used.

Metric Standard English

0.38Q

A =

1.8T - 1.1

Where T is temperature difference between inside air and outside ambient (°C), Q is heat generated in enclosure (Watts), and A is enclosure surface area (m The exterior surface of all six sides of an enclosure is calculated as:

A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) /144

Where d (depth), w (width), and h (height) are in meters.

Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in

enclosure (Watts), and A is enclosure surface area (ft2). The exterior surface of all six sides of an enclosure is calculated as:

Where d (depth), w (width), and h (height) are in inches.

A =

4.08Q

T - 1.1

If the maximum ambient rating of the Kinetix 5700 drive system is 50 °C (122 °F) and if the maximum environmental temperature is 20 °C (68 °F), then T=30. In this example, the total heat dissipation is 416 W (sum of all components in enclosure). So, in the equation below, T=30 and Q=416.

In this example, the enclosure must have an exterior surface of at least 2.99 m

If any portion of the enclosure is not able to transfer heat, do not include that value in the calculation.

Because the minimum cabinet depth to house the Kinetix 5700 system (selected for this example) is 300 mm (11.8 in.), the cabinet needs to be approximately 1500 x 700 x 300 mm (59.0 x 27.6 x 11.8 in.) HxWxD.

1.5 x (0.300 x 0.70) + 1.5 x (0.300 x 2.0) + 1.5 x (0.70 x 2.0) = 3.31 m

Because this cabinet size is considerably larger than what is necessary to house the system components, it can be more efficient to provide a means of cooling in a smaller cabinet. Contact your cabinet manufacturer for options available to cool your cabinet.

54 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Table 18 - Power Dissipation Specifications

Usage as % of Rated Power Output

DC-bus Power Supply Cat. No.

20% 40% 60% 80% 100%

2198-P031 97 101 105 109 113

2198-P070 108 119 130 140 151

2198-P141 249 267 286 304 323

2198-P208 265 294 323 352 380

Regenerative Bus Supply Cat. No.

2198-RP088 253 399 544 690 835

2198-RP200 532 832 1132 1432 1732

2198-RP263 850 1261 1672 2083 2494

2198-RP312 1037 1576 2115 2654 3193

Dual-axis Inverter Cat. No.

2198-D006-ERSx 17 29 41 53 65

2198-D012-ERSx 34 58 82 106 130

2198-D020-ERSx 52 84 116 148 180

2198-D032-ERSx 100 155 210 265 320

2198-D057-ERSx 252 354 456 558 660

Single-axis Inverter Cat. No.

2198-S086-ERSx 190 255 325 400 475

2198-S130-ERSx 225 340 460 590 725

2198-S160-ERSx 270 420 570 760 950

2198-S263-ERSx 556 759 989 1245 1529

2198-S312-ERSx 610 883 1200 1561 1965

iTRAK Power Supply Cat. No.

2198T-W25K-ER 206 272 338 404 470

Capacitor Module Cat. No.

2198-CAPMOD-2240 28 34 42 51 62

2198-CAPMOD-DCBUS-IO 1.1 1.4 1.6 2.1 2.5

DC-bus Conditioner Module Cat. No.

2198-DCBUSCOND-RP312 1.4 2.1 3.2 4.7 6.7

(watts)

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Clearance right of the module is not required.

Clearance left of the

module is not required.

Kinetix 5700 Drive Module (DC-bus power supply is shown)

Clearance below module

for airflow and installation

(see Tab le 19 on page 57 for values).

Clearance above module

for airflow and installation

(see Tab le 19

on page 57 for values).

Refer to the Kinetix Servo Drives Technical

Data, publication KNX-TD003

, for

Kinetix 5700 drive module dimensions.

Kinetix 5700 Accessory Module (2198-CAPMOD-2240 module is shown)

Clearance above for wiring to DC-bus studs and lug cover installation.

Clearance where cover and

DC-bus cabling attaches.

Minimum Clearance Requirements

This section provides information to assist you in sizing your cabinet and positioning your Kinetix 5700 drive system:

• Additional clearance is required for cables and wires or the shared-bus connection system connected to the top of the drive modules.

– Accessory modules require extra clearance above for wiring DC-bus

stud connections and installing the cover.

• Additional clearance is required if other devices are installed above and/ or below the drive module and have clearance requirements of their own.

– Accessory modules require extra clearance to route DC-bus wiring

into or away from the drive system.

• Additional clearance left and right of the drive module is required when mounted adjacent to noise sensitive equipment or clean wire ways.

• The recommended minimum cabinet depth is 300 mm (11.81 in.).

Figure 20 - Minimum Clearance Requirements

29.5 (1.16)

DC BUS

MODULE

STATUS

MOD

NET

I/O

IMPORTANT

Mount the drive module in an upright position as shown. Do not mount the module on its side.

See the Kinetix 5700 Drive Module Clearance Specifications table on page 57 for clearance specifications.

56 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

MOD

NET

MOD

NET

MOD

NET

Zero-stack Tab and

Cutout Aligned

Shared-bus connection system is not shown for clarity.

Table 19 - Kinetix 5700 Drive Module Clearance Specifications

Clearance Above,

Kinetix 5700 Drive Modules Drive Module Cat. No.

min

mm (in.)

2198-P031

DC-bus power supply

2198-P070 2198-P141

40 (1.57) 100 (3.94)

2198-P208

2198-RP088 2198-RP200

40 (1.57)

Regenerative bus supply

2198-RP263 2198-RP312

80 (3.15) 200 (7.87)

2198-S086-ERSx

Single-axis inverters

2198-S130-ERSx 2198-S160-ERSx

2198-S263-ERSx 2198-S312-ERSx

40 (1.57) 185 (7.28)

80 (3.15) 200 (7.87)

2198-D006-ERSx 2198-D012-ERSx

Dual-axis inverters

2198-D020-ERSx

40 (1.57) 100 (3.94) 2198-D032-ERSx 2198-D057-ERSx

iTRAK power supply 2198T-W25K-ER 40 (1.57) 100 (3.94)

Capacitor module 2198-CAPMOD-2240

115 (4.53) 100 (3.94)Extension module 2198-CAPMOD-DCBUS-IO

DC-bus conditioner module 2198-DCBUSCOND-RP312

(1) Additional clearance can be required depending on the actual wiring harness being installed.

Clearance Below, min

mm (in.)

100 (3.94)

150 (5.91)

(1)

In multi-axis shared-bus configurations, drive modules must be spaced by aligning the zero-stack tab and cutout.

Figure 21 - Multi-axis Shared-bus Clearance Requirements

Multi-axis Shared DC-Bus Configurations

The Kinetix 5700 shared DC-bus system can be supplied by the following sources:

• Single 2198-Pxxx DC-bus power supply

• Multiple 2198-P208 DC-bus power supplies (up to three are possible)

• Single 2198-RPxxx regenerative bus supply

• Multiple 8720MC-RPS regenerative power supplies

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Table 20 - Shared DC-bus Terminology

Term Definition

DC-bus group Drive modules that are all connected to the same DC bus.

Cluster

Extended cluster

Power supply cluster The cluster that contains the AC to DC conver ter (power supply).

Extended DC-bus

Group of power supply and/or drive modules that are directly connected together via Kinetix 5700 DC bus-bars only.

Group of drive modules that are directly connected together via Kinetix 5700 DC bus-bars and connected to the power supply cluster via customer-supplied DC-bus cable.

When 2 drive clusters are part of the same DC-bus group joined by the DC bus-bars and customer-supplied DC-bus cable.

The Kinetix 5700 DC-bus power is shared in the following ways:

• Across drive clusters by DC-bus links that are included with the drive module.

• From the power supply cluster to an extended cluster by connection points provided on accessory modules.

System Sizing Considerations

Multi-axis Kinetix 5700 shared-bus drive systems require thorough evaluation to make sure each drive will perform as expected. Consider the following when sizing your system to determine the appropriate configuration:

Consider the following to determine your system configuration:

• Determine motor/drive combinations for full-motor performance

• No more than three 2198-P208 DC-bus power supplies can be used to increase the converter power

• Define the DC-bus groups

• Calculate system and external-bus capacitance

• Calculate the total motor-power cable length

• Calculate the 24V DC control-power current demand

• If using the 24V DC shared-bus connection system to distribute control input power to a cluster of drive modules, current from the 24V power supply must not exceed 40 A

• Calculate the 24VDC voltage drops

• Minimize drive-to-motor cable lengths. Overall system design can significantly limit the drive-to-motor cable lengths. See Appendix D for more information.

See Appendix C

beginning on page 391 for more information and sizing

examples.

58 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Capacitor

Module

Single-axis

Inverters

Dual-axis Inverters

DC Bus

Capacitor

Module

Single-axis

Inverters

Dual-axis

Inverters

DC-Bus

Power Supply

DC Bus

This example includes:

•1 Bus group

•2 Drive clusters

Accessory Module Selection

Accessory Module Cat. No.

2198-CAPMOD-2240 Capacitor Module

2198-CAPMOD-DCBUS-IO Extension Module

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

Accessory Module Description

The requirements for when to use accessory modules vary depending on whether your system is powered by the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply.

8720MC-RPS regenerative power supplies follow the same requirements as 2198-RPxxx regenerative bus supplies for accessory modules needed for extended clusters. See 8720MC-RPS wiring examples beginning on page 352

Table 21 - Introduction to Kinetix 5700 Accessory Modules

Use for energy storage and to extend the DC-bus voltage to another inverter cluster. Modules are zero-stacked with servo drives and use the shared-bus connection system to extend the external DC-bus voltage in applications up to 104 A. Can parallel with itself or with another accessory module for up to 208 A.

The extension module, paired with a capacitor module or DC-bus conditioner module, is used to extend the DC-bus voltage to another inverter cluster in systems with ≥104 A current and up to 208 A.

Decreases the voltage stress on insulation components in an inverter system with long cable lengths and used to extend the DC-bus voltage to another inverter cluster. Modules are zero-stacked with servo drives and use the shared-bus connection system to extend the external DC-bus voltage in applications up to 104 A. Can parallel with itself or with another accessor y module for applications up to 208 A.

On the following pages (by power supply) are system configurations showing which accessory modules are required. The examples account for single (power supply) clusters, extended clusters, maximum system current, the input-power ground configuration, and total motor-cable length. Also included are flowcharts to help you determine your accessory module requirements.

DC-bus Power Supply Systems

The following system configurations illustrate the minimum number of accessory modules required.

Figure 22 - DC-bus Power Supply Example/Extended Cluster (104 A, max)

2198-Pxxx

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-Dxxx-ERSx

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-Pxxx

2198-CAPMOD-2240

Capacitor

Module

Single-axis

Inverters

Dual-axis Inverters

DC-Bus

Power Supply

DC Bus

Capacitor

Module

This example includes:

•1 Bus group

•1 Drive cluster

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-P208

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-CAPMOD-2240

2198-CAPMOD-DCBUS-IO

2198-P208

Capacitor

Module

Single-axis

Inverters

Dual-axis

Inverters

DC-Bus

Power Supply

Extension

Module

Extension

Module

Capacitor

Module

Single-axis

Inverters

Dual-axis

Inverters

DC Bus

DC-Bus

Power Supply

DC-Bus

Power Supply

This example includes:

•1 Bus group

•2 Drive clusters

Figure 23 - DC-bus Power Supply Example/Multiple Capacitor Modules

IMPORTANT In both of these examples, the Kinetix 5700 drive system includes two

accessory modules per cluster. Flexible bus bars are included with only the 2198-CAPMOD-DCBUS-IO extension module. So, if you have two capacitor modules, two DC-bus conditioner modules, or a capacitor module and DC-bus conditioner module mounted side by side, you must order the 2198-KITCON-CAPMOD2240 or 2198-KITCON-DCBUSCOND connector set separately.

Figure 24 - Multiple DC-bus Power Supply Example/Extended Cluster (208 A, max)

IMPORTANT The systems that are shown are typical. The maximum number of inverter

modules depends on the maximum system capacitance precharge capability of the power supply. With multiple 2198-P208 modules, there is more precharge capability. When there are two or three DC-bus power supplies, they must be catalog number 2198-P208.

Refer to Appendix C

on page 391 for more system sizing information.

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Single-axis

Inverters

Dual-axis

Inverters

Regenerative

Bus Supply

DC Bus

This example includes:

•1 Bus group

•1 Drive clusters

DC-bus conditioner is required on this single cluster only because cable length exceeds 400 m (1312 ft).

2198-RPxxx

(power supply cluster)

DC-bus Conditioner

Module

Motor Array

2198-Dxxx-ERSx

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-CAPMOD-2240

2198-DCBUSCOND-RP312

2198-Sxxx-ERSx

90 m (295 ft) x 5 axes = 450 m (1476 ft)

90 m (295 ft) x 3 axes = 270 m (886 ft)

Capacitor

Module

Single-axis

Inverters

DC Bus

Capacitor

Module

Single-axis

Inverters

Dual-axis

Inverters

Regenerative

Bus Supply

DC Bus

This example includes:

•1 Bus group

•2 Drive clusters

DC-bus conditioner requirements:

• Required on Cluster #1 because cable length exceeds 400 m (1312 ft)

• Required on Cluster #2 because it’s an extended cluster

2198-RPxxx

(power supply cluster)

Cluster #1

2198-DCBUSCOND-RP312

(extended cluster)

Cluster #2

DC-bus Conditioner

Module

DC-bus Conditioner

Module

Motor Array

Regenerative Bus Supply Systems

Mount the 2198-DCBUSCOND-RP312 DC-bus conditioner module on the far right or far left of any 2198-RPxxx regenerative bus supply system cluster, depending on the input power configuration.

• A DC-bus conditioner module is required on all extended clusters

• A DC-bus conditioner module is required on the power supply cluster if the total motor cable length connected to the power supply cluster is ≥400 m (1312 ft)

• A DC-bus conditioner module is required on each cluster of drive systems with impedance-grounded input power

• When a DC-bus conditioner module is installed and there is no use-case for installation, the module does not provide any benefit

The following system configurations illustrate the minimum number of accessory modules required.

Figure 25 - Regenerative Bus Supply Example/Single Cluster

Figure 26 - Regenerative Bus Supply Example/Extended Cluster

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2198-Sxxx-ERSx

90 m (295 ft) x 5 axes = 450 m (1476 ft)

2198-Dxxx-ERSx

2198-DCBUSCOND-RP312

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

2198-Dxxx-ERSx

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-CAPMOD-2240

2198-Sxxx-ERSx

90 m (295 ft) x 4 axes = 360 m (1182 ft)

90 m (295 ft) x 3 axes = 270 m (886 ft)

Capacitor

Module

Dual-axis

Inverters

DC Bus

Capacitor

Module

This example includes:

•1 Bus group

•2 Drive clusters

DC Bus

Single-axis

Inverters

Regenerative

Bus Supply

2198-RP088

(power supply cluster)

Cluster #1

2198-DCBUSCOND-RP312

(extended cluster)

Cluster #2

DC-bus Conditioner

Module

DC-bus conditioner requirements:

• Not required on Cluster #1 because cable length <400 m (1312 ft)

• Required on Cluster #2 because it’s an extended cluster Extension module not required because the power supply cluster < 104 A

Motor Array

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-CAPMOD-2240

2198-Sxxx-ERSx

90 m (295 ft) x 3 axes = 270 m (886 ft)

2198-CAPMOD-DCBUS-IO

Capacitor

Module

DC Bus

Capacitor

Module

This example includes:

•1 Bus group

•2 Drive clusters

DC Bus

Single-axis

Inverters

Regenerative

Bus Supply

2198-RP200

(power supply cluster)

Cluster #1

2198-DCBUSCOND-RP312

(extended cluster)

Cluster #2

DC-bus Conditioner

Module

DC-bus conditioner requirements:

• Not required on Cluster #1 because cable length <400 m (1312 ft)

• Required on Cluster #2 because it’s an extended cluster Extension module required on Cluster #1 because the power supply cluster ≥104 A, but <208 A.

Extension

Module

Motor Array

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-CAPMOD-2240

90 m (295 ft) x 2 axes = 180 m (591 ft)

2198-CAPMOD-DCBUS-IO

2198-Sxxx-ERSx

2198-CAPMOD-2240

90 m (295 ft) x 2 axes = 180 m (591 ft)

2198-DCBUSCOND-RP312

2198-CAPMOD-DCBUS-IO

Capacitor

Module

DC Bus

Capacitor

Module

DC Bus

Single-axis

Inverters

Regenerative

Bus Supply

2198-RPxxx

(power supply cluster)

Cluster #1

2198-DCBUSCOND-RP312

(extended cluster)

Cluster #3

DC-bus Conditioner

Module

DC-bus conditioner requirements:

• Not required on Cluster #1 because cable length <400 m (1312 ft)

• Required on Cluster #2 and #3 because they are extended clusters Extension module required on Cluster #1 and #2 because the entire extended bus system must have the same current rating (208 A, in this example).

Extension

Module

Extension

Module

Single-axis

Inverters

Capacitor

Module

DC-bus Conditioner

Module

DC Bus

2198-CAPMOD-DCBUS-IO

(extended cluster)

Cluster #2

Motor Array

Extension

Module

Figure 27 - Regenerative Bus Supply Example/Extended Cluster/104 A System

Figure 28 - Regenerative Bus Supply Example/Extended Cluster/208 A System

Figure 29 - Regenerative Bus Supply Example/Two Extended Clusters/208 A, max

62 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

2198-CAPMOD-2240

2198-Sxxx-ERSx

90 m (295 ft) x 2 axes = 180 m (591 ft)

2198-Sxxx-ERSx

2198-CAPMOD-2240

90 m (295 ft) x 2 axes = 180 m (591 ft)

2198-DCBUSCOND-RP312

2198-CAPMOD-DCBUS-IO

Capacitor

Module

Capacitor

Module

DC Bus

Single-axis

Inverters

Regenerative

Bus Supply

2198-RPxxx

(power supply cluster)

Cluster #2

2198-DCBUSCOND-RP312

(extended cluster)

Cluster #3

DC-bus Conditioner

Module

DC-bus conditioner requirements:

• Not required on Cluster #2 because cable length <400 m (1312 ft)

• Required on Cluster #1 and #3 because they are extended clusters Extension module required on Cluster #2 for making DC-bus connections to Cluster #1.

Single-axis

Inverters

Capacitor

Module

DC-bus Conditioner

Module

DC Bus

2198-CAPMOD-2240

(extended cluster)

Cluster #1

Motor Array

Extension

Module

This example includes:

•1 Bus group

•3 Drive clusters

2198-Dxxx-ERSx

2198-DCBUSCOND-RP312

90 m (295 ft) x 4 axes = 360 m (1181 ft)

L3 L2 L1

Impedance Ground

Input Power

Dual-axis Inverters

Regenerative

Bus Supply

DC Bus

Three- phase

Input Voltage

2198-RPxxx

DC-bus Conditioner

Module

DC-bus conditioner requirements for impedance-grounded systems:

• Required on single cluster system

• Required on each cluster of multi-cluster systems

Figure 30 - Regenerative Bus Supply Example/Center Power Supply Cluster/104 A, max

IMPORTANT In Figure 30, the Kinetix 5700 drive system includes two accessory modules

in each of the clusters. Flexible bus bars are included with only the 2198-CAPMOD-DCBUS-IO extension module. So, if you have two capacitor modules, two DC-bus conditioner modules, or a capacitor module and DC-bus conditioner module mounted side by side, you must order the 2198-KITCON-CAPMOD2240 or 2198-KITCON-DCBUSCOND connector set separately.

Figure 31 - Regenerative Bus Supply Example/Impedance-grounded Input Power

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 63

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

2198-Sxxx-ERSx

2198-Dxxx-ERSx

8720MC-RPS065

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-DCBUSCOND-RP312

Regenerative

Power Supply

DC Bus

This example includes:

•1 Bus group

•1 Drive cluster

Capacitor

Module

Single-axis

Inverters

Dual-axis

Inverters

DC-bus Conditioner

Module

DC-bus conditioner is required only if the total power-cable length exceeds 400 m (1312 ft).

2198-Sxxx-ERSx

2198-Dxxx-ERSx

8720MC-RPS190

2198-CAPMOD-2240

2198-Sxxx-ERSx

2198-Dxxx-ERSx

2198-DCBUSCOND-RP312

Capacitor

Module

Single-axis

Inverters

Dual-axis Inverters

DC Bus

Regenerative Power Supply

This example includes:

•1 Bus group

•1 Drive cluster

DC-bus Conditioner

Module

DC-bus conditioner is required because this is a 208 A system. DC-bus conditioner is also required if the total power-cable length exceeds 400 m (1312 ft).

8720MC-RPS or Other Regenerative Power Supply

The following system configurations illustrate the minimum number of accessory modules required.

Figure 32 - Regenerative Power Supply Example (104 A, max)

IMPORTANT In both of these examples, the Kinetix 5700 drive system includes two

accessory modules. Flexible bus bars are included with only the 2198-CAPMOD-DCBUS-IO extension module. So, if you have two capacitor modules, two DC-bus conditioner modules, or a capacitor module and DC-bus conditioner module mounted side by side, you must order the 2198-KITCON-CAPMOD2240 or 2198-KITCON-DCBUSCOND connector set separately.

Figure 33 - Regenerative Power Supply Example Power (208 A, max)

IMPORTANT The 8720MC-RPS power supply is not compatible with the iTRAK power

supply.

64 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

<400 m (1312 ft)

≥400 m (1312 ft)

What type of AC to DC

converter i s used?

Start

Is this an impedance

grounded system?

DC-bus Conditioner Module

What is the total motor

cable length?

No accessory

modules required.

DC-bus Power

Supply

Regenerative Bus Supply

Yes

Accessory Module Flowcharts

The following flowcharts are designed to help you determine the minimum number of accessory modules that are needed for your application.

IMPORTANT Specific system demands can justify additional accessory modules based on

the previously mentioned benefits.

In this flowchart, a 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply supplies DC-bus power to a single cluster of drives.

System variables that you need to know include the following:

• The type of AC to DC converter used

• The input power ground configuration

• The total motor cable length

Figure 34 - Single-cluster Drive System

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 65

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

<104 A

<400 m

(1312 ft)

≥400 m (1312 ft)

<104 A

Each Cluster:

• Capacitor Module

• Extension Module

What type of AC to DC

converter is used?

Start

Is this an impedance

grounded system?

What is the total

motor cable length of

the power supply

cluster?

What is the

external D C-bus

current?

DC-bus Power

Supply

Regenerative Bus Supply

Yes

Each Cluster: Capacitor Module

Each Cluster:

• Capacitor Module

• DC-bus Conditioner Module

Power Supply Cluster:

• Capacitor Module All Extended Clusters:

• Capacitor Module

• DC-bus Conditioner Module Power Supply Cluster:

• Capacitor Module

• Extension Module All Extended Clusters:

• Capacitor Module

• DC-bus Conditioner Module

What is the

external DC-bus

current?

≥104 A up to 208 A, max

≥104 A

up to 208 A, max

In this flowchart, a 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply supplies DC-bus power to a multi-cluster drive system.

TIP The ‘power supply’ cluster includes the 2198-Pxxx DC-bus power supply or

2198-RPxxx regenerative bus supply. Extended clusters are part of the same DC-bus group and connected to the power supply cluster via stud terminals that are available on accessory modules.

System variables that you need to know include the following:

• The type of AC to DC converter used

• The input-power ground configuration

• The external DC-bus current

• The total motor-cable length of the power supply cluster

Figure 35 - Multi-cluster Drive System

66 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Electrical Noise Reduction

This section outlines best practices that minimize the possibility of noiserelated failures as they apply specifically to Kinetix 5700 system installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication

GMC-RM001

Bonding Modules

Bonding is the practice of connecting metal chassis, assemblies, frames, shields, and enclosures to reduce the effects of electromagnetic interference (EMI).

Unless specified, most paints are not conductive and act as insulators. To achieve a good bond between the drive module and subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance return path for high-frequency energy.

IMPORTANT To improve the bond between the drive module and subpanel, construct

your subpanel out of zinc plated (paint-free) steel.

Improper bonding of metal surfaces blocks the direct return path and allows high-frequency energy to travel elsewhere in the cabinet. Excessive highfrequency energy can effect the operation of other microprocessor controlled equipment.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 67

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Stud-mounting the Subpanel

to the Enclosure Back Wall

Stud-mounting a Ground Bus

or Chassis to the Subpanel

Subpanel Weld ed St ud

Scrape Paint

Flat Washer

If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the materia l around the mounting hole.

Star Washer

Nut

Flat Washer

Mounting Bracket or

Ground Bus

Use a wire brush to rem ove paint from threads to maximize ground connection.

Back Wall of Enclosure

Welde d Stud

Subpanel

Star Washer

Use plated panels or scrape paint on front of panel.

Subpanel

Nut

Star Washer

Flat Washer

Star Washer

Star Washer Scrape paint on both sides of panel and use star washers.

Tap ped Hol e

Bolt

Flat Washer

Ground Bus or

Mounting Bracket

If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole.

Bolt-mounting a Ground Bus or Chassis to the Back-panel

These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Figure 36 - Recommended Bonding Practices for Painted Panels

68 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Wire B raid

25.4 mm (1.0 in.) by

6.35 mm (0.25 in.)

Paint removed

from cabinet.

Cabinet ground bus

bonded to the subpanel.

Wire B raid

25.4 mm (1.0 in.) by

6.35 mm (0.25 in.)

Bonding Multiple Subpanels

Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together do not necessarily share a common low impedance path. This difference in impedance can affect networks and other devices that span multiple panels:

• Bond the top and bottom of each subpanel to the cabinet by using

25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid. As a rule, the wider and shorter the braid is, the better the bond.

• Scrape the paint from around each fastener to maximize metal-to-metal contact.

Figure 37 - Multiple Subpanels and Cabinet Recommendations

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 69

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

(1)

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

I/O

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

DC BUS

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

1616

Dirty Wireway

Clean Wireway

Motor Cables

(2)

Circuit

Protection

24V DC

Power Supply

AC Line Filter

(required for CE)

Kinetix 5700 Servo Drive System

(1)

Very Dirty Filter/AC Input

Connections Segregated

(not in wireway)

Route motor cables in shielded cable.

Route registration and communication

signals in shielded cables.

Safety Cable

(hardwired drives only)

Module

Status

Contactor Enable

Establishing Noise Zones

The Kinetix 5700 DC-bus system power can be supplied by the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply.

Observe these guidelines when routing cables used in the Kinetix 5700 system:

• The clean zone (C) is right of the drive system and includes the digital inputs wiring and Ethernet cable (gray wireway).

• The dirty zone (D) is left and below the drive system (black wireways) and includes the circuit breakers, 24V DC power supply, safety, and motor cables.

• The very dirty zone (VD) is limited to where the AC (EMC) line filter VAC output jumpers over to the DC-bus power supply. Shielded cable is required only if the very dirty cables enter a wireway.

Figure 38 - Noise Zones (DC-bus power supply)

(1) When space to the right of the module does not permit 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For

examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

(2) When the 2198-H2DCK feedback converter kit or 2198-K57CK-D15M universal feedback kit is used, feedback cable routes in the

clean wireway.

70 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Plan the Kinetix 5700 Drive System Installation Chapter 2

(1)

Dirty Wireway

Clean Wireway

Motor Cables

(2)

Circuit

Protection

24V DC

Power Supply

AC Lin e Filter

(required for CE)

Kinetix 5700 Servo Drive System

(1)

Very Dirty Filter/AC Input

Connections Segregated

(not in wireway)

Route motor cables in shielded cable.

Route registration and communication

signals in shielded cables.

Safety Cable

(hardwired drives only)

Module

Status

Contactor Enable

Figure 39 - Noise Zones (regenerative bus supply)

MOD

NET

I/O

MOD

NET

I/O-A

I/O-B

UFB-A UFB-B

MF-A MF-B

510

D+ D-

I/O-A

510

UFB-A UFB-B

D+

D-

MF-A MF-B

OK+

OK–

EN–

EN+

510

D+ D-

MOD

NET

I/O-B

1616

UFB-A UFB-B

D+

D-

MF-A MF-B

MOD

DC BUS

(1) When space to the right of the module does not permit 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For

examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

(2) When the 2198-H2DCK feedback converter kit or 2198-K57CK-D15M universal feedback kit is used, feedback cable routes in the

clean wireway.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 71

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Cable Categories for Kinetix 5700 Systems

These tables indicate the best zone for running cables and wires. The tables also show how the use of ferrite sleeves and shielded cable can reduce the noise effects of dirty and very-dirty wires and cables.

Table 22 - DC-bus Power Supply or Regenerative Bus Supply

Wire/Cable

L1, L2, L3 (shielded cable)

L1, L2, L3 (unshielded cable) X – – – –

DC-/DC+ (DC bus)

DC+/SH (passive shunt) 2198-Pxxx

DC+/DC– (active shunt) 2198-RPxxx ––––

CONT EN– and CONT EN+ (M1 contactor)

CONV OK– and CONV OK+ 2198-RPxxx ––––

24V DC

Dedicated digital inputs

Ethernet (shielded cable)

Power S upply Cat. No.

2198-Pxxx 2198-RPxxx

Connector

IPD

DC Bus-bar only, no wiring connector.

CED

CP – X – – –

IOD – X – – –

PORT1 PORT2

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

–X–– X

–

––X– X

Zone Method

–– –

Table 23 - Dual-axis and Single-axis Inverters

Wire/Cable Connector

DC-/DC+ (DC bus) DC Bus-bar only, no wiring connector.

U, V, W (motor power)

Motor feedback MF X X

Motor brake BC X X

U, V, W (motor power)

Motor feedback MF or UFB – X X

Motor brake BC X – X

24V DC CP – X – – –

Safety enable for safe torque-off (hardwired) STO – X – – –

Registration input

Dedicated digital inputs (other than registration inputs) – X – – –

Ethernet (shielded cable)

Kinetix VP motors

MP-Series™ motors

IOD

PORT1 PORT2

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

–

––X– X

Zone Method

––

X–

–

72 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 73

Table 24 - iTRAK Power Supply

Plan the Kinetix 5700 Drive System Installation Chapter 2

Wire/Cable Connector

DC-/DC+ (DC bus) DC Bus-bar only, no wiring connector.

iTRAK DC-bus output A and B IDC – X – – X

24V DC control input power CP

iTRAK 24V DC control output power A and B ICP

iTRAK digital inputs IOD – – X – –

iTRAK ready output IR – – X – –

Ethernet (shielded cable)

PORT1 PORT2

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

–X–– X

––X– X

Zone Method

Table 25 - Capacitor Module or DC-bus Conditioner Module

Wire/Cable Connector

DC-/DC+ (DC bus) DC Bus-bar only, no wiring connector.

DC-/DC+ M8 Stud – X – – –

24V DC CP – X – – –

Module status MS – X – – –

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

Zone Method

Table 26 - Extension Module

Wire/Cable Connector

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

DC-/DC+ (DC bus) DC Bus-bar only, no wiring connector.

DC-/DC+ M8 Stud – X – – –

Zone Method

Noise Reduction Guidelines for Drive System Accessories

Refer to this section when mounting an AC (EMC) line filter or external shunt resistor for guidelines designed to reduce system failures caused by excessive electrical noise.

AC Line Filters

Observe these guidelines when mounting your AC (EMC) line filter (refer to the figure on page 70

• If your facility has grounded WYE power distribution, as shown in

Figure 80

Kinetix 5700 power supply and as close to the power supply as possible.

• Good HF bonding to the panel is critical. For painted panels, refer to the examples on page 68

• Segregate input and output wiring as far apart as possible.

for an example):

on page 129, mount the AC line filter on the same panel as the

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 73

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Dirty Wireway

Clean Wireway

Motor Cables

150 mm (6.0 in.) clearance (min) on all four sides of the shunt module.

Enclosure

Metal Conduit

(where required by local code)

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice). Twisted pair, two twists per foot (min) (2nd choice).

Circuit

Protection

Digital Inputs

and Ethernet Cables

Route motor cables in shielded cable.

Route registration and communication

signals in shielded cables.

Kinetix 5700 Servo Drive System

24V DC

Power Su pply

AC Lin e Filter

(required for CE)

Module Status

Safety Cable

(hardwired safety only)

No sensitive

equipment within

150 mm (6.0 in.).

610 mm (24 in.) clearance (min) above the shunt module.

Contactor Enable

Ver y Dir ty Fi lter/ AC Inp ut

Connections Segregated

(not in wireway)

External Passive Shunt Modules

Observe these guidelines when mounting your 2198-R014, 2198-R031, or 2198-R127 external passive shunt modules:

• Mount the shunt module outside of the drive system enclosure.

• Mount the shunt module so that wiring routes in the very dirty zone inside the drive system enclosure.

• Keep unshielded wiring as short as possible, not to exceed 3 m (9.8 ft). Keep shunt wiring as flat to the cabinet as possible.

Figure 40 - External Passive Shunt Module Mounted On Top of the Drive System Enclosure

MOD

NET

MOD

NET

I/O

D+ D-

I/O-A I/O-B

510

MF-A MF-B

I/O-A I/O-B

16 1616 1616

UFB-A UFB-B

D+

D-

MF-A MF-B

D+ D-

MF-A MF-B

I/O-A I/O-B

UFB-A UFB-B

MOD

NET

D+ D-

MOD

DC BUS

74 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 75

Plan the Kinetix 5700 Drive System Installation Chapter 2

MOD

NET

I/O-A I/O-B

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

I/O

MOD

NET

I/O-A I/O-B

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

I/O-A I/O-B

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MOD

DC BUS

510

16 1616 1616

Dirty Wireway

Clean Wireway

Motor Cables

Enclosure

No sensitive

equipment within

150 mm (6.0 in.).

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice). Twisted pair, two twists per foot (min) (2nd choice).

Circuit

Protection

Digital Inputs and

Ethernet Cables

Route motor cables in shielded cable.

Route registration and communication

signals in shielded cables.

Kinetix 5700 Servo Drive System

24V DC

Power Su pply

AC Lin e Filter

(required for CE)

Module Status

76 mm (3.0 in.)

clearance (min) below, left,

and right of the shunt resistor.

Safety Cable

(hardwired safety only)

150 mm (6.0 in.)

clearance (min) above the

shunt resistor.

Very Dirty Filter/AC Input

Connections Segregated

(not in wireway)

Observe these guidelines when mounting your 2198-R004 external passive shunt resistor:

• Mount the shunt resistors anywhere in the dirty zone, but as close to the Kinetix 5700 power supply as possible.

• Route the shunt power wires with other very dirty wires.

• Keep unshielded wiring as short as possible, not to exceed 457 mm (18 in.). Keep shunt wiring as flat to the cabinet as possible.

• Separate shunt power cables from other sensitive low-voltage signal cables.

Figure 41 - External Shunt Resistor Mounted Inside the Drive System Enclosure

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 75

Page 76

Chapter 2 Plan the Kinetix 5700 Drive System Installation

Dirty Wireway

Clean Wireway

Motor Cables

150 mm (6.0 in.) clearance (min) on all four sides of the shunt module.

Enclosure

Metal Conduit

(where required by local co de)

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice).

Twisted pair, two twists per foot (min) (2nd choice).

Circuit

Protection

Digital Inputs

and Ethernet Cables

Route motor cables in shielded cable.

Route registration and communication

signals in shielded cables.

Kinetix 5700 Servo Drive System

24V DC

Power Su pply

AC Lin e Filter

(required for CE)

Module Status

Safety Cable

(hardwired safety only)

No sensitive

equipment within

150 mm (6.0 in.).

610 mm (24 in.) clearance (min) above the shunt module.

Contactor Enable

Very Dirty Filter/AC Input

Connections Segregated

(not in wireway)

External Active Shunt

External Active Shunt Modules

Observe these guidelines when mounting external active shunt outside the drive system enclosure:

• Mount the shunt module so that wiring routes in the very dirty zone inside the drive system enclosure.

• Keep unshielded wiring as short as possible, not to exceed 3 m (9.8 ft). Keep shunt wiring as flat to the cabinet as possible.

Figure 42 - External Active Shunt Module Mounted On Top of the Drive System Enclosure

MOD

NET

MOD

NET

I/O

I/O-A I/O-B

16 1616 1616

OK+

OK–

EN–

EN+

510

UFB-A UFB-B

D+

D-

MF-A MF-B

D+ D-

MF-A MF-B

MOD

NET

I/O-A I/O-B

UFB-A UFB-B

D+

D-

MF-A MF-B

MOD

NET

MODULE

STATUS

76 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 77

Plan the Kinetix 5700 Drive System Installation Chapter 2

MOD

NET

I/O-A I/O-B

UFB-A UFB -B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

I/O-A I/O-B

UFB-A UFB -B

D+ D-

MF-A MF-B

D+ D-

MOD

NET

I/O-A I/O-B

UFB-A UFB -B

D+ D-

MF-A MF-B

D+ D-

510

16 1616 1616

MOD

NET

I/O

OK+

OK–

EN–

EN+

MOD

NET

MODULE

STATUS

Dirty Wireway

Clean Wireway

Motor Cables

Enclosure

No sensitive

equipment within

150 mm (6.0 in.).

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice).

Twisted pair, two twists per foot (min) (2nd choice).

Circuit

Protection

Route motor cables in shielded cable.

Route registration and communication

signals in shielded cables.

Kinetix 5700 Servo Drive System

24V DC

Power Su pply

AC Lin e Filter

(required for CE)

Module Status

76 mm (3.0 in.)

clearance (min) below, left,

and right of the shunt resistor.

Safety Cable

(hardwired safety only)

150 mm (6.0 in.)

clearance (min) above the

shunt resistor.

Very Dirty Filter/AC Input

Connections Segregated

(not in wireway)

Digital Inputs

and Ethernet Cables

External Ac tive Shunt

Observe these guidelines when mounting your external active shunt inside the drive system enclosure:

• Mount the shunt resistors anywhere in the dirty zone, but as close to the Kinetix 5700 power supply as possible.

• Route the shunt power wires with other very dirty wires.

• Keep unshielded wiring as short as possible, not to exceed 3 m (9.8 ft). Keep shunt wiring as flat to the cabinet as possible.

• Separate shunt power cables from other sensitive low-voltage signal cables.

Figure 43 - External Active Shunt Mounted Inside the Drive System Enclosure

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 77

Page 78

Chapter 2 Plan the Kinetix 5700 Drive System Installation

Notes:

78 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 79

Chapter 3

Mount the Kinetix 5700 Drive System

This chapter provides installation procedures for mounting your Kinetix® 5700 drive system to the system panel and installing DC-bus links and 24V sharedbus connector kits to the drive modules.

Top ic Pa ge

Determine Mounting Order 80

Mount Accessory Modules 83

Zero-stack Tab and Cutout 84

Install Shared-bus Connection Systems 84

Drill-hole Patterns 87

Mount Your Kinetix 5700 Drive Modules 90

This procedure assumes that you have prepared your panel and understand how to bond your system. For installation instructions regarding equipment and accessories not included here, refer to the instructions that came with those products.

SHOCK HAZARD: To avoid the hazard of electrical shock, perform all mounting and wiring of the Kinetix 5700 drive system before applying power. Once power is applied, connector terminals can have voltage present even when not in use.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 79

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Chapter 3 Mount the Kinetix 5700 Drive System

Highest Power Utilization

Lowest Power Utilization

2198-S086-ERSx

Single-axis Inverter

2198-D012-ERSx

Dual-axis Inverter

2198-D006-ERSx

Dual-axis Inverter

2198-P141

DC-bus Power Supply

Shared-bus Connection Systems (DC-bus and 24V DC)

Determine Mounting Order

Mount the DC-bus power supply or regenerative bus supply on the far right or far left, whichever makes the best use of panel space. Mount inverter modules and iTRAK® power supplies in order from left to right (as shown in Figure 44 or right to left (as shown in Figure 46

IMPORTANT We recommend that you mount inverter modules and iTRAK power supplies

according to power rating (highest to lowest) from left to right (or right to left) starting with the highest power rating.

Table 27 - Kinetix 5700 Single-axis Inverter Modules

Attribute 2198-S086-ERSx 2198-S130-ERSx 2198-S160-ERSx 2198-S263-ERSx 2198-S312-ERSx

Continuous Power Output, nom

29.7 kW 44.9 kW 60.1 kW 90 kW 112 kW

Table 28 - Kinetix 5700 Dual-axis Inverter Modules

Attribute 2198-D006-ERSx 2198-D012-ERSx 2198-D020-ERSx 2198-D032-ERSx 2198-D057-ERSx

Continuous Power Output, nom

2 x 1.7 kW 2 x 3.4 kW 2 x 5.5 kW 2 x 8.9 kW 2 x 15.9 kW

Table 29 - iTRAK Power Supply

Attribute 2198T-W25K-ER

Continuous Power Output, nom

4.1 kW

)

The Kinetix 5700 drive system in Figure 44 could be powered by the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply. This example is powered by the DC-bus power supply (positioned on the left) with inverter modules mounted according to power rating (highest to lowest) from left to right.

Figure 44 - System Mounting Order Example (single DC-bus power supply)

MOD

NET

I/O

MOD

NET

MOD

NET

I/O

UFB

I/O-A

I/O-B

510

UFB-A UFB-B

D+D-D+

D-

MF-A MF-B MF-A MF-B

MBRK

MOD

NET

I/O-A

I/O-B

510

UFB-A UFB-B

D+

D-

80 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 81

Mount the Kinetix 5700 Drive System Chapter 3

MOD

NET

MOD

NET

MOD

NET

MOD

NET

I/O

UFB

UFB-A UFB-B

D+D-D+

D-

D+ D-

MF-A MF-B MF-A MF-B

D+ D-

MBRK

MOD

NET

I/O

MOD

NET

I/O

I/O-A

510

I/O-B

510

I/O-A

510

I/O-B

510

Highest Power Utilization

Lowest Power U tilization

2198-S086-ERSx

Single-axis Inverter

2198-D012-ERSx

Dual-axis Inverter

2198-D006-ERSx

Dual-axis Inverter

2198-P208 DC-bus Power Supplies

(1)

Shared-bus Connection Systems (DC-bus and 24V DC)

IMPORTANT The maximum number of inverter modules depends on the maximum

system capacitance precharge capability of the power supplies and the total system capacitance. When there are two or three DC-bus power supplies, they must be catalog number 2198-P208.

Refer to Appendix C on page 391

Figure 45 - System Mounting Order Example (multiple DC-bus power supplies)

for more system sizing information.

(1) The DC-bus power supplies can be left or right of the inverters.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 81

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Chapter 3 Mount the Kinetix 5700 Drive System

MOD

NET

I/O

MBRK

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

W V U

MOD

NET

I/O

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

MODULE

STATUS

MOD

DC BUS

I/O-A

510

I/O-B

510

L1 L2 L3

21mm (4-4/0 AWG)

15-20 Nm (132-177 lbin)

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

I/O-A

6101

I/O-B

510

Dual-axis Inverters

Regenerative Bus Supply

(1)

Single-axis Inverters

Highest Power Utilization

Lowest Power Utilization

2198-S312-ERSx

Single-axis Inverter

2198-D012-ERSx Dual-axis Inverter

2198-D006-ERSx

Dual-axis Inverter

Shared-bus Connection System (DC-bus and 24V DC)

2198-DCBUSCOND-RP312

DC-bus Conditioner

This example is powered by the regenerative bus supply (positioned on the right) with inverter modules mounted according to power rating (highest to lowest) from right to left.

Figure 46 - System Mounting Order Example (regenerative bus supply)

(1) The regenerative bus supply can be mounted left or right of the inverters.

IMPORTANT The maximum number of inverter modules depends on the maximum

system capacitance precharge capability of the power supply and the total system capacitance.

Refer to Appendix C on page 391

for more system sizing information.

82 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

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Mount the Kinetix 5700 Drive System Chapter 3

Flexible Bus-bars

External DC-bus Wire Lug Connections

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

2198-CAPMOD-DCBUS-IO Extension Module

DC-bus Link

Conne ctions

2198-xxxx-ERSx

Inverters

DC-bus Links

Mount Accessory Modules

Mount the 2198-CAPMOD-2240 capacitor module on the far right or far left of any system cluster, depending on the input power configuration. A capacitor module is required in the following situations:

• Required in each cluster of a multi-cluster system

• More than one capacitor module can be used in a cluster, if needed

IMPORTANT Each additional capacitor module adds to the total system capacitance and

increased energy storage.

The 2198-CAPMOD-DCBUS-IO extension module is always mounted next to a capacitor module or DC-bus conditioner module and always positioned on the outside of the system cluster (either first or last). The extension module can be paired with another accessory module and flexible bus-bars if external DC-bus current is ≥104 A up to a maximum of 208 A.

IMPORTANT When the extension module is mounted next to another accessory module,

they must be connected by flexible bus bars.

Figure 47 - Flexible Bus Bar Example

SB+/NC S1A SCA S2A SBNC NC

IMPORTANT In a multi-cluster system with a power supply rated ≥104 A, two accessory

modules connected by flexible bus bars must be used to create a 208 A extended cluster system. See the Accessory Module Connector Specifications table on page 181

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 83

for DC-bus wiring requirements.

Page 84

Chapter 3 Mount the Kinetix 5700 Drive System

MOD

NET

MOD

NET

Kinetix 5700 Drive Modules

(front view)

Zero-stack Tab and Cutout Engaged

Zero-stack Tab and Cutout

Engaging the zero-stack tab and cutout from one drive module to another makes efficient use of panel space, especially for high axis-count installations.

IMPORTANT Engaging the zero-stack tab and cutout from module-to-module is

required for any input power configuration. This is done to make sure that the DC-bus connectors are spaced properly to accept the shared-bus connection system.

Figure 48 - Zero-stack Tab and Cutout Example

For Kinetix 5700 system sizing examples, refer to Appendix C on page 391.

Install Shared-bus Connection Systems

The shared-bus connection system is used to extend the DC-bus power and 24V control power from one drive module to another.

IMPORTANT The zero-stack tab and cutout must be engaged between adjacent drive

modules for the shared-bus connection system to fit properly.

DC-bus Connection System

The DC-bus connection system is required and comprised of these two components:

• DC-bus links that are inserted between drive modules to extend the DC-bus from one drive module to another.

IMPORTANT DC-bus links are included with inverter and accessory modules, so

when two or three 2198-P208 DC-bus power supplies are connected in parallel, order extra 2198-BARCON-85DC200 DC-bus links.

• DC-bus end-caps that are inserted into the first and last drive modules to cover the exposed DC-bus connector on both ends of the bus.

84 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 85

Figure 49 - DC-bus Connector Example

Kinetix 5700 Drive System

End Caps (2)

DC-bus Link, 85 mm

Zero-stack Tab

and Cutout Engaged

DC-bus Link, 55 mm

DC-bus Link, 100 mm

(seated)

DC-bus power supply is mounted

leftmost followed by drive with

largest amp rating.

Latch

Align the DC-bus link

lower pivots with the

latches and push downward

until they latch.

Upper Pivot

Lower Pivot

Dual Axis Inverter, 55 mm

Single Axis Inverter, 85 mm

Single Axis Inverter, 100 mm

DC-bus Power Supply

DC Link Latched

(1)

Mount the Kinetix 5700 Drive System Chapter 3

(1) DC-bus links latch on both sides when inserted into the DC-bus connectors. To remove the DC-bus link, depress both sets of

upper pivots to unlatch the lower pivots and hold the DC-bus link firmly while pulling upward.

24V Input Power Connection System

The optional 24V input power connection system always feeds 24V DC from left to right and is comprised of three components:

• The 24V input wiring connector that plugs into the DC-bus power supply or first module supplied by the 24V external power receives 24V DC input wiring.

• 24V DC T-connectors that plug into the drive modules downstream from the power supply or first module supplied by the 24V external power where the 24V control power is shared.

• Bus bars that connect between drive modules to extend the 24V control power from one drive module to another.

Multiple 24V shared-bus input wiring connectors can be used in a high axiscount system. If the 40 A shared-bus current rating is exceeded, you can add another connector at any point in the cluster. 2198-S263-ERSx and 2198-S312-ERSx drives and 2198-RP263 and 2198-RP312 bus supplies use the 2198T-W25K-P-IN input wiring connector. All other modules use the 2198-TCON-24VDCIN36 input wiring connector. Both wiring connectors

accept up to 10 mm

(6 AWG) wire. The CP connectors that are included with each module accept up to 10 mm shared-bus input wiring connectors can provide the means to use larger gauge conductors for reduced voltage drop on long wire runs.

(12 AWG) or 6 mm2 (10 AWG), so the

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 85

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Chapter 3 Mount the Kinetix 5700 Drive System

24V Input Wiring

Connector

24V T-connectors

Bus-bar Conne ctors

24V Input Wiring

Zero-stack Tab

and Cutout Engaged

Kinetix 5700 Drive System

DC-bus power supply is mounted

leftmost followed by drive with

largest amp rating.

100 mm

Bus-bar

85 mm

Bus-bar

55 mm

Bus-bar

Figure 50 - 24V Connector Example

The three 24V input power components must assemble from left to right across the drive system.

1. Attach wiring to 24V input wiring connector.

2. Insert input wiring connector and T-connectors into the appropriate

drive module connectors.

3. Insert bus-bars to connect between wiring connector and T-connectors.

IMPORTANT The input wiring connector can be inserted into any drive module (mid-

stream in the drive system) to begin a new 24V control bus when the maximum current value is reached. However, the input connector must always extend the 24V DC-bus from left to right.

IMPORTANT Mount the 24V power supply as close to the drive system as possible to

minimize voltage drop on the 24V input power wiring.

The following configurations require more than one 24V input wiring connector:

• The 40 A maximum current rating is exceeded

• The 2198-RPxxx regenerative bus supply is positioned between the inverters or accessory modules in any single cluster

• The 2198-RPxxx regenerative bus supply is positioned to the right of any other module

86 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 87

Mount the Kinetix 5700 Drive System Chapter 3

SB+/NC

S1A SCA S2A SBNC NC

1606-XL

Power Supply

Input

Allen-Bradley

MOD

NET

I/O

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

I/O-A

510

I/O-B

510

L1 L2 L3

SB+/NC

S1A SCA S2A SBNC NC

MOD

NET

UFB-A UFB-B

D+ D-

MF-A MF-B

D+ D-

I/O-A

6101

I/O-B

510

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

SB+/NC

S1A SCA S2A SBNC NC

SB+/NC

S1A SCA S2A SBNC NC

MOD

NET

I/O

MBRK

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

W V U

MOD

NET

UFB-A UFB-B

MF-A MF-B

D+ D-

I/O-A

6101

I/O-B

510

1606-XLxxx

24V DC Control Power

(customer-supplied)

AC Inp ut Power

Kinetix 5700 Servo Drive System

(front view)

Kinetix 5700 Servo Drive System (top view)

Shared DC-bus Power

Dual-axis Inverters

Regenerative Bus Supply

Second 24V Input Wiring Connector

Single-axis Inverter

First 24V Input

Wiring Co nnect or

In this example, one 24V connection system spans (left to right) across the dual-axis inverters only. In the other 24V input connection system, the 2198-S312-P-T control power T-connector and bus-bar connects the regenerative bus supply and single-axis inverter only.

TIP 24V control power bus-bars that bridge across 2198-RPxxx regenerative bus

supplies are not available.

Figure 51 - Multiple 24V Input Wiring Connector Example

Drill-hole Patterns

This section provides drill-hole patterns for Kinetix 5700 drive modules that are mounted in zero-stack (shared-bus) configurations. Properly spaced drillholes are essential for engaging the zero-stack tab and cutout from module-tomodule so that the DC-bus connectors are spaced properly to accept the DCbus links.

The DC-bus power supply and regenerative bus supply can be mounted on the far right, far left, or anywhere in between. However, the far left position is preferred to accommodate the 24V shared bus.

Also available to assist you in mounting Kinetix 5700 drive modules is the 2198-K5700-MOUNTKIT system mounting toolkit.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 87

Page 88

Chapter 3 Mount the Kinetix 5700 Drive System

32.0 mm

Module Top, reference

27.5 mm

Module Top, reference

176 mm

Lower Mounting Hole

345 mm

Lower Mo unting Hole

420 mm

Lower Mounting Hole

465 mm

Lower Mou nting Hole

Ø 6.0 mm Typ ic al

Ø 6.0 mm Typical

00.0 mm

Upper Mounting Holes

45.0 mm See Mounting Hole Pattern Calculations

30.0 mm See Mounting Hole Pattern Calculations

100 mm

Wide Module

85 mm

Wide Module

55 mm

Wide Module

55 mm

Wide Module

Applies to only 2198-S160-ERSx

Single-axis Inverter

Applies to 2198-P141, 2198-P208 Power Supplies 2198-S086-ERSx and 2198-S130-ERSx Inverters, and 2198-D057-ERSx Inverters

Applies to 2198-P031 and 2198-P070 Power Supplies 2198-D006-ERSx, 2198-D012-ERSx, 2198-D020-ERSx, and 2198-D032-ERSx, Inverters 2198-CAPMOD-2240 Capacitor Module 2198-DCBUSCOND-RP312 DC-bus Conditioner Module

First Mounting Hole

(typical) Upper and Lower

Mounting Hole

(all drive modules)

Applies to only 2198-CAPMOD-DCBUS-IN Extension Module

45.0 mm See Mounting Hole Pattern Calculations

100 mm

Wide Module

Applies to only 2198T-W25K-ER iTRAK Power Supply

Drill-hole Pattern Calculations

Use Figure 52 to calculate the left-to-right hole pattern for Kinetix 5700 drive system configurations that include the 2198-Pxxx DC-bus power supply.

1. The first hole location is zero.

2. The second hole location is module width minus 55 mm.

3. The next hole location is 55 mm.

4. Repeat step 2

Figure 52 - DC-bus Power Supply Mounting Hole Patterns

and step 3 for the remaining holes.

88 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 89

Mount the Kinetix 5700 Drive System Chapter 3

176 (6.93)

Lower Mou nting Hole

345 (13.58)

Lower Mou nting Hole

420 (16.54)

Lower Mou nting Hole

0.0 Upper

Mounting Holes

332 Module Height

345 Ground Stud

350

452 Module Height

465 Ground Stud

470

345 Lower

Mounting Hole

465 Lower

Mounting Hole

2198-RP312

2198-RP263

Regenerative Bus Supply

(440 mm module width)

2198-RP200

Regenerative Bus Supply

(275 mm module width)

2198-S263-ERSx

2198-S312-ERSx

Single-axis Inverter

(220 mm module width)

2198-RP088

Regenerative

Bus Supply

(165 mm

module width)

IMPORTANT

Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.

Use Figure 53 to calculate the left-to-right hole pattern for Kinetix 5700 drive system configurations that include the 2198-RPxxx regenerative bus supply.

Mounting holes for the Kinetix 5700 regenerative bus supply modules are based on 55 mm spacing, however, only the holes specified for each module are required.

Figure 53 - Regenerative Bus Supply Mounting Hole Patterns

110

110 110 165

110 55.0

55.0

110

55.0

8.0

27.5

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 89

32.00

Page 90

Chapter 3 Mount the Kinetix 5700 Drive System

Mounting Bar

Drill-hole Guide

Dimensions are in mm (in.)

M4 thread-forming

fasteners, 1.7 N•m (15 lb•in)

Drill-hole Patterns by Using the System Mounting Toolkit

The mounting bar must be mounted horizontally on the system panel. The drill-hole guide inserts behind the mounting bar and slides left and right. Holes and slots in the drill-hole guide let you establish the location of each Kinetix 5700 drive module.

Figure 54 - Mounting Bar

3x Ø4.50 (0.18)

10 (0.39)

2x 10 (0.39)

Mount Your Kinetix 5700 Drive Modules

100

2x 190 (7.48)

100

43.2 (1.70) Ref

400 (15.75)

For step-by-step instructions on how to use the system mounting toolkit, see the Kinetix 5700 System Mounting Toolkit Installation Instructions, publication 2198-IN012

This procedure assumes that you have prepared your panel and understand how to bond your system. For installation instructions regarding other equipment and accessories, refer to the instructions that came with those products.

A hoist, straps, and J-hooks with a lockable clasp capable of supporting the maximum module weight are recommended for catalog numbers 2198-RP200, 2198-RP263, and 2198-RP312. For lifting instructions, see the Kinetix 5700 Regenerative Bus Supply Installation Instructions, publication 2198-IN014

Follow these steps to mount your Kinetix 5700 drive modules to the panel.

1. Lay out the hole pattern for each drive module in the enclosure.

See Establishing Noise Zones recommendations.

IMPORTANT To improve the bond between the drive modules and subpanel,

construct your subpanel out of zinc plated (paint-free) steel.

2. Drill holes in the panel for mounting your drive system.

Refer to Drill-hole Patterns

90 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

beginning on page 87.

on page 70 for panel layout

Page 91

Mount the Kinetix 5700 Drive System Chapter 3

Kinetix 5700 Drive System (DC bus supply and dual-axis inverter are shown)

Top Scre ws

(bottom screws not shown)

Zero-s tack Tab

and Cutout Engaged

3. Loosely attach the mounting hardware to the panel.

The recommended mounting hardware is M5 (#10-32) steel bolts. Observe bonding techniques as described in Bonding Modules

page 67

4. Attach the DC-bus supply (or supplies) or the regenerative bus supply to the cabinet panel.

5. Attach additional drive modules to the right or left of the previous module by using the same method, but also making sure that the zerostack tabs and cutouts are engaged.

Zero-stack mounting is required for all configurations. See the Zero-

stack Tab and Cutout Example on page 84.

6. Tighten all mounting fasteners.

Apply 4.0 N•m (35.4 lb•in) maximum torque to each fastener.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 91

Page 92

Chapter 3 Mount the Kinetix 5700 Drive System

Notes:

92 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 93

Chapter 4

Connector Data and Feature Descriptions

This chapter illustrates connectors and indicators for the Kinetix® 5700 drive system components, including the DC-bus power supply, regenerative bus supply, single-axis inverter, dual-axis inverter, and accessory modules. Also included in this chapter are connector pinouts and descriptions for Kinetix 5700 system components.

Top ic Pa ge

Kinetix 5700 Connector Data 94

Understand Control Signal Specifications 108

Feedback Specifications 114

Funct ional Saf ety Feature s 125

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 93

Page 94

Chapter 4 Connector Data and Feature Descriptions

MOD–

NET–

I/O

DC+

DC–

24V–

24V+

L3 L2 L1

5700

DC-bus Power Supply, Top View

(2198-P031 module is shown)

DC-bus Power Supply, Bottom View

(2198-P031 module is shown)

DC-bus Power Supply, Front View

(2198-P031 module is shown)

Kinetix 5700 Connector Data

Use these illustrations to identify the connectors and indicators for the Kinetix 5700 drive modules.

Figure 55 - DC-bus Power Supply Features and Indicators

Item Description Item Description Item Description

1 Digital inputs (IOD) connector 7 LCD display 13 Shunt resistor (RC) connector

2 Ethernet (PORT1) RJ45 connector 8 Navigation pushbuttons 14 DC bus (DC) connector

3 Ethernet (PORT2) RJ45 connector 9 Link speed status indicators 15 24V control input power (CP) connector

4 Zero-stack mounting tab/cutout 10 Link/Activity status indicators 16 AC Input power (IPD) connector

5 Module status indicator 11 Contactor-enable (CED) connector 17 Cooling fan

6 Network status indicator 12 Ground terminal

94 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 95

Connector Data and Feature Descriptions Chapter 4

DC+

DC–

24V–

24V+

L3 L2 L1

MOD

NET

I/O

OK+

OK–

EN–

EN+

5700

DC–

2198-RP088 and 2198-RP200

Regenerative Bus Supply

Bottom View

(2198-RP088 is shown)

2198-RP263

and 2198-RP312

Regenerative Bus Supply

(bottom view)

2198-RPxxx

Regenerative Bus Supply

Top Vie w

(2198-RP088 is shown)

2198-RPxxx

Regenerative Bus Supply

Front View

(2198-RP088 is shown)

Figure 56 - Regenerative Bus Supply Features and Indicators

Item Description Item Description Item Description

1 Ground jumper in operation 8 Network status indicator 15 Lifting points

2 Ground jumper in storage 9 LCD display 16 Active shunt (RC) connector

3 Digital inputs (IOD) connector 10 Navigation push buttons 17 DC bus (DC) connector

4 Ethernet (PORT1) RJ45 connector 11 Link speed status indicators 18 24V control input power (CP) connector

5 Ethernet (PORT2) RJ45 connector 12 Link/Activity status indicators 19 AC Input power (IPD) connector

6 Zero-stack mounting tab/cutout 13 Contactor enable (CED) connector 20 Cooling fans

7 Module status indicator 14

Ground lug (partially obscured behind input plug)

(1) Connector plug orientation applies to 2198-RP088 and 2198-RP200 modules (2198-RP200 connector size is larger). See adjacent figure for 2198-RP263 and 2198-RP312

connector plug size and orientation.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 95

(1)

Page 96

Chapter 4 Connector Data and Feature Descriptions

UFB-A

UFB-B

D+D-D+

D-

MF-A

MF-B

DC+

DC–

24V–

24V+

W-B V-B U-B

MBRK-A

– +

W-A V-A U-A

MBRK-B

– +

MOD–

NET–

5700

1 2 3 4 5

6 7 8 9

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

I/O-A

510

I/O-B

510

SB+/NC

S1A SCA S2A SBNC NC

Dual-axis Inverter, Front View (2198-D006-ERS4 module is shown)

Dual-axis Inverter, Top View

(2198-D006-ERS4 module is shown)

Dual-axis Inverter, Bottom View

(2198-D006-ERS4 module is shown)

Figure 57 - Dual-axis Inverter Features and Indicators

Item Description Item Description Item Description

1 Motor cable clamp with spacers 10 Ethernet (PORT2) RJ45 connector 19 DC bus (DC) connector

2 Ground terminal 11 Zero-stack mounting tab/cutout 20 24V control input power (CP) connec tor

3 Motor feedback (MF) connector - A 12 Module status indicator 21 Motor brake (BC) connector - A

4 Motor feedback (MF) connector - B 13 Network status indicator 22 Motor power (MP) connector - A

5 Universal feedback (UFB) connector - A 14 LCD display 23 Motor power (MP) connector - B

6 Universal feedback (UFB) connector - B 15 Navigation pushbuttons 24 Motor brake (BC) connector - B

7 Digital inputs (IOD) connector - A 16 Link speed status indicators 25 Cooling fan

8 Digital inputs (IOD) connector - B 17 Link/Activity status indicators

9 Ethernet (PORT1) RJ45 connector 18 Safe torque-off (STO) connector

96 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 97

Connector Data and Feature Descriptions Chapter 4

DC+

DC–

24V–

24V+

UFB

D+ D-

–

MBRK

MOD–

NET–

5700

1 2 3 4 5

6 7 8 9 10

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

SB+/NC

S1A SCA S2A SBNC NC

I/O

Single-axis Inverter, Front View (2198-S086-ERS4 module is shown)

Single-axis Inverter, Top View

(2198-S086-ERS4 module is shown)

Single-axis Inverter, Bottom View

(2198-S086-ERS4 module is shown)

Item Description Item Description

1 Motor cable clamp 12 LCD display

2 Tie-wrap bracket for feedback cable 13 Navigation pushbuttons

3 Motor brake (BC) connector 14 Link speed status indicators

4 Motor feedback (MF) connector 15 Link/Activity status indicators

5 Universal feedback (UFB) connector 16 Safe torque-off (STO) connector

6 Digital inputs (IOD) connector 17 DC bus (DC) connector

7 Ethernet (PORT1) RJ45 connector 18 24V control input power (CP) connector

8 Ethernet (PORT2) RJ45 connector 19 Motor power (MP) connector

9 Zero-stack mounting tab/cutout 20 Cooling fans

10 Module status indicator 21 Ground terminal

11 Network status indicator

Figure 58 - Single-axis Inverter Features (2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx)

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 97

Page 98

Chapter 4 Connector Data and Feature Descriptions

–

MBRK

UFB

MOD–

NET–

5700

1 2 3 4 5

6 7 8 9 10

I/O

21mm (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

W V U

24V–

24V+

DC+

DC–

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

SB+/NC

S1A SCA S2A SBNC NC

W V U

Single-axis Inverter, Front View (2198-S263-ERSx and 2198-S312-ERSx modules)

Single-axis Inverter, Top View

(2198-S263-ERSx and 2198-S312-ERSx modules)

Single-axis Inverter, Bottom View

(2198-S263-ERSx and 2198-S312-ERSx modules)

Item Description Item Description

1 Motor cable clamp 13 Navigation pushbuttons

2 Tie-wrap bracket for feedback cable 14 Link speed status indicators

3 Motor brake (BC) connector 15 Link/Activity status indicators

4 Motor feedback (MF) connector 16 Ground jumper in operation

5 Universal feedback (UFB) connector 17 Safe torque-off (STO) connector

6 Digital inputs (IOD) connector 18 Lifting points

7 Ethernet (PORT1) RJ45 connector 19 Motor power (MP) connector

8 Ethernet (PORT2) RJ45 connector 20 Ground terminal

9 Zero-stack mounting tab/cutout 21 DC bus (DC) connector

10 Module status indicator 22 24V control input power (CP) connector

11 Network status indicator 23 Cooling fans (replacement kits available)

12 LCD display

Figure 59 - Single-axis Inverter Features (2198-S263-ERSx, 2198-S312-ERSx)

98 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Page 99

Connector Data and Feature Descriptions Chapter 4

iTRAK Power Supply

(top view)

iTRAK Power Supply

(bottom view)

iTRAK Power Supply (front view)

iTRAK® Power Supply

(left side view)

Figure 60 - iTRAK Power Supply Features and Indicators

MOD–

NET–

5700

I/O

510

iPS RDY

–

7 8

IN 24V -

IN 24V +

DC+

DC-

Item Description Item Description Item Description

1 Power bus cable clamp 8 Network status indicator 15 24V control input power (CP) connector

Ground lug (partially obscured behind output plugs)

9 LCD display 16 24V control output power (ICP) connector -A

3 Digital inputs (IOD) connector 10 Navigation push buttons 17 DC bus output (IDC) connector - A

4 Ethernet (PORT1) RJ45 connector 11 Link speed status indicators 18 24V control output power (ICP) connector - B

5 Ethernet (PORT2) RJ45 connector 12 Link/Activity status indicators 19 DC bus output (IDC) connector - B

6 Zero-stack mounting tab/cutout 13 iTRAK power-supply ready (IR) connector 20 Cooling fan

7 Module status indicator 14 DC bus input (DC) connector 21 Power supply internal fuse

IMPORTANT See the iTRAK System User Manual, publication 2198T-UM001, for IOD, IR,

IDC, and ICP connector pinouts, and internal fuse information.

Rockwell Automation Publication 2198-UM002G-EN-P - February 2019 99

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Chapter 4 Connector Data and Feature Descriptions

MODULE

STATUS

MOD

DC BUS

24V–

24V+

24V–

24V+

5700

2198-CAPMOD-2240 Capacitor Module and 2198-DCBUSCOND-RP312 DC-bus Conditioner Module (front view)

2198-CAPMOD-2240 Capacitor Module and 2198-DCBUSCOND-RP312 DC-bus Conditioner Module (side view, lug cover removed)

2198-CAPMOD-2240 Capacitor Module and

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

(top views)

Figure 61 - Capacitor Module and DC-bus Conditioner Module Features and Indicators

Item Description Item Description Item Description

1 Ground stud 5 Stud/lug cover with wires

(1)

2 Module status (MS) connector 6 Stud cover without wires 10

DC– M8 stud (external DC-bus), shown

with flexible bus-bar

DC+ M8 stud (external DC-bus), shown with wire lug

(2)

3 DC-bus status indicator 7 DC-bus (DC) connector 11 M8 hex nut

4 Module status indicator 8 24V control input power (CP) connector 12 Lug spacer

(1) This example shows the lug cover oriented for wires exiting to the left (module is on the far left of the drive configuration). Rotate lug cover 180° when wires exit to the right (module is on the far right

of the drive configuration).

(2) Flexible bus-bars are included with only the 2198-CAPMOD-DCBUS-IO extension module. So, if you have two capacitor modules, two DC-bus conditioner modules, or a capacitor module and DC-bus

conditioner module mounted side by side, you must order the 2198-KITCON-CAPMOD2240 or 2198-KITCON-DCBUSCOND connector set separately.

100 Rockwell Automation Publication 2198-UM002G-EN-P - February 2019

Allen-Bradley 2198-P031, 2198-P208, 2198-S160-ERS3, 2198-P070, 2198-D006-ERS3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Preface

Summary of Changes

Conventions Used in This Manual

Access the Attachments

Additional Resources

Kinetix 5700 Servo Drives Series Change

About the Kinetix 5700 Servo Drive System

DC-bus Power Supply Input Power Configurations

Typical DC-bus Power Supply Configuration Example

Multiple DC-Bus Power Supply Configuration Example

Extended DC-bus Configuration Example

iTRAK Power Supply Configuration Example

Regenerative Bus Supply Input Power Configurations

Typical Regenerative Bus Configuration Examples

Extended Regenerative Bus Configuration Example

iTRAK Power Supply Configuration Example

8720MC-RPS Power Supply Input Power Configuration

Motor and Auxiliary Feedback Configurations

Typical Communication Configurations

Linear Topology

Ring Topology

Star Topology

Functional Safety Configurations

Hardwired Configuration

Integrated Safety Configurations

Safe Stop and Safe Monitor Configurations

Catalog Number Explanation

Agency Compliance

System Design Guidelines

System Mounting Requirements

DC-bus Voltage Regulation

AC Line Filter Selection

AC Line Impedance Considerations

Circuit Breaker/Fuse Selection

24V Control Power Evaluation

Contactor Selection

Passive Shunt Considerations

Active Shunt Considerations

Enclosure Selection

Minimum Clearance Requirements

Multi-axis Shared DC-Bus Configurations

Accessory Module Selection

DC-bus Power Supply Systems

Regenerative Bus Supply Systems

8720MC-RPS or Other Regenerative Power Supply

Accessory Module Flowcharts

Electrical Noise Reduction

Bonding Modules

Bonding Multiple Subpanels

Establishing Noise Zones

Cable Categories for Kinetix 5700 Systems

Noise Reduction Guidelines for Drive System Accessories

Determine Mounting Order

Mount Accessory Modules

Zero-stack Tab and Cutout

Install Shared-bus Connection Systems

DC-bus Connection System

24V Input Power Connection System

Drill-hole Patterns

Drill-hole Pattern Calculations

Drill-hole Patterns by Using the System Mounting Toolkit

Mount Your Kinetix 5700 Drive Modules

Kinetix 5700 Connector Data