Rockwell Automation Allen-Bradley Kinetix 5700 Series, Allen-Bradley 2198-P070, Allen-Bradley 2198-P031, Allen-Bradley 2198-P208, Allen-Bradley 2198-P141 Installation Instructions Manual

Installation Instructions

Original Instructions

Kinetix 5700 DC-bus Power Supply

Catalog Numbers 2198-P031, 2198-P070, 2198-P141, 2198-P208

Topi c Pag e

Summary of Changes 1

About the DC-bus Power Supply 2

Catalog Number Explanation 2

Before You Begin 2

Remove the Ground Screw in Select Power Configurations 3

Install the DC-bus Power Supply 4

Drill Hole Patterns 5

Connector Data 8

Wiring Requirements 11

Circuit Breaker/Fuse Specifications 12

Specifications 14

Additional Resources 14

Summary of Changes

Topi c Page

Revised mounting guidelines for the DC-bus power supply and inverter modules. 5

• Removed inch conversions from hole spacing dimensions to avoid errors due to rounding.

• Added 2198-DCBUSCOND-RP312 DC-bus conditioner module to diagram.

Added 24V shared-bus input wiring connector to top view. 8

Corrected wire size specifications for 2198-P031 and 2198-P070 DC-bus power supplies. 11

Updated the UL/CSA and IEC circuit protection specifications. 13

6

Kinetix 5700 DC-bus Power Supply

About the DC-bus Power Supply

The Kinetix® 5700 DC-bus (converter) power supply with 400V-class three-phase AC input
provides continuous output power and current to servo drives for applications with requirements
in the range of 7…46 kW and 10.5…69.2 A, respectively. 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.

See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002

, for detailed
information on wiring, applying power, troubleshooting, and integration with ControlLogix®
EtherNet/IP communication modules or CompactLogix™ 5370 controllers.

Catalog Number Explanation

This publication applies to the following Kinetix 5700 DC-bus power supplies.

DC-bus Power Supply Catalog Numbers

DC-bus Power Supply
Cat. No.

2198-P031

2198-P070 17 25.5

2198-P141

2198-P208 46 69.2

Module
Width

mm

55

85

Input Voltage

324…528V rms,
three-phase

Continuous
Output Power

kW

710.5

31 46.9

Continuous
Output Current

rms

A

DC

Before You Begin

Remove all packing material, wedges, and braces from within and around the components. After
unpacking, check the item nameplate catalog number against the purchase order.

Parts List

The DC-bus power supplies ship with the following:

•DC-bus end caps

• Wiring plug connector set for mains input power (IPD), 24V control input power (CP),
digital inputs (IOD), shunt power (RC), and contactor enable (CED)

• Wiring plug connector for shunt power (RC) connections installed on the drive

• These installation instructions, publication 2198-IN009

TIP Replacement connector sets are also available. See the Kinetix Servo Drives Specifications

Technical Data, publication KNX-TD003, for more information.

2 Rockwell Automation Publication 2198-IN009C-EN-P - March 2019

Kinetix 5700 DC-bus Power Supply

Ground screw installed

for grounded power configuration

(ground screw installed is default setting).

Remove screw for ungrounded, corner-grounded, and

impedance-grounded power configurations.

Ground Screw
Access Door

DC-bus Power Supply

(side view)

Ground Screw

Remove the Ground Screw in Select Power Configurations

Remove the ground screw when using ungrounded, corner-grounded, and impedance-grounded
power configurations.

IMPORTANT If you have grounded-wye power distribution, you do not need to remove the screw. Go to

Install the DC-bus Power Supply on page 4.

EMC performance can be affected if you remove the ground screw.

We recommend that you remove the ground screw before mounting the power supply to the
panel. Place the power supply on its side, on a solid surface equipped as a grounded static-safe
workstation.

ATTENTION: To avoid personal injury, the ground-screw access door must be kept closed when
power is applied. If power was present, and then removed, wait at least 5 minutes for the DC-bus
voltage to dissipate, and verify that no DC-bus voltage exists before accessing the ground screw.

To access the ground screw, open the small plastic door on the right side of the module.

Remove the Ground Screw

ATTENTION: Risk of equipment damage exists. The drive-module ground configuration must be

accurately determined. Leave the ground screw installed for grounded power configurations
(default). Remove the screw for ungrounded, corner-grounded, and impedance-grounded power.

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 3

Kinetix 5700 DC-bus Power Supply

Ground Screw Settings

Ground Configuration

Grounded (wye) Ground screw installed (default setting)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

(1) Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002, for example configurations.
(2) Ground screw is factory installed.

(1)

2198-Pxxx DC-bus Power Supply

(2)

Remove ground screw

Install the DC-bus Power Supply

These procedures assume 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 hazard of electrical shock, perform all mounting and wiring of the
Kinetix 5700 drive prior to applying power. Once power is applied, connector terminals can have
voltage present even when not in use.

ATTENTION: Plan the installation of your system so that you can per form 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 any metal debris from falling into it. Metal debris or
other foreign matter can become lodged in the circuitry and result in damage to components.

Mount the DC-bus Power Supply

Observe these clearance requirements when mounting the DC-bus power supply:

• Additional clearance is required for cables and wires or the shared-bus connection

system connected to the top of the drive module.

• Additional clearance is required if other devices are installed above and/or below the

drive and have clearance requirements of their own.

• 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.).

4 Rockwell Automation Publication 2198-IN009C-EN-P - March 2019

Kinetix 5700 DC-bus Power Supply

Clearance right of the
drive is not required.

Clearance left of the

drive is not required.

Kinetix 5700 DC-bus

Power S upply

100 mm (3.94 in.) clearance below
drive for airflow and installation.

40 mm (1.57 in.) clearance above
drive for airflow and installation.

Refer to Product Dimensions

on page 7

for DC-bus power supply dimensions.

MOD

NET

MOD

NET

MOD

NET

Zero-st ack Tab and

Cutout Aligned

Shared-bus connection system is
not shown for clarity.

Minimum Clearance Requirements

MOD

NET

2

1

1

4

I/O

IMPORTANT Mount the drive module in an upright position as shown. Do not mount the drive module on

its side.

The Kinetix 5700 drive system must be spaced by aligning the zero-stack tab and cutout. For
mounting, sizing, and configuring shared-bus configurations, refer to the Kinetix 5700 Servo
Drives User Manual, publication 2198-UM002

Mount the Kinetix 5700 drive module to the cabinet subpanel with M5 (#10-32) steel bolts
torqued to 4.0 N•m (35.4 lb•in), max.

Drill Hole Patterns

.

This section provides hole patterns for Kinetix 5700 drive modules that are mounted in zero­stack (shared-bus) configurations:

• Mount the DC-bus power supply anywhere within the cluster, whatever makes the best
use of panel space. If multiple 2198-P208 power supplies are mounted within the same
cluster, mount them adjacent to each other anywhere within the cluster.

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 5

Kinetix 5700 DC-bus Power Supply

27.5 mm

Module Top

176 mm

Lower Moun ting Hole

345 mm

Lower Mou nting Hole

420 mm

Lower Mou nting Hole

465 mm

Lower Moun ting Hole

Ø 6.0 mm Typical

Ø 6.0 mm Typical

00.0 mm
Upper Mounting Holes

32.0 mm
Module Top, re ference

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 Inverters

Applies to 2198-P141 and 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

• Mount the inverter modules according to power rating (highest to lowest) from left to
right or right to left, depending on where the power supply is mounted, with the highest
rated inverter adjacent to the power supply.

Calculate the left-to-right hole pattern for any Kinetix 5700 drive module configuration by
following these steps.

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 and step 3 for the remaining holes.

Kinetix 5700 Mounting Hole Patterns

6 Rockwell Automation Publication 2198-IN009C-EN-P - March 2019

Kinetix 5700 DC-bus Power Supply

Dimensions are in mm (in.)

2198-P031

DC-bus Power Supply is Shown

When your Kinetix 5700 system configuration includes 2198-S263-ERSx or 2198-S312-ERSx
single-axis inverters, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002,
for those mounting hole patterns.

Also available to assist you with mounting holes is the Kinetix 5700 System Mounting Toolkit,
catalog number 2198-K5700-MOUNTKIT.

Product Dimensions

Refer to the Kinetix Servo Drives Technical Data, publication KNX-TD003, for product
dimensions of all Kinetix 5700 drive modules.

A

MOD

NET

2

1

1

4

I/O

DC-bus Power Supply
Cat. No.

2198-P031

2198-P070

2198-P141

2198-P208

12.0

(0.47)

C

B

A

mm (in.)

B

mm (in.)

55 (2.17) 300 (11.8) 358 (14.1)

85 (3.35) 375 (14.8) 433 (17.0)

D

C

mm (in.)

D

mm (in.)

252 (9.9)

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 7

Kinetix 5700 DC-bus Power Supply

5

2

10

3

7

6

9

4

4

11

15

14

8

12

1

13

2

1

1

4

I/O

DC+

SH

DC+

DC–

24V–

24V+

L3 L2 L1

16

17

MOD–

NET–

5700

DC-bus Power Supply

(top view)

DC-bus Power Supply

(bottom view)

DC-bus Power Supply
(front view)

Shared-bus 24V Input
Wiring Connector

Connector Data

Use this illustration to identify the DC-bus power supply features and indicators.

DC-bus Power Supply Features and Indicators (2198-P031 power supply is shown)

Item Description Item Description Item Description

1 Digital inputs (IOD) connec tor 7 LCD display 13 Shunt resistor (RC) connector

2 Ethernet (PORT1) RJ45 connector 8 Navigation push buttons 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/c utout 10 Link/Activity statu s 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

8 Rockwell Automation Publication 2198-IN009C-EN-P - March 2019

DC-bus Power Supply Connectors

L3 L2 L1

1
2

EN–

EN+

Designator Description Connector

IPD AC mains input power 4-position plug, terminal screws

DC DC common bus power DC-bus links and end caps

CP 24V control input power 2-position plug, terminal screws

RC Shunt power 2-position plug, terminal screws

IOD Digital inputs 4-position plug, spring terminals

CED Contactor enable 2-position plug, terminal screws

PORT1, PORT2 Ethernet communication ports RJ45 Ethernet

Mains Input Power (IPD) Connector Pinout

IPD Pin Description Signal

Chassis ground

Kinetix 5700 DC-bus Power Supply

L3

L2 L2

L1 L1

Three-phase input power

L3

Shunt Power (RC) Connector Pinout

RC Pin Description Signal

1

2DC+

Shunt connections

SH

Contactor Enable (CED) Connector Pinout

CED Pin Description Signal

EN–

EN+ CONT EN+

Contactor-enable connections

The contactor-enable circuitry includes a relay-driven contact within the 2198-Pxxx DC-bus
power supply. The relay protects the Kinetix 5700 drive system in the event of overloads or other
fault conditions.

An AC three-phase mains contactor must be wired in series between the branch circuit
protection and the DC-bus power supply. In addition, the AC three-phase contactor control
string must be wired in series with the contactor-enable relay at the contactor enable (CED)
connector. Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002
wiring examples.

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 9

CONT EN –

, for

Kinetix 5700 DC-bus Power Supply

2
1

1

8

Standard RJ45

ATTENTION: Wiring the contactor-enable relay is required. To avoid personal injury or damage to
the Kinetix 5700 drive system, wire the contactor-enable relay into your control string so that:

• three -phase power is removed and the DC-bus 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.

Control Input Power (CP) Connector Pinout

CP Pin Description Signal

1 24V power supply, customer-supplied 24V+

2 24V common 24V-

Digital Inputs (IOD) Connector Pinout

IOD Pin Description Signal

1 Digital input #1 IN1

2 I/O common for customer-supplied 24V supply. COM

3 Digital input #2 IN2

4 I/O cable shield termination point. SHLD

Pin 1

Ethernet Communication PORT1 and PORT2 Pinout

Port Pi n Descri ption Signal

1 Transmit port (+) data terminal + TX

2 Transmit port (-) data terminal - TX

3 Receive port (+) data terminal + RX

4– –

5– –

6 Receive port (-) data terminal - RX

7– –

8– –

10 Rockwell Automation Publication 2198-IN009C-EN-P - March 2019

Kinetix 5700 DC-bus Power Supply

L3
L2
L1

L3
L2
L1

Wiring Requirements

Wire must be copper with 75 °C (167 °F) minimum rating. Phasing of mains AC power is
arbitrary and earth ground connection is required for safe and proper operation.

IMPORTANT The National Electrical Code and local electrical codes take precedence over the values and

methods provided.

DC-bus Power Supply Wiring Requirements

DC-bus Power Supply
Cat. No.

2198-P031

2198-P070

2198-P141
2198-P208

2198-Pxxx

(1) Applies to solid wire. If using stranded wire, the maximum wire size is 6 mm2 (10 AWG).

(2) Applies to solid wire. If using stranded wire, the maximum wire size is 6 mm2 (10 AWG). To meet CE requirements above 45 °C (113 °F) for 6 mm2

stranded wires, single-core copper conductors must be used with 90 °C minimum rating.

(3) Shared DC-bus power connections are always made from drive to drive over the bus-bar connection system. These terminals d o not receive dis crete

wires.

(4) This connector uses spring tension to hold wires in place.

Description

Mains input power

PELV/SELV
24V power

(connector plug)

DC Bus power Bus bar

Contactor enable

Shunt resistor

Digital inputs

Connects to Terminals

Pin Si gnal

CP-1
CP-2

EN–
EN+

RC-1
RC-2

IOD-1
IOD-2
IOD-3
IOD-4

24V+
24V–

DC–
DC+

CONT EN –
CONT EN +

SH
DC+

IN1
COM
IN2
SHLD

Wire Size

2

mm

6…10
(10…8)

6…10
(10…8)

10…35
(8…2)

0.5…4
(20…12)

(3)

N/A

0.14…2.5
(26…12)

1.5…6
(16…10)

0.14…1.5
(26…16)

(AWG)

(1)

(2)

Strip
Length

mm (in.)

10.0 (0.39)

20.0 (0.79)

7.0 (0.28)

(3)

N/A

7.0 (0.28)

12.0 (0.47)

10.0 (0.39) N/A

Tor que
Value

N•m (lb•in)

0.5…0.8
(4.4…7.1)

2.5…4.5
(22…40)

0.22…0.25
(1.9…2.2)

N/A

0.4…0.5
(3.5…4.4)

0.5…0.6
(4.5…5.3)

(3)

(4)

ATTENTION: To avoid personal injury and/or equipment damage, observe the following:

• Make sure that installation complies with specifications regarding wire types, conductor sizes,
branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local
codes outline provisions for safely installing electrical equipment.

• Use motor power connectors only for connection purposes. Do not use them to turn the unit on
and off.

• Ground shielded power cables to prevent potentially high voltages on the shield.

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 11

Kinetix 5700 DC-bus Power Supply

MBRK

+

-

Braided Ground Straps
12 mm (0.5 in.) by 0.8 mm (0.03 in.)
Keep straps as short as possible.

4

3

2

1

DC-bus Power Supply
(typical example)

Kinetix 5700 Servo Drives
(typical system)

Ground Your DC-bus Power Supply to the Subpanel

Ground Kinetix 5700 drives and Bulletin 2198 capacitor modules to a bonded-cabinet ground
bus with a braided ground strap. Keep the braided ground strap as short as possible for optimum
bonding.

Connect the Braided Ground Strap

Item Description

1 Ground screw (green) 2.0 N•m (17.5 lb•in), max

2 Braided ground strap (customer supplied)

3 Ground grid or power distribution ground

4 Bonded-cabinet ground bus (customer supplied)

Circuit Breaker/Fuse Specifications

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 that can
deliver up to 200,000 A (fuses) and 65,000 A (circuit breakers).

12 Rockwell Automation Publication 2198-IN009C-EN-P - March 2019

Kinetix 5700 DC-bus Power Supply

Molded Case CB

Cat. No.

Molded Case CB

Cat. No.

(2)

Motor Protection CB

Cat. No.

Motor Protection CB,

Self Protected CMC Cat. No.

(2)

Miniature CB

Cat. No.

While circuit breakers offer some convenience, there are limitations for their use. Circuit breakers do not handle high-current inrush as well as fuses.

Miniature CB

Cat. No.

(1)

LPJ-15SP (15A) 1489-M3D250 140M-D8E-C25 140G-G 6C3-C25

Cat. No.

UL/CSA Circuit-protection Specifications

Bussmann Fuses

Input Voltage

DC-bus Power Supply

(three-phase) nom

Cat. No.

324…528V AC

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

required when AC line fuses are used for branch circuit protection.

(1) For applications requiring CSA cer tification, fuses (Bussmann catalog number 170M1760) must be added to the DC link between the two drive clusters when circuit breakers are used for bra nch circuit protection. The DC bus fuses are not

(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).

DIN gG Fuses

Amps, max

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

Input Voltage

(three-phase) nom

DC-bus Power Supply

Make sure that the selected components are properly coordinated and meet acceptable codes, which includes requirements for branch circuit protection.

Evaluation of the short-circuit available current is critical and must be kept below the short-circuit current rating of the circuit breaker.

IEC (non-UL/CSA) Circuit-protection Specifications

Cat. No.

324…528V AC

2198-P031

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

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

2198-P208 110 N/A N/A 140MG-H8 E-D10 1 40G-G6C3-D12

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 13

Kinetix 5700 DC-bus Power Supply

Specifications

Attribute 2198-P031 2198-P070 2198-P141 2198-P208

Surrounding air temperature

Operating
Storage

Weight, kg (lb) approx 4.33 (9.55) 4.42 (9.74) 6.91 (15.2) 7.04 (15.5)

Short-circuit current rating 200,000 A rms symmetrical

Branch-circuit short-circuit
protection

• Kinetix 5700 drives produce leakage current in the protective-earthing conductor that exceeds 3.5 mA AC and/
or 10 mA DC. The minimum size of the protective-earthing (ground) conductor used in the application must

Leakage
current

comply with local safety regulations for high-protective-earthing conduc tor current equipment.

• Kinetix 5700 drives produce DC current in the protective-earthing conductor and can reduce the ability of a
residual current device (RCD) or residual current monitor (RCM) of type A or AC to provide protection for the
drive module and other equipment in the installation.

0…50 °C (32…122 °F)

-40…70 °C (-40…158 °F)

Integral solid-state short circuit protection does not provide branch circuit protection. Branch
circuit protection must be provided in accordance with the Nation al Electric Code (NEC) and any
additional local codes.

Additional Resources

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

Resource Description

Kinetix Servo Drives Specifications Technical Data,
publication KNX-TD003

Kinetix Motion Accessories Specifications Technical Data,
publication KNX-TD004

Kinetix 5700 Servo Drives User Manual, publication 2198-UM002

AC Line Filter Installation Instructions, publication 2198-IN003

Kinetix 5700 Passive Shunt Modules Installation Instructions,
publication 2198-IN011

Product Certifications website, rok.auto/certifications

Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1

Provides product specifications for the Kinetix Integrated
Motion over 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, low-profile connector kits, drive power
components, and other servo drive accessory items.

Provides information on how to install, configure, startup,
and troubleshoot your Kinetix 5700 servo drive system.

Provides information on how to install and wire the AC line
filter for Kinetix 5500 and Kinetix 5700 servo drives.

Provides information on how to install and wire Kinetix 5700
external passive shunt modules.

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

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-IN009C-EN-P - March 2019

Notes:

Kinetix 5700 DC-bus Power Supply

Rockwell Automation Publication 2198-IN009C-EN-P - March 2019 15

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*PN-538011*

Publication 2198-IN009C-EN-P - March 2019

Supersedes Publication 2198-I N009B-EN-P - June 2017 Copyright © 2019 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

PN-538011

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