Kinetix 5700 Servo Drives User Manual

Rockwell Automation

Kinetix 5700 Servo Drives User Manual - Literature Library ...

480 pages · 60 MB — Rockwell Automation Publication 2198-UM002K-EN-P - October 2020. Kinetix 5700 Servo Drives User Manual. Important User Information. Read this document ...

This manual links to Knowledgebase Technote: Kinetix 5700 Servo Drive ... To comply with UL and CE requirements, the Kinetix 5700 drive.

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2198-um002 -en-p

This manual links to Knowledgebase Technote: Kinetix 5700 Servo Drive Fault Codes; download the spreadsheet for offline access.

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

User Manual

Original Instructions

Kinetix 5700 Servo Drives User Manual
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).

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Table of Contents

Start
Plan the Kinetix 5700 Drive System Installation

Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Access Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Download Firmware, AOP, EDS, and Other Files. . . . . . . . . . . . . . . . 12 Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CIP Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Kinetix 5700 Servo Drives Series Change. . . . . . . . . . . . . . . . . . . . . . . . 16 About the Kinetix 5700 Servo Drive System . . . . . . . . . . . . . . . . . . . . . 16 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 8720MC-RPS Power Supply Input Power Configuration. . . . . . . . . 27 Motor and Auxiliary Feedback Configurations . . . . . . . . . . . . . . . . . . 28 Typical Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . 29 Linear Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Ring Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Star Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Functional Safety Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hardwired Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Integrated Safety Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Safe Stop and Safe Monitor Configurations. . . . . . . . . . . . . . . . . . 35 Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 2
System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 DC-bus Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 AC Line Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 AC Line Impedance Considerations . . . . . . . . . . . . . . . . . . . . . . . . 43 Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 24V Control Power Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Contactor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Passive Shunt Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Active Shunt Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 54

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Table of Contents

Mount the Kinetix 5700 Drive System
Connector Data and Feature Descriptions

Multi-axis Shared DC-Bus Configurations. . . . . . . . . . . . . . . . . . . 56 Accessory Module Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DC-bus Power Supply Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Regenerative Bus Supply Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 8720MC-RPS or Other Regenerative Power Supply . . . . . . . . . . 62 Accessory Module Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Electrical Noise Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 HF Bond for Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 HF Bond for Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Establish Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Cable Categories for Kinetix 5700 Systems . . . . . . . . . . . . . . . . . . 70 Noise Reduction Guidelines for Drive System Accessories. . . . . 71
Chapter 3
Determine Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Mount Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Zero-stack Tab and Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Install Shared-bus Connection Systems . . . . . . . . . . . . . . . . . . . . . . . . . 82
DC-bus Connection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 24V Input Power Connection System . . . . . . . . . . . . . . . . . . . . . . . 83 Drill-hole Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Drill-hole Pattern Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Drill-hole Patterns by Using the System Mounting Toolkit . . . 88 Mount Your Kinetix 5700 Drive Modules. . . . . . . . . . . . . . . . . . . . . . . 88
Chapter 4
Kinetix 5700 Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Safe Torque-off Connector Pinout. . . . . . . . . . . . . . . . . . . . . . . . . 100 Input Power Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 DC Bus and Shunt Resistor Connector Pinouts . . . . . . . . . . . . . 101 Digital Inputs Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . 101 Ethernet Communication Connector Pinout . . . . . . . . . . . . . . . 103 Motor Power, Brake, and Feedback Connector Pinouts . . . . . . 103 Motor Feedback Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . 104 Universal Feedback Connector Pinouts . . . . . . . . . . . . . . . . . . . . 105 Accessory Module Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Understand Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . 106 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Ethernet Communication Specifications . . . . . . . . . . . . . . . . . . . 107 Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Converter OK Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Motor Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Encoder Feedback Supported on the DSL Feedback Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Table of Contents

Encoder Feedback Supported on the UFB Feedback Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Encoder Phasing Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Functional Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Hardwired STO Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Integrated Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Connect the Kinetix 5700 Drive System

Chapter 5
Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . 122
Input Power Configurations for Kinetix 5700 Power Supplies . . . 123 DC-bus Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Regenerative Bus Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Ground Screw/Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Kinetix 5700 Drive System Power Supply. . . . . . . . . . . . . . . . . . . 129 Kinetix 5700 Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Kinetix 5700 iTRAK Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 131
Remove/Install the Ground Screw/Jumper . . . . . . . . . . . . . . . . . . . . . 131 Ground the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Ground the System Subpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Wire the Power Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Wire the 24V Control Power Input Connector . . . . . . . . . . . . . 140 Wire the Input Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Wire the Contactor Enable Connector . . . . . . . . . . . . . . . . . . . . . 143 Wire the Digital Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 2198-xxxx-ERS3 (series A) Connector Plugs . . . . . . . . . . . . . . . . 144 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Connector Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Wire the Safe Torque-off Connector . . . . . . . . . . . . . . . . . . . . . . . 145 Wire the Digital Inputs Connector . . . . . . . . . . . . . . . . . . . . . . . . 146 Wire Motor Power and Brake Connectors . . . . . . . . . . . . . . . . . . . . . 147 Maximum Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Connect Single Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Apply the Single Motor Cable Shield Clamp . . . . . . . . . . . . . . . . 156 Connect Power/Brake and Feedback Cables . . . . . . . . . . . . . . . . . . . . 158 Motor Power and Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Motor Power/Brake Cable Series Change. . . . . . . . . . . . . . . . . . . 159 Dual-axis Inverter Power/Brake Cable Installation . . . . . . . . . . 160 Single-axis Inverter Power/Brake Cable Installation . . . . . . . . . 163 Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Customer-supplied Motor Power Cables . . . . . . . . . . . . . . . . . . . . . . . 173

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Table of Contents

Configure and Start the Kinetix 5700 Drive System

Accessory Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 External Passive-shunt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 External Active-shunt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
DC-bus Power Supply Active Shunt Connections . . . . . . . . . . . 178 Regenerative Bus Supply Active Shunt Connections . . . . . . . . . 178 Wire the External DC-bus Connections . . . . . . . . . . . . . . . . . . . . 179 Kinetix VPC Motors and the Extended Speed Feature . . . . . . . 180 Considerations for Powerohm Shunt Installation . . . . . . . . . . . 180 Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Chapter 6
Understand the Kinetix 5700 Display. . . . . . . . . . . . . . . . . . . . . . . . . . 184 Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Set the Network Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Studio 5000 Logix Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Version History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Install the Kinetix 5700 Add-On Profile. . . . . . . . . . . . . . . . . . . . 195
Configure the Logix 5000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Configure the Kinetix 5700 Drive Modules . . . . . . . . . . . . . . . . . . . . 199
Configure the DC-bus Power Supply. . . . . . . . . . . . . . . . . . . . . . . 199 Configure the Regenerative Bus Supply. . . . . . . . . . . . . . . . . . . . . 203 Configure the iTRAK Power Supply . . . . . . . . . . . . . . . . . . . . . . . 207 Configure the Inverter Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Continue Inverter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Configure Regenerative Bus Supply Axis Properties . . . . . . . . . . . . . 225 Configure Vertical Load Control Axis Properties . . . . . . . . . . . . . . . 230 Configure Feedback-only Axis Properties . . . . . . . . . . . . . . . . . . . . . . 231 Configure Induction-motor Frequency-control Axis Properties . . 233 General and Motor Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Basic Volts/Hertz Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Sensorless Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Fan/Pump Volts/Hertz Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Configure IPM Motor Closed-loop Control Axis Properties . . . . . 242 Configure SPM Motor Closed-loop Control Axis Properties. . . . . 246 Configure Induction-motor Closed-loop Control Axis Properties 251 Configure Feedback Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Configure Module Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Apply Power to the Kinetix 5700 Drive System . . . . . . . . . . . . . . . . . 264 Understand Bus-sharing Group Configuration . . . . . . . . . . . . . . . . . 265 Bus-sharing Group Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Configure Bus-sharing Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Table of Contents

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Test the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Troubleshoot the Kinetix 5700 Drive System

Chapter 7
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Display Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Fault Code Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 SAFE FLT Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Kinetix 5700 Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Kinetix 5700 Accessory Module Status Indicators . . . . . . . . . . . 277 Axis Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Regenerative Bus Supply Troubleshooting. . . . . . . . . . . . . . . . . . . . . . 279 Logix 5000 Controller and Drive Module Behavior . . . . . . . . . . . . . 281 DC-bus Power Supply Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Regenerative Bus Supply Behavior . . . . . . . . . . . . . . . . . . . . . . . . . 284 iTRAK Power Supply Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Inverter Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Remove and Replace Drive Modules

Chapter 8
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Remove and Replace Kinetix 5700 Drive Modules . . . . . . . . . . . . . . 294
Remove Power and All Connections . . . . . . . . . . . . . . . . . . . . . . . 294 Remove the Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Replace the Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Start and Configure the Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . 300 Replacing 2198-xxxx-ERS3 (series A) Drives with Series B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Kinetix 5700 Safe Torque-off Function

Chapter 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Average Frequency of a Dangerous Failure . . . . . . . . . . . . . . . . . . 305 Safe Torque-off Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Out of Box State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Safe Torque-off Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Hardwired Safe Torque-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Compatible Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Troubleshoot the Safe Torque-off Function . . . . . . . . . . . . . . . . 314 Safe Torque-off Connector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Wire the Safe Torque-off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Safe Torque-off Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . 319

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Table of Contents

Safe Torque-off Feature Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Cascade the Safe Torque-off Signal. . . . . . . . . . . . . . . . . . . . . . . . . 320 Hardwired Safe Torque-off Electrical Specifications . . . . . . . . . 322 Integrated Safe Torque-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Compatible Safety Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Safe Torque-off Assembly Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 STO Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Troubleshoot the Safe Torque-off Function . . . . . . . . . . . . . . . . 328 Understand Integrated Safety Drive Replacement . . . . . . . . . . . 329 Replace an Integrated Safety Drive in a GuardLogix System . . 330 Motion Direct Commands in Motion Control Systems. . . . . . 331 Integrated Safe Torque-off Specifications . . . . . . . . . . . . . . . . . . . 338

Interconnect Diagrams

Appendix A
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

Upgrade the Drive Firmware

Appendix B
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 Inhibit the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Upgrade Your Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 Use ControlFLASH Plus Software to Upgrade Your Drive Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Use ControlFLASH Software to Upgrade Your Drive Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

Size Multi-axis Shared-bus Configurations

Appendix C
Shared DC-bus Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 Shared DC-bus Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395 General Sizing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
System Sizing Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 Select Drive/Motor Combinations. . . . . . . . . . . . . . . . . . . . . . . . . 398 Select the Power Supply and Define the DC-bus Groups . . . . . 398 Calculate System and External-bus Capacitance . . . . . . . . . . . . . 398 Calculate the Total Motor Power Cable Length. . . . . . . . . . . . . 399

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Table of Contents

Calculate 24V DC Control Power Current Demand . . . . . . . . 400 24V DC Voltage Drop Calculation Example. . . . . . . . . . . . . . . . 401 System Sizing Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 System Sizing Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

Appendix D
DC-bus Power Supply Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 406 Regenerative Bus Supply Configurations . . . . . . . . . . . . . . . . . . . . . . . 409 Third-party Motor Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
DC-bus Power Supply Configurations . . . . . . . . . . . . . . . . . . . . . 410 Regenerative Bus Supply Configurations . . . . . . . . . . . . . . . . . . . 412

Regenerative Bus Supply Sequence Operation

Appendix E
Converter Startup Method - Enable Request . . . . . . . . . . . . . . . . . . . 414 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 Start Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 Stopped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Converter Startup Method - Automatic . . . . . . . . . . . . . . . . . . . . . . . . 417 Sequence Operation of Discharging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

Motor Control Feature Support

Appendix F
Frequency Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Basic Volts/Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 Basic Volts/Hertz for Fan/Pump Applications . . . . . . . . . . . . . . 422 Sensorless Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Current Limiting for Frequency Control . . . . . . . . . . . . . . . . . . . . . . . 424 The Effects of Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 Enable the Current Limiting Feature . . . . . . . . . . . . . . . . . . . . . . . 426 Set the CurrentVectorLimit Attribute Value. . . . . . . . . . . . . . . . 426
Stability Control for Frequency Control . . . . . . . . . . . . . . . . . . . . . . . 427 Enable the Stability Control Feature . . . . . . . . . . . . . . . . . . . . . . . 428
Skip Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 Multiple Skip Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Flux Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431 Flux Up Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432 Configure the Flux Up Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . 433
Current Regulator Loop Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 Motor Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Motor Tests and Autotune Procedure . . . . . . . . . . . . . . . . . . . . . . 436 Motor Analyzer Category Troubleshooting . . . . . . . . . . . . . . . . . 437 Selection of Motor Thermal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Generic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Thermally Characterized Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 441

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Table of Contents
History of Changes

Speed Limited Adjustable Torque (SLAT) . . . . . . . . . . . . . . . . . . . . . 442 Motion Polarity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 SLAT Min Speed/Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 SLAT Max Speed/Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 SLAT Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444 Configure the Axis for SLAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 Motion Drive Start (MDS) Instruction. . . . . . . . . . . . . . . . . . . . . 448
Motor Overload Retention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Phase-loss Detection Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 Phase-loss Detection Configuration . . . . . . . . . . . . . . . . . . . . . . . . 455 Phase Loss Detection Current Example . . . . . . . . . . . . . . . . . . . . 456 Velocity Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Velocity Droop Attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Velocity Droop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 Commutation Self-sensing Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 Commutation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Adaptive Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Virtual Torque Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 Field Weakening Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 Extended Speed Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 Configure Extended Speed Operation . . . . . . . . . . . . . . . . . . . . . . 463
Appendix G
History of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

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 5000TM 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 iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, or iTRAK 5730 System User Manual, publication 2198T-UM003.
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/IPTM communication module or controller.

Summary of Changes

This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes.

Topic
Updated the DC-bus power supply input-power range and shared DC power range to include 240V AC (nom) operation (firmware revision 13.001 or later).
Added drive/motor compatibility for Kinetix VPL, VPF, and VPH 200V-class servo motors and Kinetix 5700 drives with 240V AC (nom) input power. Added drive/motor compatibility for Kinetix MPL, MPM, MPF, and MPS 200V-class servo motors and Kinetix 5700 drives with 240V AC (nom) input power. Added Bulletin 842E-CM and 843ES EtherNet/IP absolute external encoders.
Updated the iTRAK ground-screw setting stating that only the 2198-Pxxx DC-bus power supply is compatible for use with the iTRAK power supply.
Updated Tune the Axes with load observer and adaptive tuning (tuningless) features. Added FLT M05 - FDBK Battery Loss and FLT M06 - FDBK Battery Low fault codes to the Kinetix 5700 inverter module behavior. Added ControlFLASH PlusTM software as an option for firmware upgrades. Added maximum drive-to-motor cable lengths for 240V AC drive operation to Appendix D. Added the Commutation Self-sensing Startup feature to Appendix F. Added the Virtual Torque Sensor feature to Appendix F. Added the History of Changes appendix.

Page 36 and throughout Throughout Throughout 116, 117 131 and Throughout 271 292 381 408 458 461 465

Access Fault Codes

For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes. You can download the spreadsheet from this public article.
You will be asked to log in to your Rockwell Automation web account or create an account if you do not have one. You do not need a support contract to access this article.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Preface

Download Firmware, AOP, EDS, and Other Files

Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes from the Product Compatibility and Download Center at rok.auto/pcdc.

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

CIP Security
12

CIP SecurityTM is a standard, open-source communication method that helps to provide a secure data transport across an EtherNet/IP network. It lets CIP-connected devices authenticate each other before transmitting and receiving data.
CIP Security uses the following security properties to help devices protect themselves from malicious communication:
· Device Identity and Authentication · Data Integrity and Authentication · Data Confidentiality
Rockwell Automation uses the following products to implement CIP Security: · FactoryTalk® Services Platform, version 6.11 or later, with the following components enabled: FactoryTalk Policy Manager FactoryTalk System Services · FactoryTalk Linx, version 6.11 or later · Studio 5000® Design Environment, version 32.00.00 or later · CIP Security-enabled Rockwell Automation® products, for example, the product described in this publication
For more information on CIP Security, including which products support CIP Security, see the CIP Security with Rockwell Automation Products Application Technique, publication SECURE-AT001.
Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Preface

Additional Resources

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

Table 1 - Additional Resources

Resource

Description

Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001

Provides product specifications for Kinetix VPL, VPC, VPF, VPH, and VPS motors, Kinetix MPL, MPM, MPF, and MPS motors, and Kinetix HPK rotary motors.

Kinetix Linear Motion Specifications Technical Data, publication KNX-TD002

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

Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003

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.

Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004

Provides product specifications for 2090-Series motor and interface cables, low-profile connector kits, drive power components, and other servo drive accessory items.

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

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

iTRAK System User Manual, publication 2198T-UM001 iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002 iTRAK 5730 System User Manual, publication 2198T-UM003

Provides information on how to install the Kinetix 5700 iTRAK power supply with an iTRAK system and program the iTRAK system.

1321 Power Conditioning Products Technical Data, publication 1321-TD001

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

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

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

Servo Drive Installation Best Practices Application Technique, publication MOTION-AT004

Best practice examples to help reduce the number of potential noise or electromagnetic interference (EMI) sources in your system and to make sure that the noise sensitive components are not affected by the remaining noise.

Kinetix 5700 Drive Systems Design Guide, publication KNX-RM010

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.

Motor Nameplate Datasheet Entry for Custom Motor Applications Application Provides information on the use of nameplate data entry for custom induction motors and

Technique, publication 2198-AT002

permanent-magnet motors that are used in applications with Kinetix 5700 servo drives.

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

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

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 Provides information on configuring and troubleshooting your ControlLogix® and CompactLogixTM

User Manual, publication MOTION-UM003

EtherNet/IP network modules.

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

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

GuardLogix 5570 Controllers User Manual, publication 1756-UM022 GuardLogix 5580 Controllers User Manual, publication 1756-UM543

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

Compact GuardLogix 5370 Controllers User Manual, publication 1769-UM022 Provides information on how to install, configure, program, and use CompactLogix and Compact Compact GuardLogix 5380 Controllers User Manual, publication 5069-UM001 GuardLogix controllers.

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

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.

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

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

EtherNet/IP Network Devices User Manual, ENET-UM006

Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP network.

Ethernet Reference Manual, ENET-RM002

Describes basic Ethernet concepts, infrastructure components, and infrastructure features.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Preface

Table 1 - Additional Resources (continued) Resource CIP Security with Rockwell Automation Products Application Technique, publication SECURE-AT001.
System Security Design Guidelines Reference Manual, SECURE-RM001
ControlFLASH User Manual, publication 1756-UM105 ControlFLASH Plus Quick Start Guide, publication CFP-QS001
Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control, publication SGI-1.1
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Product Certifications website, rok.auto/certifications.

Description
Provides information on CIP Security, including which Rockwell Automation products support CIP Security.
Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access, and dispose of equipment.
Provides guidance on how to use ControlFLASHTM or ControlFLASH PlusTM software to upgrade drive firmware. Refer to your product release notes to determine whether it supports firmware upgrades by using ControlFLASH or ControlFLASH Plus software.
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solid-state components.
Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at rok.auto/literature.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

1 Chapter

Start

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

Topic

Page

Kinetix 5700 Servo Drives Series Change

About the Kinetix 5700 Servo Drive System

DC-bus Power Supply Input Power Configurations

Regenerative Bus Supply Input Power Configurations

8720MC-RPS Power Supply Input Power Configuration

Motor and Auxiliary Feedback Configurations

Typical Communication Configurations

Functional Safety Configurations

Catalog Number Explanation

Agency Compliance

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

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 2 - Integrated Functional Safety Support

Integrated Safety Over the EtherNet/IPTM Network Drive-based stopping functions
Controller-based stopping functions
Controller-based monitoring functions

Safety Function
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

Single-axis Inverters Cat. No.
2198-Sxxx-ERS3 (series B) 2198-Sxxx-ERS4

Minimum Controller (1) Required

2198-Dxxx-ERS4

2198-Sxxx-ERS4

· GuardLogix® 5580 · CompactLogixTM 5380

Safety feedback function Integrated STO mode

Safety Feedback Interface (SFX) Safe Torque-off (STO)

2198-Dxxx-ERS4 2198-Dxxx-ERS3

2198-Sxxx-ERS4 2198-Sxxx-ERS3

· ControlLogix® 5570 · CompactLogix 5370

(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.

About the Kinetix 5700 Servo Drive System
Table 3 - Kinetix 5700 Drive System Overview

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.

Drive System Component

Cat. No.

Kinetix 5700 DC-bus Power Supply

2198-Pxxx

Kinetix 5700 Regenerative Bus Supply

2198-RPxxx

Kinetix 5700 Singleaxis Servo Drives

2198-Sxxx-ERS3 2198-Sxxx-ERS4

Description
Converter power supply with 200V and 400V-class (three-phase) AC input. Provides output current in a range of 10.5...69.2 A. 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 Hiperface DSL, Hiperface, and 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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1

Table 3 - Kinetix 5700 Drive System Overview (continued)

Drive System Component

Cat. No.

Kinetix 5700 Dualaxis Servo Drives

2198-Dxxx-ERS3 2198-Dxxx-ERS4

Kinetix 5700 iTRAK Power Supply

2198T-W25K-ER

Kinetix 5700 Capacitor Module

2198-CAPMOD-2240

Kinetix 5700 Extension Module

2198-CAPMOD-DCBUS-IO

Kinetix 5700 DC-bus Conditioner Module

2198-DCBUSCOND-RP312

8720MC Regenerative Power Supply

8720MC-RPSxxx

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

Shared-bus Connector Kits

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

2198-BARCON-xxDC200 2198-KITCON-ENDCAP200

DSL Feedback Connector Kit

2198-KITCON-DSL

Universal Feedback Connector Kit

2198-K57CK-D15M

Hiperface to DSL Converter Kit
Kinetix 5700 System Mounting Toolkit
Kinetix 5700 Cable Clamp Spacer Kit

2198-H2DCK (series B or later) 2198-K5700-MOUNTKIT
2198-K5700-CLAMPSPACER

Encoder Output Module

2198-ABQE

Logix 5000TM Controller Platform
Studio 5000® Environment

Bulletin 1769 Bulletin 5069
1756-EN2T module 1756-EN2TR module 1756-EN3TR module
N/A

Description
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 options, PL e and SIL 3 safety ratings, and support for Hiperface DSL, Hiperface, and EnDat encoder feedback. 2198-Dxxx-ERS3 (series B) drives also support Timed SS1 drive-based stopping functions.
Dual-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.
DC-DC converter that generates DC-bus power for iTRAK® systems.
Use for energy storage, external active-shunt connection, 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 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 Kinetix VPL, VPC-Q, VPH, VPF, VPS 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 Kinetix MPL, MPM, MPF, MPS, Kinetix HPK rotary motors, Kinetix MPAS, MPMA, MPAR, MPAI linear actuators, LDAT-Series linear thrusters, and LDC-SeriesTM linear motors.
Provides Hiperface-to-DSL feedback conversion for use with compatible motors and actuators.
Use to position the drive modules and identify drill-holes for mounting your Kinetix 5700 servo drive system.
Replacement cable clamp spacers for 2198-Dxxx-ERSx dual-axis inverters.
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, CompactLogix 5380, and CompactLogix 5480 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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start

Table 3 - Kinetix 5700 Drive System Overview (continued)

Drive System Component

Cat. No.

Description

Kinetix VP motors Rotary Servo Motors Kinetix MP motors

· Compatible 400V-class motors include Kinetix VPL, VPC, VPF, VPH, and VPS servo motors. · Compatible 200V-class motors include Kinetix VPL, VPF, and VPH servo motors.
Compatible 200V and 400V-class motors include Kinetix MPL, MPM, MPF, and MPS servo motors.

Kinetix HPK motors

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

Linear Actuators

Kinetix MPAS, VPAR, MPAR, and MPAI actuators LDAT-Series

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

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.

2090-CSxM1DE-xxxxxx

Bulletin 2090 single cable for motor power, feedback, and optional 24V DC brake power with Kinetix VPL, VPC-Q, VPH, VPF, VPS motors. Feedback conductors are wired to the 2198-KITCON-DSL feedback connector kit.

2090-CSxM1DG-xxxxxx

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

Cables

2090-CFBM7DF-CEAxxx 2090-CPxM7DF-xxAxxx

Bulletin 2090 motor feedback cables for Kinetix MPL, MPM, MPF, and MPS rotary motors and Kinetix MPAS, MPMA, MPAR, MPAI linear actuators with Hiperface encoders.
Bulletin 2090 motor power/brake cables for Kinetix MPL, MPM, MPF, and MPS rotary motors and Kinetix MPAS, MPMA, MPAR, MPAI linear actuators.

2090-XXNFMF-Sxx 2090-CFBM7DF-CDAFxx

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

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.

AC Line Filters

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

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.

2198-DBR20-F, 2198-DBR40-F, Bulletin 2198 three-phase AC line filters are required to meet CE and available for use with DC-bus power supplies and 2198-DBR90-F, 2198-DBR200-F regenerative bus supplies. Select 2198-DBRxx-F filters for all new systems and remove all inverter ground jumpers.

Line Reactors

1321-3Rxx-x

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.

AC Contactor

100-Cxxxxx 100-Dxxxxx 100-Exxxxx

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.

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

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

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

N/A

External active shunts from Rockwell Automation EncompassTM 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 178 for catalog numbers.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1

DC-bus Power Supply Input Power Configurations

A single 2198-Pxxx DC-bus (converter) power supply can supply the Kinetix 5700 drive system with 276...747V shared DC-bus power. 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

Bulletin 2198

Shunt Module

DC+

(optional component)

Kinetix 5700 Servo Drive System (top view)

Shared DC-bus Power

1606-XLxxx

24V DC Control, Digital Inputs,

Allen-Bradley 1606-XL

Power Supply

and Motor Brake Power (customer-supplied)

19 8 16

SB+/NC S1A SCA S2A SBNC NC
NC

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

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

Input
AC Input Power

DC-bus Single-axis Power Supply Inverter

Kinetix 5700 Servo Drive System

(front view)

MOD NET

Dual-axis Inverters

MOD NET

Capacitor Module
MOD DC BUS

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

Converter Digital Inputs 2
1 1 4
Magnetic Contactor (M1) Control String I/O
195...528V AC Three-phase Input Power
Line Disconnect Device
Circuit Protection

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

MODULE STATUS

Inverter Digital Inputs

D+ D-
MF

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

Magnetic (M1) Contactor

2198-DBRxx-F AC Line Filter (required for CE)

Bonded Cabinet Ground Bus

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start

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.

Bulletin 2198 Shunt Module (optional component)

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

DC+

Kinetix 5700 Servo Drive System (top view)

1606-XLxxx 24V DC Control Power Allen-Bradley
1606-XL
Power Supply
(customer-supplied)
Input
AC Input Power

2198-P208 DC-bus Power Supplies

Kinetix 5700 Servo Drive System

(front view)

MOD NET

195...528V AC

Three-phase

Input Power

Magnetic Contactor

4 I/O

Line Disconnect

(M1) Control String

Device

Circuit Protection

Magnetic (M1) Contactor

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Single-axis Inverter

MOD NET

I/O

MBRK
+

W V

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

2198-DBR200-F AC Line Filter
(required for CE)

Circuit Protection

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

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

Capacitor Dual-axis Inverters Module

MOD NET

MOD DC BUS

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

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

MODULE STATUS

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

Bonded Cabinet Ground Bus

1321-3R80-B Line Reactors (required components)
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-UM002K-EN-P - October 2020

Start Chapter 1

Extended DC-bus Configuration Example

In this example, two drive clusters in the same cabinet are connected by the same 276...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 on page 57 for more information on the when accessory modules are required.

Figure 3 - Extended DC-bus Installation

Kinetix 5700 Extended Servo Drives Cluster 2 (front view)

Extension Capacitor Module Module

Dual-axis Inverters

Shared DC-bus and

MOD DC BUS

MOD NET

24V DC Control Power

DC-bus Extension

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

MODULE STATUS

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+ D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

195...528V AC Three-phase Input Power
Line Disconnect Device
Circuit Protection
Magnetic (M1) Contactor

Bulletin 2198 Shared-bus Connection System
(24V shared-bus connection system is optional)
Magnetic Contactor (M1) Control String
Kinetix 5700 Servo Drives Cluster 1 (front view)

2198-P208 DC-bus Power Supplies

MOD NET

2
1 1 4
I/O

Single-axis Dual-axis Capacitor Extension Inverter Inverters Module Module

MOD NET

MOD DC BUS

DC-bus Extension

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

MODULE STATUS

D+ D-
MF

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

ATTENTION: 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.

2198-DBR200-F AC Line Filter
(required for CE)

1321-3R80-B

Circuit Protection

Line Reactors (required components)

Bonded Cabinet Ground Bus

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-UM002K-EN-P - October 2020

Chapter 1 Start

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 36 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

Bulletin 2198 SH
Shunt Module

(optional component)

DC+

Kinetix 5700 iTRAK System (top view)

Shared DC-bus Power

1606-XLxxx

24V DC Control, Digital Inputs, Allen-Bradley

and iTRAK Motor Module Control Power

1606-XL
Power Supply

(customer-supplied)

Input

AC Input Power

DC-bus

iTRAK

Power Supply Power Supply

Kinetix 5700 iTRAK System

MOD

NET

(front view)

Shared 24V Control Power (1) (24V shared-bus connection system is optional)

iTRAK Power Supply
MOD NET

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

Converter Digital Inputs 2

324...528V AC Three-phase Input Power

Magnetic Contactor

4 I/O

(M1) Control String

Line Disconnect Device

2 1

I/O

iPS RDY
+

2 1

I/O

iPS RDY
+

iTRAK Power Supply Digital Inputs

Circuit Protection
Magnetic (M1) Contactor

2198-DBRxx-F AC Line Filter (can be required for CE)

Bonded Cabinet Ground Bus

2198T-CHBFLS8 Motor Power
Cables

iTRAK Motor Modules iTRAK Motor Modules

(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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1

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 57 for more information on accessory module requirements.

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

Active Shunt (optional component)

See External Active-shunt Connections

DC+

on page 178 for more information.

1606-XLxxx
24V DC Control, Digital Inputs, and Allen-Bradley 1606-XL Power Supply
Motor Brake Power (customer-supplied)

19 8 16

SB+/NC S1A SCA S2A SBNC NC
NC

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Input
AC Input Power

Single-axis Regenerative Bus Supply (1) Inverter

Kinetix 5700 Servo Drive System (front view)

MOD NET

Dual-axis Inverters

MOD NET

Kinetix 5700 Servo Drive System (top view)
Shared DC-bus Power Shared 24V Control Power (24V shared-bus connection system is optional)
Shared-bus connection system for DC-bus and 24V DC control power.
MOD DC BUS

Converter Digital Inputs
Magnetic Contactor (M1) Control String
324...506V AC Three-phase Input Power
Line Disconnect Device

I/O

OK+ OK EN EN+

UFB

D+ D-
MF

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

MODULE STATUS

Inverter Digital Inputs

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

DC-bus Conditioner Module

MBRK
+

Circuit Protection

Magnetic (M1) Contactor

2198-DBRxx-F AC Line Filter (required for CE)

Bonded Cabinet Ground Bus

(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-UM002K-EN-P - October 2020

Chapter 1 Start

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 57 for more information on accessory module requirements.
Figure 6 - Typical Shared DC-bus Installation (mounted right to left)
Kinetix 5700 Servo Drive System (top view)

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Shared 24V Control Power

Shared DC-bus Power
24V DC Control Power Connector Plug

1606-XLxxx 24V DC Control Power Allen-Bradley
1606-XL
Power Supply
(customer-supplied)
Input
AC Input Power

Dual-axis Inverters

Single-axis Inverter

MOD DC BUS

MOD NET

I/O-A

I/O-B

I/O-A

I/O-B

I/O

MODULE STATUS

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

DC-bus Conditioner Module

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

Regenerative Bus Supply (1)

MOD NET

I/O

Magnetic Contactor (M1) Control String

Kinetix 5700 Servo Drive System (front view)

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

L1 L2 L3
21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Bonded Cabinet Ground Bus
1321-3Rxx-x Line Reactor (recommended)

2198-DBRxx-F AC Line Filter (required for CE)

324...506V AC Three-phase Input Power
Line Disconnect Device
Circuit Protection

Magnetic (M1) Contactor

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1

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

Dual-axis Regenerative Bus Supply Inverter

DC-bus Power Dual-axis Supply Inverter

Kinetix 5700 Servo Drive Systems (front view)
Magnetic Contactor (M1) Control String

MOD NET

I/O

MOD NET

I/O-A

I/O-B

OK+ OK EN EN+

10 5

UFB-A

UFB-B

Additional Inverters
M1 Control String

MOD NET

I/O

MOD NET

I/O-A

I/O-B

OK+ OK EN EN+

10 5

UFB-A

UFB-B

Additional 2

Inverters

1 1

4
M1 Control I/O

String

2 1

I/O-A

I/O-B

UFB-A

UFB-B

10 5

Additional Inverters

324...506V AC Three-phase Input Power
Line Disconnect Device
Circuit Protection

D+

D-

MF-A

MF-B

Circuit Protection

Bulletin 1321 Line Reactors
2198-DBRxx-F AC Line Filter (required for CE)

2198-DBRxx-F AC Line Filter (required for CE)

2198-DBRxx-F AC Line Filter (required for CE)
Magnetic (M1) Contactors

Bonded Cabinet Ground Bus

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

IMPORTANT The regenerative bus supply is not compatible with the iTRAK power supply.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start

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 57 for more information on accessory module requirements.

Kinetix 5700 Drive System Cluster 1 (front view)
ATTENTION: 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.
324...506V AC Three-phase Input Power
Line Disconnect Device

Figure 8 - Extended DC-bus Installation

Regenerative Bus Supply

Single-axis Inverter Dual-axis Inverters

MOD NET

Shared DC-bus and 24V DC Control Power

I/O

Magnetic Contactor

(M1) Control String

I/O

OK+

EN+

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

MODULE STATUS

2198-CAPMOD-DCBUS-IO Extension Module

D+ D-
MF

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

2198-CAPMOD-2240 Capacitor Module

Combined motor cable lengths equal
300 m (984 ft).

DC-bus Extension

Circuit Protection

Magnetic (M1) Contactor

2198-DBRxx-F AC Line Filter (required for CE)

Bulletin 1321 Line Reactor (recommended)

Bonded Cabinet Ground Bus

Kinetix 5700 Extended Drive System Cluster 2 (front view)
Dual-axis Inverters

MOD NET

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+ D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MOD NET

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

MODULE

STATUS

Combined motor cable lengths equal 480 m (1575 ft).

2198-CAPMOD-2240 Capacitor Module

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1

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 57 for more information on accessory module requirements.

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

Figure 9 - 8720MC-RPS Power Supply Installations
324...506V AC Three-phase Input Power
Circuit Protection

8720MC-RFI80 AC Line Filter
(required for CE)

Bonded Cabinet Ground Bus

Kinetix 5700 Servo Drive System (top view)

Magnetic (1) (M1) Contactor
8720MC-LRxx Line Reactor

READY

FAULT

PROGRAM

RST PRG ENT

8720 MC
REGENERATTIIVVEE PPOOWWEERR SSUUPPPPLLYY

8720MC-HF-B2 Harmonic Filter
8720MC-VA-B Varistor

Shared DC-bus Power Input

19 8 16

SB+/NC S1A SCA S2A SBNC NC
NC

8 16

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

DC-bus Conditioner Capacitor Single-axis
Module Module Inverter

Dual-axis Inverters

MOD DC BUS

MOD NET

Shared 24V Control Power Input (24V shared-bus connection system is optional)
Bulletin 2198 shared-bus connection system for DC-bus and 24V DC control power.

MODULE STATUS

I/O

MODULE STATUS

UFB

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

Kinetix 5700 Servo Drive System (front view)

8720MC-RPS065-BM-HV2 Regenerative Power Supply
1606-XLxxx 24V DC Control, Digital Inputs, Allen-Bradley
1606-XL
Power Supply
and Motor Brake Power (customer-supplied)

D+ D-
MF

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-B

MBRK
+

Input
AC Input Power

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

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start

Motor and Auxiliary Feedback Configurations

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 on page 121.
Figure 10 - Feedback Configuration Example

MOD
2198-Dxxx-ERSx NET

or 2198-Sxxx-ERSx Inverters

(2198-Dxxx-ERSx dual-axis 2

inverter is shown) 1I/O-A

I/O-B 6

10 5

UFB-A

UFB-B

UFB-A

UFB-B

D+

D-

MF-A

MF-B

15-pin Universal Feedback (UFB) Connectors
2-pin Motor Feedback (MF) Connectors

2090-CSxM1DG Single Motor Cables 2090-CSxM1DE Single Motor Cables

UFB-A

UFB-B

D+

D-

MF-A

MF-B

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

UFB-A

UFB-B

2198-KITCON-DSL Connector Kit

Accepts Hiperface DSL motor feedback from VPC-Bxxxxx-Q,

Kinetix VPL, VPF, VPH, VPS rotary motors, and

Kinetix VPAR electric cylinders.

Kinetix VPAR Electric Cylinders

D+

D-

MF-A

MF-B

2198-K57CK-D15M Universal Connector Kit

Accepts multiple encoder feedback types:

· Hiperface high-resolution absolute multi-turn and single-turn encoders

VPC-Bxxxxx-S and VPC-B3004x-M rotary motors

Kinetix MPL (-S/M or -E/V), MPM, MPF, MPS rotary motors

Kinetix HPK asynchronous rotary motors

Kinetix MPAS (ballscrew), MPMA, VPAR, MPAR, MPAI linear actuators

LDAT-Series (-xDx)linear thrusters

· Sin/Cos or Digital AqB with UVW incremental encoders

Kinetix MPL-H

LDAT-Series (-xBx) linear thrusters

Kinetix MPAS (direct drive) LDC-Series linear motors

· EnDat high-resolution absolute encoders

VPC-Bxxxxx-Y rotary motors

Kinetix RDB direct-drive motors

· Feedback-only, master feedback, or load feedback

(absolute single-turn/multi-turn Hiperface)

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

Kinetix VPL, VPF, VPH, VPS and VPC-Bxxxxx-Q Rotary Motors (VPL-Bxxxx motor is shown)
Kinetix VPC-Bxxxxx-S, VPC-B3004x-M, and VPC-Bxxxxx-Y Rotary Motors
Kinetix MPL, MPM, MPF, MPS Rotary Motors (MPL-Bxxxx motor is shown)
Bulletin 2090 Motor Power and Feedback Cables

2198-H2DCK Converter Kit Converts 15-pin Hiperface feedback into 2-pin DSL feedback for: · VPC-Bxxxxx-S and VPC-B3004x-M rotary motors · Kinetix MPL, MPM, MPF, MPS rotary motors and Kinetix MPAS, MPMA, MPAR, MPAI linear actuators · Kinetix HPK asynchronous rotary motors · LDAT-Series linear thrusters and LDC-Series linear motors · Feedback-only, master feedback, or load feedback (absolute single-turn/multi-turn Hiperface)

LDC-Series Linear Motors

Kinetix RDB

CSEARTI.ANLON. LOD. XCX-MXX07X5X50X0XX SERIES A

wMwADwE.aIbN.cUoSmA

Direct Drive Rotary Motors

Kinetix HPK Asynchronous Rotary Motors and Induction Rotary Motors (closed-loop control)

Kinetix MPAR Electric Cylinders

LDAT-Series Linear Thrusters
Kinetix MPAS Integrated Linear Stages

Kinetix MPAI Heavy-duty Electric Cylinders

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Typical Communication Configurations

Start Chapter 1
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 11 - Kinetix 5700 Linear Communication Installation ControlLogix Controller Programming Network

Studio 5000 Logix Designer Application

EtherNet/IP
ControlLogix 5570 Controller
LNK1 LNK2 NET OK
with Bulletin 1756 EtherNet/IP Module

2 1
1585J-M8CBJM-x Ethernet (shielded) Cable
2198-ABQE MOD NET
Encoder Output Module

Kinetix 5700 Servo Drive System

MOD NET

2
1 1 4
I/O

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

OUTPUT-A OUTPUT-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

1585J-M8CBJM-OM15 0.15 m (6 in.) Ethernet cables for drive-to-drive connections.

00 2
Link 1 Activity/ Status

1734-AENTR
POINT I O
Module Status
Network Activity
Network Status
Point Bus Status
System Power
Field Power

1734-AENTR POINT I/OTM EtherNet/IP Adapter

Link 2 Activity/ Status

PanelViewTM 5510

MBRK

Display Terminal

Line Scan

Cameras

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start

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 12 - Kinetix 5700 Ring Communication Installation
ControlLogix Controller Programming Network

EtherNet/IP
LNK1LNK2NETOK ControlLogix 5570 Controller with Bulletin 1756 EtherNet/IP Module

2 1

1585J-M8CBJM-x Ethernet

(shielded) Cable

1783-ETAP

Module

2198-ABQE MOD NET
Encoder Output Module
OUTPUT-A OUTPUT-B

Kinetix 5700 Servo Drive System

Studio 5000 Logix Designer Application

PanelView 5510 Display Terminal

00 2
Link 1 Activity/ Status

1734-AENTR
POINT I O
Module Status
Network Activity
Network Status
Point Bus Status
System Power
Field Power

1734-AENTR POINT I/O EtherNet/IP Adapter

Link 2 Activity/ Status

MOD NET

Line Scan Cameras

2
1 1 4
I/O

I/O

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

1585J-M8CBJM-OM15 0.15 m (6 in.) Ethernet cable for drive-to-drive connections.

MBRK
+

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1
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 13 - Kinetix 5700 Star Communication Installation ControlLogix Controller Programming Network

EtherNet/IP
LNK1LNK2NETOK ControlLogix 5570 Controller with Bulletin 1756 EtherNet/IP Module
2 1

Studio 5000 Logix Designer Application
Kinetix 5700 Servo Drive System

1585J-M8CBJM-x Ethernet (shielded) Cable

2198-ABQE MOD NET
Encoder Output Module
OUTPUT-A OUTPUT-B
Line Scan Cameras

1783-BMS Stratix® 5700
Switch

MOD NET

2
1 1 4
I/O

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

1585J-M8CBJM-OM15 0.15 m (6 in.) Ethernet cable for drive-to-drive connections.
PanelView 5510 Display Terminal
L8

842E-CM Integrated Motion Encoder

1734-AENTR POINT I/O EtherNet/IP Adapter

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 mitigates the need for point-to-point wiring while letting you 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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start
Functional Safety Configurations

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 14 - Safe Torque-off (hardwired) Configuration

EtherNet/IP LNK1 LNK2 NET OK

2 1
Any Logix 5000 Controller (ControlLogix 5570 controller is shown)

Studio 5000 Logix Designer Application

Module Definition Configured with
Motion Only Connection
1585J-M8CBJM-x Ethernet (shielded) Cable

1606-XLxxx

Allen-Bradley

24V DC Control, Digital Inputs,

1606-XL
Power Supply

and Motor Brake Power

(customer-supplied) Input

AC Input Power

Safety Device

Kinetix 5700 Servo Drive System (top view)
SH DC+

19 8 16

SB+/NC S1A SCA S2A SBNC NC
NC

8 16

SB+/NC S1A SCA S2A SBNC NC
NC

8 16

Kinetix 5700 Servo Drive System (front view)

MOD NET

Digital Inputs to Sensors and Control String

2
1 1 4
I/O

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

Safe Torque-off (STO) Connectors

Logix5585 TM SAFETY ON
0 0 0 0 NET LINK
RUN FORCE SD OK

DC INPUT

AC OUTPUT

ControlLogix 5570 Controllers or GuardLogix 5570 Safety Controllers
ControlLogix 5580 Controllers or GuardLogix 5580 Safety Controllers

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

CompactLogix 5370 Controllers or Compact GuardLogix 5370 Safety Controllers CompactLogix 5380 Controllers or Compact GuardLogix 5380 Safety Controllers
Kinetix VP Servo Motors

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Studio 5000 Logix Designer Application
Module Definition Configured with Motion and Safety
Connection

Start Chapter 1

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 15 - Motion and Safety Configuration (single controller)

EtherNet/IP Compact GuardLogix 5370 Controller, LNK1LNK2NETOK Compact GuardLogix 5380 Safety Controller or
GuardLogix 5570 Controller, GuardLogix 5580 Safety Controller 2 (GuardLogix 5570 Safety Controller is shown)
1

Kinetix 5700 Servo Drive System (top view)
SH
DC+

1783-BMS Stratix 5700 Switch

1585J-M8CBJM-x Ethernet (shielded) Cable

1734-AENTR POINT Guard I/OTM EtherNet/IP Adapter
Safety Device

1606-XLxxx
Allen-Bradley
24V DC Control, Digital Inputs, 1606-XL Power Supply and Motor Brake Power (customer-supplied) Input
AC Input Power

Digital Inputs to Sensors and Control String

19 8 16

SB+/NC S1A SCA S2A SBNC NC
NC

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Kinetix 5700 Servo Drive System (front view)

MOD NET

2
1 1 4
I/O

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

Kinetix VP Servo Motors

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start
EtherNet/IP LNK1 LNK2 NET OK
2 1
Any Logix 5000 Controller (ControlLogix 5570 controller is shown)
Motion Program Module Definition Configured with
Motion Only Connection
EtherNet/IP LNK1 LNK2 NET OK
2 1
Compact GuardLogix 5370 Controller, Compact GuardLogix 5380 Safety Controller or
GuardLogix 5570 Controller, GuardLogix 5580 Safety Controller (GuardLogix 5570 Safety Controller is shown)
Safety Program Module Definition Configured with
Safety Only Connection

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 16 - Motion and Safety Configuration (multi-controller)

1783-BMS Stratix 5700 Switch

Studio 5000 Logix Designer Application

1585J-M8CBJM-x Ethernet (shielded) Cable
1734-AENTR POINT Guard I/O EtherNet/IP Adapter

Kinetix 5700 Servo Drive System (top view)
SH DC+

Safety Device

1606-XLxxx

24V DC Control, Digital Inputs,

Allen-Bradley 1606-XL

Power Supply

and Motor Brake Power

(customer-supplied) Input

AC Input Power

19 8 16

SB+/NC S1A SCA S2A SBNC NC
NC

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Kinetix 5700 Servo Drive System (front view)

MOD NET

Digital Inputs to Sensors and Control String

2
1 1 4
I/O

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

Kinetix VP Servo Motors

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Compact GuardLogix 5380 or GuardLogix 5580 Safety Controller (GuardLogix 5580 Safety Controller is shown)

Start Chapter 1

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 table on page 16.

In this example, the SS1 stopping function is used in a motion and safety controller-based configuration with dual-feedback monitoring.
Figure 17 - Safe Motion-monitoring Configuration

EtherNet/IP

LNK1 LNK2 NET OK

1783-BMS

Stratix 5700

Switch

1585J-M8CBJM-x Ethernet (shielded) Cable

Studio 5000 Logix Designer Application

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

Safety Device

Kinetix 5700 Servo Drive System with Integrated Safety Functions

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.

MOD NET
2 1 1 4
I/O

MOD NET

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

Controller-based Instruction Example

Secondary Feedback Bulletin 842HR SIN/COS Encoder for
Dual Feedback Monitoring Applications

Position feedback is sent separately to the drive for safety and for motion control.
Secondary Feedback to UFB Connector
Primary Feedback to MF Connector
Primary Feedback · Kinetix VPL/VPF/VPH) servo motors
with -W or -Q encoders · Kinetix VPC servo motors
with -Q encoders · Kinetix VPAR electric cylinders with
-W or -Q encoders

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 1 Start

Catalog Number Explanation Kinetix 5700 drive module catalog numbers and performance descriptions.

Table 4 - Kinetix 5700 Drive Module Catalog Numbers

Kinetix 5700 Drive Modules

Cat. No.

Continuous Output Module Current to Bus Width

ADC rms

Continuous Output Power

240V Input kW

480V Input kW

Output Current

Continuous A 0-pk

Peak A 0-pk

2198-P031

10.5

DC-bus Power Supply

2198-P070

25.5

3.5 8.5

7 17

(195...528V AC rms,

three-phase input power) 2198-P141

46.9

2198-P208

69.2

15.5 23.0

31 46

2198-RP088

35.3

165

Regenerative (1)

Power Supply

2198-RP200

100.0

(324...506V AC rms,

2198-RP263

176.4

275

67
119

three-phase input power)

440

2198-RP312

207.0

140

2198-S086-ERS3 2198-S130-ERS3

2198-S086-ERS4 2198-S130-ERS4

14.9 22.5

29.7 44.9

60.8 91.9

121.6 183.8

Single-axis Inverters

2198-S160-ERS3 2198-S160-ERS4 100

30.1

60.1

120.2

226.2

2198-S263-ERS3 2198-S312-ERS3

2198-S263-ERS4 2198-S312-ERS4

220

45.0 56.0

90 112

212.1

371.9

271.5

441.2

2198-D006-ERS3 2198-D006-ERS4

0.9

1.7

3.5

8.8

Dual-axis Inverters

2198-D012-ERS3 2198-D020-ERS3

2198-D012-ERS4 2198-D020-ERS4

2198-D032-ERS3 2198-D032-ERS4

1.7 2.8 4.5

3.4 5.5 8.9

7.0

17.6

11.3

28.2

18.3

45.9

2198-D057-ERS3 2198-D057-ERS4 85

8.0

15.9

32.5

81.3

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 40.

Table 5 - Accessory Module Catalog Numbers

Accessory Modules (1)

Cat. No.

Module Width System Current (2) mm

Rated Voltage

Capacitance

Capacitor Module

2198-CAPMOD-2240

2240 F

Extension Module

2198-CAPMOD-DCBUS-IO 55

104 A

DC-bus Conditioner Module 2198-DCBUSCOND-RP312

276...747V DC, nom

(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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Start Chapter 1

Table 6 - Shared-bus Connector Kit Catalog Numbers

Shared-bus Connector Kits Drive Module

Cat. No.

Application

Description

2198-TCON-24VDCIN36 (1) (2)

2198-P031, 2198-P070, 2198-P141, 2198-P208 2198-CAPMOD-2240
2198-RP088, 2198-RP200, 2198-DCBUSCOND-RP312 24V DC input power to control bus

24V DC input wiring connector

2198T-W25K-P-IN (1) (2)

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

2198-H040-P-T

2198-D006-ERSx, 2198-D012-ERSx 2198-D020-ERSx, 2198-D032-ERSx 2198-CAPMOD-2240, 2198-DCBUSCOND-RP312

Control power sharing

Control power T-connector with bus bars, 55 mm

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 2198T-W25K-P-T

2198-S160-ERSx 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 111, and CP Connector Plug Wiring Specifications table on page 141, respectively.

Agency Compliance

If this product is installed within the European Union and has the CE mark, the following regulations apply.
ATTENTION: 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 123.
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 with 50 mm (1.97 in.) minimum clearance between the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply. Minimize the cable length as much 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 83 on page 134. · When using the 2198-P070 DC-bus power supply above 45 °C (113 °F) with stranded input power wiring, conductors must be single-core 6 mm2 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 mm2 stranded copper with 90 °C minimum rating.

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Chapter 1 Start

· Use Bulletin 2090 single motor cables with Kinetix VP motors and actuators. Use Bulletin 2090 motor power/brake and feedback cables for other compatible Allen-Bradley motors and actuators. Motor cable shield-clamp 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-P070, 2198-P141, and 2198-P208, 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.
400 m (1312 ft) for 2198-P031 DC-bus power supplies when paired with 2198-DBxx-F or 2198-DBRxx-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-UM002K-EN-P - October 2020

2 Chapter
Plan the Kinetix 5700 Drive System Installation

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

Topic

Page

System Design Guidelines

Accessory Module Selection

Electrical Noise Reduction

ATTENTION: 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).

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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 83 on page 134.
Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001, to better understand the concept of electrical noise reduction.

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.

ATTENTION: 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

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Plan the Kinetix 5700 Drive System Installation Chapter 2

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.
Bus Voltage Set Point (VDC ) > AC Input Voltage (VRMS) · 2 · 1.05
Boost voltage is the difference between the rectified AC voltage and the BusVoltageSetPoint.
Boost Voltage = Bus Voltage Set Point (VDC) AC Input Voltage (VRMS) · 2

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 225 for more information.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

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 with 50 mm (1.97 in.) minimum clearance between the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply. Minimize the cable length as much as possible.
IMPORTANT AC line filters are recommended only with grounded WYE power configurations. For facility power configuration examples, see Input Power Configurations for Kinetix 5700 Power Supplies on page 123.

Table 7 - 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)

AC Line Filter (1) (2) (3) 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

Regenerative Bus Supply Cat. No.
2198-RP088
2198-RP200
2198-RP263 2198-RP312

AC Line Filter(1) (2) (4) Cat. No. 2198-DBR40-F
2198-DBR90-F
2198-DBR200-F

(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). Maximum motor-power cable length for 2198-P031 DC-bus power supplies when paired with 2198-DBxx-F or 2198-DBRxx-F line filters is with 400 m (1312 ft).
(2) See Chapter 5 beginning on page 121, for more information on maximum cable lengths and how the use of 2198-DBRxx-F line filters affect ground screw/jumper settings. See Kinetix Servo Drive Specifications Technical Data, publication KNX-TD003, for AC line filter specifications.
(3) When using 2198-DBRxx-F line filters with DC-bus power supplies, remove all inverter ground jumpers to reduce overall system leakage 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.

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.

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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 123 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
200V AC. · 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-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

· 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)

Zdrive =

Vline-line 3 · Iinput-rating

Transformer Impedance (in ohms)

Zxfmr =

Vline-line · % Impedance 3 · Ixfmr-rated
Or

Zxfmr

(

Vline-line VA

Impedance

% impedance is the nameplate impedance of the transformer.

Transformer Impedance (in ohms)

Zxfmr =

Vline-line · % Impedance 3 · Ixfmr-rated

% impedance is the nameplate impedance of the transformer.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Plan the Kinetix 5700 Drive System Installation Chapter 2

Kinetix 5700 Power Supply DC-bus Power Supply
Regenerative Bus Supply

Power Supply Cat. No. 2198-P031 2198-P070 2198-P141
2198-P208
2198-RP088 2198-RP200 2198-RP263 2198-RP312

EXAMPLE

The DC-bus power supply or regenerative bus supply is rated 1 Hp, 480V, 2.7 A input.

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

Zdrive =

Vline-line

480V =

3 · Iinput-rating

3 · 2.7

= 102.6 Ohms

Zxfmr

(

Vline-line VA

Impedance

4802 =
50,000

0.05

0.2304

Ohms

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

Zxfmr Zdrive

0.2304 102.6

= 0.00224 = 0.22%

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.

Table 8 - Bulletin 1321 Line Reactor Selection

Number of Power Supplies in a Bus Group 1 1 1 1 2 3 1 1 1 1

Bulletin 1321 Line Reactor Cat. No. 1321-3R12-B 1321-3R35-B 1321-3R55-B
1321-3R80-B
1321-3R35-A 1321-3R100-A 1321-3R160-B 1321-3R200-A

Status
Recommended Recommended Recommended Recommended Required Required Recommended Recommended Recommended 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-UM002K-EN-P - October 2020

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.

ATTENTION: 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.

Input Voltage (three-phase) nom

Bussmann Fuses (1) Cat. No.

Miniature CB (2) Cat. No.

Motor Protection CB, (2) Self Protected CMC Cat. No.

Molded Case CB Cat. No.

2198-P031

LPJ-15SP (15A)

1489-M3D250

140M-D8E-C25

140G-G6C3-C25

2198-P070 2198-P141

LPJ-40SP (40A)

N/A

195...528V AC rms

LPJ-70SP (70A)

N/A

140M-F8E-C45 N/A

140G-G6C3-C50 140G-G6C3-C90

2198-P208

LPJ-100SP (100A)

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).

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

Regenerative Bus Supply Input Voltage (1)

Cat. No.

(three-phase) nom

Bussmann Fuses (2) Cat. No.

Mersen Fuses Cat. No.

Miniature CB Cat. No.

Molded Case CB Cat. No.

2198-RP088

LPJ-45SP (45A)

AJT45 (45A)

140G-G6C3-C60

2198-RP200 2198-RP263

LPJ-125SP (125A)

AJT125 (125A)

324...506V AC rms

LPJ-200SP (200A)

AJT200 (200A)

140G-J6F3-D15 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 on page 40.
(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.

DC-bus Power Supply Cat. No.
2198-P031 2198-P070 2198-P141 2198-P208

Drive Voltage (three-phase) nom
195...528V AC rms

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

DIN gG Fuses Amps, max 16 40 75 110

Miniature CB Cat. No.

1489-M3D250 N/A

N/A

1492-SPM3D400

N/A

1492-SPM3D630

N/A

Motor Protection CB Cat. No.
140M-D8E-C25 140M-F8E-C45 140MG-H8E-C60 140MG-H8E-D10

Molded Case CB Cat. No.
140G-G6C3-C25 140G-G6C3-C50 140G-G6C3-C90 140G-G6C3-D12

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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.

Input Voltage (1)

DIN gG Fuses

(three-phase) nom Amps, max

Miniature CB Cat. No.

Motor Protection CB Molded Case CB

Cat. No.

2198-RP088

1489-M3C600 1492-SPM3C630 140MG-H8E-C60

140G-G6C3-C60

2198-RP200 2198-RP263

125 324...506V AC rms
200

140MG-J8E-D15

140G-J6F3-D15

140G-K6F3-D30

2198-RP312

250

140G-K6F3-D40

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 400 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 mm2 (12 AWG) and 6 mm2 (10 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 mm2 (6 AWG) and result in a lower voltage drop.
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 401.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

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.

ATTENTION: 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.

Contactor (1) (2) Cat. No.

Intermediate Relay (3) Cat. No.

2198-P031 2198-P070

100-C16EJ10 N/A
100-C37EJ10

2198-P141

100-C72DJ10

2198-P208 2198-P208 (2 in parallel)

100-C97DJ10 100-E190KJ11

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

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 for more information. (3) These DC-bus power supplies require an additional intermediate relay used with the contactor.

Table 14 - Regenerative Bus Supply Contactor Specifications

Regenerative Bus Supply Cat. No.

Contactor (1) (2) Cat. No.

Intermediate Relay Cat. No.

2198-RP088

100-C43EJ10

2198-RP200 2198-RP263

100-E116KJ11
N/A 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 configurations 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 for more information.

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Plan the Kinetix 5700 Drive System Installation Chapter 2

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.

Internal Shunt Specifications

External Shunt Module Compatibility (1) Cat. No.

2198-R127

2198-R031

2198-R014

2198-P031

37.5

2198-P070

2198-P141

13.5

200

2198-P208

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

2198-R004 X X X X

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 18 - External Passive Shunts

2198-R014, 2198-R031, and 2198-R127 Shunt Modules

2198-R004 Shunt Resistor

External Shunt Module Specifications

Shunt Module Cat. No.

Resistance

Continuous Power W

Weight, approx kg (lb)

2198-R004

400

1.8 (4.0)

2198-R014

9.4

1400

9.1 (20)

2198-R031

2198-R127 (1)

3100 12,700

16.8 (37) 22.2 (49)

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

How the Bulletin 2198-Rxxx shunts connect to the 2198-Pxxx DC-bus power supply is explained in External Passive-shunt Connections on page 177 and illustrated with interconnect diagrams in Passive Shunt Wiring Examples on 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 on page 462 for a description of this feature. · 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.
ATTENTION: 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.

ATTENTION: 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 EncompassTM 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

Powerohm Resistors Cat. No. (1)

Input Voltage, nom

Turn -on Bus Voltage

Continuous Power
kW

Resistance (internal)

Resistance Continuous Peak (minimum) Current Current

Amps

2198-Pxxx DC-bus power supply or

PKB005

1.50

108

2198-RPxxx regenerative bus supply PKB010

750V DC 2.06

52.7

when DC-bus regulation is not enabled. PKB050

240V (DC-bus power supply

7.00

10.5

PKB005-800

only) or 480V AC

1.50

108

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

PKB010-800

800V DC 2.06

52.7

PKB050-800

7.00

10.5

2.00

6.9

2.75

14.2

9.30

71.4

1.88

7.4

2.58

15.2

8.72

76.2

(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 178 and illustrated with interconnect diagrams in Active Shunt Wiring Examples on page 360.

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

Kinetix 5700 Power Supply

Powerohm Resistors Cat. No. (1)

Input Voltage, nom

Turn -on Bus Voltage

Continuous Power
kW

Resistance (internal)

Resistance Continuous Peak (minimum) Current Current

Amps

2198-Pxxx DC-bus power supply or PWB035

26.25

2198-RPxxx regenerative bus supply

750V DC

when DC-bus regulation is not enabled. PWB110

480V AC

82.5

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

PWB035-800 PWB110-800

26.25

800V DC

82.5

7.5

100

2.5

110

300

8.0

100

2.7

110

300

(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 178 and illustrated with interconnect diagrams in Active Shunt Wiring Examples on page 360.

ATTENTION: 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 178, when making active shunt connections.

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

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 Table 18).

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

A =

0.38Q 1.8T - 1.1

A =

4.08Q T - 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 (m2). The exterior surface of all six sides of an enclosure is calculated as:

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:

A = 2dw + 2dh + 2wh

A = (2dw + 2dh + 2wh) /144

Where d (depth), w (width), and h (height) are in meters.

Where d (depth), w (width), and h (height) are in inches.

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.

A =

0.38 (416) 1.8 (30) - 1.1

= 2.99 m 2

In this example, the enclosure must have an exterior surface of at least 2.99 m2. 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 m2

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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

DC-bus Power Supply Cat. No. 20%

2198-P031

2198-P070

108

2198-P141

249

2198-P208

265

Regenerative Bus Supply Cat. No.

2198-RP088

253

2198-RP200

532

2198-RP263

850

2198-RP312

1037

Dual-axis Inverter Cat. No.

2198-D006-ERSx

2198-D012-ERSx

2198-D020-ERSx

2198-D032-ERSx

100

2198-D057-ERSx

252

Single-axis Inverter Cat. No.

2198-S086-ERSx

190

2198-S130-ERSx

225

2198-S160-ERSx

270

2198-S263-ERSx

556

2198-S312-ERSx

610

iTRAK Power Supply Cat. No.

2198T-W25K-ER

206

Capacitor Module Cat. No.

2198-CAPMOD-2240

2198-CAPMOD-DCBUS-IO

1.1

DC-bus Conditioner Module Cat. No.

2198-DCBUSCOND-RP312

1.4

Plan the Kinetix 5700 Drive System Installation Chapter 2

Table 18 - Power Dissipation Specifications

Usage as % of Rated Power Output (watts)

40%

60%

80%

100%

101

105

109

113

119

130

140

151

267

286

304

323

294

323

352

380

399

544

690

835

832

1132

1432

1732

1261

1672

2083

2494

1576

2115

2654

3193

106

130

116

148

180

155

210

265

320

354

456

558

660

255

325

400

475

340

460

590

725

420

570

760

950

759

989

1245

1529

883

1200

1561

1965

272

338

404

470

1.4

1.6

2.1

2.5

2.1

3.2

4.7

6.7

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Clearance where cover and DC-bus cabling attaches.

29.5 (1.16)
MOD DC BUS

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 19 - Minimum Clearance Requirements
Clearance above for wiring to DC-bus studs and lug cover installation.

Clearance above module for airflow and installation (see Table 19 on page 55 for values).

MOD NET

Clearance left of the module is not required.
MODULE STATUS
Kinetix 5700 Accessory Module (2198-CAPMOD-2240 module is shown)

Clearance right of the

module is not required.

I/O

Kinetix 5700 Drive Module (DC-bus power supply is shown)

Refer to the Kinetix Servo Drives Technical Data, publication KNX-TD003, for
Kinetix 5700 drive module dimensions.

Clearance below module for airflow and installation (see Table 19 on page 55 for values).

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 55 for clearance specifications.

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Table 19 - Kinetix 5700 Drive Module Clearance Specifications

Kinetix 5700 Drive Modules Drive Module Cat. No.

DC-bus power supply

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

Clearance Above, min mm (in.)
40 (1.57)

Regenerative bus supply

2198-RP088 2198-RP200
2198-RP263 2198-RP312

40 (1.57) 80 (3.15)

Single-axis inverters

2198-S086-ERSx 2198-S130-ERSx 2198-S160-ERSx
2198-S263-ERSx 2198-S312-ERSx

40 (1.57) 80 (3.15)

Dual-axis inverters

2198-D006-ERSx 2198-D012-ERSx 2198-D020-ERSx 2198-D032-ERSx 2198-D057-ERSx

40 (1.57)

iTRAK power supply

2198T-W25K-ER

40 (1.57)

Capacitor module

2198-CAPMOD-2240

Extension module

2198-CAPMOD-DCBUS-IO 115 (4.53)

DC-bus conditioner module 2198-DCBUSCOND-RP312

(1) Additional clearance can be required depending on the actual wiring harness being installed.

Clearance Below, (1) min mm (in.) 100 (3.94) 100 (3.94) 150 (5.91) 200 (7.87) 185 (7.28) 200 (7.87)
100 (3.94)
100 (3.94)
100 (3.94)

In multi-axis shared-bus configurations, drive modules must be spaced (left to right) by aligning the zero-stack tab and cutout. Install the AC line filter (required for CE) with 50 mm (1.97 in.) minimum clearance between the power supply and filter or between filters, when more than one filter is used. Minimize the cable length as much as possible.

Figure 20 - Shared-bus and Line Filter Clearance Requirements

Shared-bus connection system is not shown for clarity.
MOD NET
Wire Connection (1) Terminals
2
1
1 4
I/O

50 mm (1.97 in.)

MOD NET

I/O-A

I/O-B

10 5

UFB-A

UFB-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

Zero-stack Tab and Cutout Aligned

Wire Connection (1) Terminals

(1) Clearance required at the terminals for NEC specified bend radius depends on the wire size in use.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

Multi-axis Shared DC-Bus Configurations

The Kinetix 5700 shared DC-bus 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

Table 20 - Shared DC-bus Terminology

Term DC-bus group Cluster
Extended cluster Power supply cluster Extended DC-bus

Definition
Drive modules that are all connected to the same 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.
The cluster that contains the AC to DC converter (power supply).
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 (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 C on page 395 for more information and sizing examples. See Appendix D on page 405 for more information on cable lengths.

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Accessory Module Selection

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

Accessory Module Cat. No. 2198-CAPMOD-2240
2198-CAPMOD-DCBUS-IO
2198-DCBUSCOND-RP312

Accessory Module Capacitor Module Extension Module DC-bus Conditioner Module

Description
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 accessory 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.

This example includes: · 1 Bus group · 2 Drive clusters

DC-bus Power Supply Systems

The following system configurations illustrate the minimum number of accessory modules required.

Figure 21 - DC-bus Power Supply Example/Extended Cluster (104 A, max)

DC-Bus Single-axis Dual-axis Capacitor Power Supply Inverters Inverters Module

Capacitor Single-axis Dual-axis Module Inverters Inverters

DC Bus

2198-Pxxx 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-CAPMOD-2240 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

This example includes: · 1 Bus group · 1 Drive cluster

Figure 22 - DC-bus Power Supply Example/Multiple Capacitor Modules

DC-Bus Single-axis Dual-axis Capacitor Power Supply Inverters Inverters Module

Capacitor Module

DC Bus

2198-Pxxx 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-CAPMOD-2240 2198-CAPMOD-2240

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 23 - Multiple DC-bus Power Supply Example/Extended Cluster (208 A, max)

DC-Bus

DC-Bus Single-axis Dual-axis Capacitor

Power Supply Power Supply Power Supply Inverters Inverters Module

Extension Module

Extension Capacitor Single-axis Dual-axis Module Module Inverters Inverters

DC Bus
This example includes: · 1 Bus group · 2 Drive clusters

DC Bus

2198-P208 2198-P208 2198-P208 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-CAPMOD-2240 2198-CAPMOD-DCBUS-IO 2198-CAPMOD-DCBUS-IO 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx

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 395 for more system sizing information.

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Plan the Kinetix 5700 Drive System Installation Chapter 2

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 24 - Regenerative Bus Supply Example/Single Cluster

Regenerative Single-axis Bus Supply Inverters
DC Bus

Dual-axis Inverters

DC-bus Conditioner Module

DC-bus conditioner is required on this single cluster only because cable length exceeds 400 m (1312 ft).

2198-RPxxx (power supply cluster) 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-DCBUSCOND-RP312

This example includes: · 1 Bus group · 1 Drive clusters
90 m (295 ft) x 5 axes = 450 m (1476 ft)
M Motor Array

Figure 25 - Regenerative Bus Supply Example/Extended Cluster

Regenerative Single-axis Dual-axis Capacitor DC-bus Conditioner

Bus Supply Inverters Inverters Module

Module

DC-bus Conditioner Capacitor

Module

DC Bus

Single-axis Inverters

2198-RPxxx (power supply cluster) Cluster #1 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-CAPMOD-2240 2198-DCBUSCOND-RP312 2198-DCBUSCOND-RP312 (extended cluster) Cluster #2 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Sxxx-ERSx

90 m (295 ft) x 5 axes = 450 m (1476 ft)
M Motor Array 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

90 m (295 ft) x 3 axes = 270 m (886 ft)
Motor Array M This example includes: · 1 Bus group · 2 Drive clusters

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

Figure 26 - Regenerative Bus Supply Example/Extended Cluster/104 A System

Regenerative Dual-axis Capacitor Bus Supply Inverters Module

DC-bus Conditioner Capacitor

Module

Single-axis Inverters

DC Bus

2198-RP088 (power supply cluster) Cluster #1 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-CAPMOD-2240 2198-DCBUSCOND-RP312 (extended cluster) Cluster #2 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Sxxx-ERSx

2198-RP200 (power supply cluster) Cluster #1 2198-CAPMOD-2240 2198-CAPMOD-DCBUS-IO 2198-DCBUSCOND-RP312 (extended cluster) Cluster #2 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Sxxx-ERSx

This example includes: · 1 Bus group · 2 Drive clusters

90 m (295 ft) x 4 axes = 360 m (1182 ft)

90 m (295 ft) x 3 axes = 270 m (886 ft)

M Motor Array

Motor Array M

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

This example includes: · 1 Bus group · 2 Drive clusters

Figure 27 - Regenerative Bus Supply Example/Extended Cluster/208 A System

Regenerative Capacitor Bus Supply Module

Extension Module

DC-bus Conditioner Capacitor

Module

Single-axis Inverters

DC Bus

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.

90 m (295 ft) x 3 axes = 270 m (886 ft) Motor Array M

Regenerative Capacitor Extension Bus Supply Module Module

Figure 28 - Regenerative Bus Supply Example/Two Extended Clusters/208 A, max

Extension DC-bus Conditioner Single-axis Capacitor Extension

Module

Inverters Module Module

DC-bus Conditioner Capacitor Single-axis

Module

Module Inverters

DC Bus

2198-RPxxx (power supply cluster) Cluster #1 2198-CAPMOD-2240 2198-CAPMOD-DCBUS-IO 2198-CAPMOD-DCBUS-IO (extended cluster) Cluster #2 2198-DCBUSCOND-RP312 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-CAPMOD-2240 2198-CAPMOD-DCBUS-IO 2198-DCBUSCOND-RP312 (extended cluster) Cluster #3 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx

DC-bus conditioner requirements:

90 m (295 ft) x 2 axes = 180 m (591 ft)

· Not required on Cluster #1 because cable length <400 m (1312 ft) · Required on Cluster #2 and #3 because they are extended clusters

Motor Array

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).

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Plan the Kinetix 5700 Drive System Installation Chapter 2

Figure 29 - Regenerative Bus Supply Example/Center Power Supply Cluster/104 A, max

Single-axis Capacitor DC-bus Conditioner

Inverters Module

Module

Extension Regenerative Capacitor Module Bus Supply Module

DC-bus Conditioner Capacitor Single-axis

Module

Module Inverters

DC Bus

2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-CAPMOD-2240 (extended cluster) Cluster #1 2198-DCBUSCOND-RP312 2198-CAPMOD-DCBUS-IO 2198-RPxxx (power supply cluster) Cluster #2 2198-CAPMOD-2240 2198-DCBUSCOND-RP312 (extended cluster) Cluster #3 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx

90 m (295 ft) x 2 axes = 180 m (591 ft)
Motor Array
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.

90 m (295 ft) x 2 axes = 180 m (591 ft) Motor Array M
This example includes: · 1 Bus group · 3 Drive clusters

Three-phase Input Voltage

Impedance Ground Input Power
L3
L2
L1

IMPORTANT

In Figure 29, 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 30 - Regenerative Bus Supply Example/Impedance-grounded Input Power

Regenerative Bus Supply
DC Bus
L3 L2 L1

Dual-axis Inverters

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

2198-RPxxx 2198-Dxxx-ERSx 2198-Dxxx-ERSx 2198-DCBUSCOND-RP312

90 m (295 ft) x 4 axes = 360 m (1181 ft) M
IMPORTANT The regenerative bus supply is not compatible with the iTRAK power supply.

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Chapter 2 Plan the Kinetix 5700 Drive System Installation

This example includes: · 1 Bus group · 1 Drive cluster

8720MC-RPS or Other Regenerative Power Supply

The following system configurations illustrate the minimum number of accessory modules required.

Figure 31 - Regenerative Power Supply Example (104 A, max)

Regenerative Power Supply

DC-bus Conditioner Capacitor Single-axis Dual-axis

Module

Module Inverters Inverters

DC Bus

8720MC-RPS065 2198-DCBUSCOND-RP312 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx

This example includes: · 1 Bus group · 1 Drive cluster

DC-bus conditioner is required only if the total power-cable length exceeds 400 m (1312 ft).

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 32 - Regenerative Power Supply Example Power (208 A, max)

Regenerative Power Supply

DC-bus Conditioner Capacitor Single-axis Dual-axis

Module

Module Inverters Inverters

DC Bus

8720MC-RPS190 2198-DCBUSCOND-RP312 2198-CAPMOD-2240 2198-Sxxx-ERSx 2198-Sxxx-ERSx 2198-Dxxx-ERSx 2198-Dxxx-ERSx

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

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Plan the Kinetix 5700 Drive System Installation Chapter 2
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 33 - Single-cluster Drive System
Start

What type of AC to DC converter is used?
Regenerative Bus Supply

DC-bus Power Supply

Yes

Is this an impedance

grounded system?

What is the total motor <400 m

cable length?

(1312 ft)

400 m (1312 ft)
DC-bus Conditioner Module

No accessory modules required.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation
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 34 - Multi-cluster Drive System
Start

What type of AC to DC converter is used?

Regenerative Bus Supply

DC-bus Power Supply

<104 A
Each Cluster: Capacitor Module

What is the external DC-bus
current?
104 A up to 208 A, max

Is this an impedance Yes grounded system?
No

Each Cluster: · Capacitor Module · Extension Module
<104 A

<400 m (1312 ft)
What is the external DC-bus
current?

What is the total motor cable length of
the power supply cluster?
400 m (1312 ft)

Power Supply Cluster:
· Capacitor Module All Extended Clusters:
· Capacitor Module · DC-bus Conditioner Module

104 A up to 208 A, max

Each Cluster:
· Capacitor Module · DC-bus Conditioner Module

Power Supply Cluster:
· Capacitor Module · Extension Module All Extended Clusters:
· Capacitor Module · DC-bus Conditioner Module

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

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.

HF Bond for 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-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Figure 35 - Recommended Bonding Practices for Painted Panels

Subpanel
Star Washer Nut

Stud-mounting the Subpanel to the Enclosure Back Wall Back Wall of Enclosure
Welded Stud
Use a wire brush to remove paint from threads to maximize ground connection. Use plated panels or scrape paint on front of panel.

Stud-mounting a Ground Bus

or Chassis to the Subpanel

Subpanel

Mounting Bracket or

Ground Bus

Welded Stud

Flat Washer Nut
Star Washer

Scrape Paint
Flat Washer
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

Subpanel

Bolt

Tapped Hole

Ground Bus or Mounting Bracket
Flat Washer Nut

Nut
Star Washer Scrape paint on both sides of panel and use star washers. Star Washer
Flat Washer

Star Washer

If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole.

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Plan the Kinetix 5700 Drive System Installation Chapter 2
HF Bond for 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 36 - Multiple Subpanels and Cabinet Recommendations

Paint removed from cabinet.

Wire Braid 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.)
Wire Braid 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.)

Cabinet ground bus bonded to the subpanel.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

Establish 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 37 - Noise Zones (DC-bus power supply)
Dirty Wireway
(1)

24V DC

Kinetix 5700 Servo Drive System

Power Supply

Clean Wireway
(1) C

Safety Cable (hardwired drives only) D

MOD NET

MOD DC BUS

Circuit

Protection

Very Dirty Filter/AC Input Connections Segregated
(not in wireway)

1
4 I/O

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

UFB-A

UFB-B

50 mm (1.97 in.)

D+

D-

D+

D-

D+

D-

AC Line Filter (required for CE)

MF-A

MF-B

MF-A

MF-B

MF-A

MF-B

(1)

Module Status

Contactor Enable

Route motor cables in shielded cable.

Motor Cables (2)

Route registration and communication signals in shielded cables.

(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-UM002K-EN-P - October 2020

Plan the Kinetix 5700 Drive System Installation Chapter 2

Dirty Wireway D

Figure 38 - Noise Zones (regenerative bus supply)

Clean Wireway
(1)
(1)

24V DC Power Supply

C Kinetix 5700 Servo Drive System

Safety Cable

(hardwired drives only)

VD
Circuit Protection

Very Dirty Filter/AC Input Connections Segregated
(not in wireway)
AC Line Filter (required for CE)

50 mm (1.97 in.)

MOD NET

MOD DC BUS

I/O

I/O-A

I/O-B

OK+ OK EN EN+

10 5

UFB-A

UFB-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

C (1)

D
Route motor cables in shielded cable.

Module Status

Contactor Enable D
C

Motor Cables (2)

Route registration and communication signals in shielded cables.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

Cable Categories for Kinetix 5700 Systems

Wire/Cable L1, L2, L3 (shielded cable) L1, L2, L3 (unshielded cable) DC-/DC+ (DC bus) DC+/SH (passive shunt) DC+/DC (active shunt) CONT EN and CONT EN+ (M1 contactor) CONV OK and CONV OK+ 24V DC
Dedicated digital inputs
Ethernet (shielded cable)

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

Power Supply Cat. No.

Connector

2198-Pxxx 2198-RPxxx
2198-Pxxx 2198-RPxxx
2198-Pxxx
2198-RPxxx
2198-Pxxx 2198-RPxxx
2198-RPxxx
2198-Pxxx 2198-RPxxx
2198-Pxxx 2198-RPxxx
2198-Pxxx 2198-RPxxx

IPD DC RC
CED
CP IOD PORT1 PORT2

Zone

Very Dirty Dirty Clean

Bus-bar only, no wiring connector.

Method

Ferrite Sleeve Shielded Cable

Table 23 - Dual-axis and Single-axis Inverters

Wire/Cable

Connector

DC-/DC+ (DC bus)

U, V, W (motor power) Motor feedback Motor brake

Kinetix VPL, VPC-Q VPF, VPH, VPS motors

U, V, W (motor power) Motor feedback Motor brake

Kinetix VPC-S/Y, MPL, MPM, MPF, MPS motors

24V DC

Safety enable for safe torque-off (hardwired)

Registration input

Dedicated digital inputs (other than registration inputs)

Ethernet (shielded cable)

DC MP MF BC MP MF or UFB BC CP STO
IOD
PORT1 PORT2

Zone

Very Dirty Dirty Clean

Bus-bar only, no wiring connector.

Method Ferrite Sleeve Shielded Cable

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Plan the Kinetix 5700 Drive System Installation Chapter 2

Table 24 - iTRAK Power Supply

Wire/Cable
DC-/DC+ (DC bus) iTRAK DC-bus output A and B 24V DC control input power iTRAK 24V DC control output power A and B iTRAK digital inputs iTRAK ready output
Ethernet (shielded cable)

Connector
DC IDC CP ICP IOD IR PORT1 PORT2

Zone

Very Dirty Dirty Clean

Bus-bar only, no wiring connector.

Method Ferrite Sleeve Shielded Cable

Wire/Cable
DC-/DC+ (DC bus) DC-/DC+ 24V DC Module status

Table 25 - Capacitor Module or DC-bus Conditioner Module

Connector
DC M8 Stud CP MS

Zone

Very Dirty Dirty Clean

Bus-bar only, no wiring connector.

Method Ferrite Sleeve Shielded Cable

Wire/Cable
DC-/DC+ (DC bus) DC-/DC+

Table 26 - Extension Module

Connector
DC M8 Stud

Zone

Very Dirty Dirty Clean

Bus-bar only, no wiring connector.

Method Ferrite Sleeve Shielded Cable

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 68 for an example):
· With grounded WYE power, as shown in Figure 72 on page 123, mount the AC line filter on the same panel as the power supply with 50 mm (1.97 in.) minimum clearance between the drive and filter.
· Minimize the line filter cable length as much as possible. · Good HF bonding to the panel is critical. For painted panels, refer to
the examples on page 66. · Segregate input and output wiring as far apart as possible.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

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 39 - External Passive Shunt Module Mounted On Top of the Drive System Enclosure
610 mm (24 in.) clearance (min) above the shunt module.

Metal Conduit (where required by local code)

Dirty Wireway D

Enclosure

150 mm (6.0 in.) clearance (min) on all four sides of the shunt module.

Shunt Power Wiring Methods: Twisted pair in conduit (1st choice). Twisted pair, two twists per foot (min) (2nd choice).

Clean Wireway C

24V DC Power Supply

VD Kinetix 5700 Servo Drive System

Safety Cable

(hardwired safety only)

MOD NET

Circuit

Protection

Very Dirty Filter/AC Input Connections Segregated
(not in wireway)

AC Line Filter (required for CE)

2 1 1 4
I/O
50 mm (1.97 in.)

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

UFB-A

UFB-B

UFB-A

UFB-B

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MOD DC BUS
Digital Inputs and Ethernet Cables
C Module Status
No sensitive equipment within 150 mm (6.0 in.).

Contactor Enable D

Route motor cables in shielded cable.

Motor Cables

Route registration and communication signals in shielded cables.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Plan the Kinetix 5700 Drive System Installation Chapter 2

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 40 - External Shunt Resistor Mounted Inside the Drive System Enclosure

D Dirty Wireway

Enclosure

150 mm (6.0 in.) clearance (min) above the
shunt resistor.

76 mm (3.0 in.) clearance (min) below, left, and right of the shunt resistor.

Shunt Power Wiring Methods: Twisted pair in conduit (1st choice). Twisted pair, two twists per foot (min) (2nd choice).

Clean Wireway C

24V DC Power Supply

VD Kinetix 5700 Servo Drive System

Safety Cable (hardwired safety only) D

MOD NET

MOD DC BUS

Circuit

Protection

Very Dirty Filter/AC Input Connections Segregated
(not in wireway)

AC Line Filter (required for CE)

2 1 1 4
I/O
50 mm (1.97 in.)

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

UFB-A

UFB-B

UFB-A

UFB-B

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

No sensitive equipment within 150 mm (6.0 in.). Digital Inputs and
Ethernet Cables C
Module Status

D
Route motor cables in shielded cable.

Motor Cables

Route registration and communication signals in shielded cables.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation

Dirty Wireway D

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 41 - External Active Shunt Module Mounted On Top of the Drive System Enclosure
610 mm (24 in.) clearance (min) above the shunt module.

Metal Conduit (where required by local code)

External Active Shunt

Enclosure

Shunt Power Wiring Methods: Twisted pair in conduit (1st choice). Twisted pair, two twists per foot (min) (2nd choice).

150 mm (6.0 in.) clearance (min) on all four sides of the shunt module.

Clean Wireway

24V DC Power Supply

Safety Cable

(hardwired safety only)

Circuit

Protection

Very Dirty Filter/AC Input Connections Segregated
(not in wireway)
AC Line Filter (required for CE)

50 mm (1.97 in.)

Kinetix 5700 Servo Drive System

MOD NET

I/O

I/O-A

I/O-B

OK+ OK EN EN+

UFB-A

UFB-B

I/O-A

I/O-B

UFB-A

UFB-B

I/O-A

I/O-B

UFB-A

UFB-B

MODULE STATUS

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

Digital Inputs and Ethernet Cables
C
Module Status
No sensitive equipment within 150 mm (6.0 in.).

D
Route motor cables in shielded cable.

Contactor Enable

Motor Cables

Route registration and communication signals in shielded cables.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Plan the Kinetix 5700 Drive System Installation Chapter 2

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 42 - External Active Shunt Mounted Inside the Drive System Enclosure

Dirty Wireway D

Enclosure

150 mm (6.0 in.) clearance (min) above the
shunt resistor.

Clean Wireway C

76 mm (3.0 in.) clearance (min) below, left, and right of the shunt resistor.

VD External Active Shunt
Shunt Power Wiring Methods: Twisted pair in conduit (1st choice). Twisted pair, two twists per foot (min) (2nd choice).

24V DC Power Supply

Safety Cable

(hardwired safety only)

Circuit

Protection

Very Dirty Filter/AC Input Connections Segregated
(not in wireway)
AC Line Filter (required for CE)

50 mm (1.97 in.)

Kinetix 5700 Servo Drive System

MOD NET

I/O

I/O-A

I/O-B

OK+ OK EN EN+

UFB-A

UFB-B

I/O-A

I/O-B

UFB-A

UFB-B

I/O-A

I/O-B

UFB-A

UFB-B

MODULE STATUS

Digital Inputs and Ethernet Cables
C

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

No sensitive equipment within 150 mm (6.0 in.).

Module Status

D
Route motor cables in shielded cable.

Motor Cables

Route registration and communication signals in shielded cables.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 2 Plan the Kinetix 5700 Drive System Installation
Notes:

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

3 Chapter
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.

Topic

Page

Determine Mounting Order

Mount Accessory Modules

Zero-stack Tab and Cutout

Install Shared-bus Connection Systems

Drill-hole Patterns

Mount Your Kinetix 5700 Drive Modules

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-UM002K-EN-P - October 2020

Chapter 3 Mount the Kinetix 5700 Drive System

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 43) or right to left (as shown in Figure 45).

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.

Attribute
Continuous Power Output, nom

2198-S086-ERSx 29.7 kW

Table 27 - Kinetix 5700 Single-axis Inverter Modules

2198-S130-ERSx

2198-S160-ERSx

2198-S263-ERSx

44.9 kW

60.1 kW

90 kW

2198-S312-ERSx 112 kW

Attribute
Continuous Power Output, nom

Table 28 - Kinetix 5700 Dual-axis Inverter Modules

2198-D006-ERSx 2198-D012-ERSx 2198-D020-ERSx 2198-D032-ERSx 2198-D057-ERSx

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
Continuous Power Output, nom

2198T-W25K-ER 4.1 kW

The Kinetix 5700 drive system in Figure 43 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 43 - System Mounting Order Example (single DC-bus power supply)

Highest Power Utilization

Lowest Power Utilization

2198-S086-ERSx

2198-D012-ERSx 2198-D006-ERSx

Single-axis Inverter

Dual-axis Inverter Dual-axis Inverter

2198-P141

MOD NET

DC-bus Power Supply

2
1 1 4
I/O

Shared-bus Connection Systems

(DC-bus and 24V DC)

MOD NET

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Mount the Kinetix 5700 Drive System Chapter 3

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 395 for more system sizing information.

Figure 44 - System Mounting Order Example (multiple DC-bus power supplies)

Highest Power Utilization

Lowest Power Utilization

2198-S086-ERSx 2198-D012-ERSx

2198-D006-ERSx

Single-axis Inverter Dual-axis Inverter

Dual-axis Inverter

2198-P208 DC-bus Power Supplies (1)

MOD NET

Shared-bus Connection Systems

(DC-bus and 24V DC)

MOD NET

2
1 1 4
I/O

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

(1) The DC-bus power supplies can be left or right of the inverters.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 3 Mount the Kinetix 5700 Drive System

Lowest Power Utilization 2198-D006-ERSx Dual-axis Inverter

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 45 - System Mounting Order Example (regenerative bus supply)

2198-D012-ERSx Dual-axis Inverter

Highest Power Utilization 2198-S312-ERSx Single-axis Inverter

Dual-axis Inverters

Single-axis Inverters

MOD DC BUS

MOD NET

2198-DCBUSCOND-RP312 DC-bus Conditioner

I/O-A

I/O-B

I/O-A

I/O-B

I/O

MODULE STATUS

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

W V

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Regenerative Bus Supply (1)

MOD NET

I/O

L1 L2 L3
21mm2 (4-4/0 AWG) 15-20 Nm (132-177 lbin)

Shared-bus Connection System (DC-bus and 24V DC)

(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 395 for more system sizing information.

IMPORTANT The regenerative bus supply is not compatible with the iTRAK power supply.

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Mount the Kinetix 5700 Drive System Chapter 3

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 46 - Flexible Bus Bar Example

Flexible Bus-bars

External DC-bus Wire Lug Connections

DC-bus Link Connections

2198-xxxx-ERSx Inverters

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

DC-bus Links
2198-CAPMOD-DCBUS-IO Extension Module 2198-DCBUSCOND-RP312 DC-bus Conditioner Module

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 176 for DC-bus wiring requirements.

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Chapter 3 Mount the Kinetix 5700 Drive System

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 47 - Zero-stack Tab and Cutout Example

Zero-stack Tab and Cutout Engaged

Kinetix 5700 Drive Modules (front view)

MOD NET

Install Shared-bus Connection Systems

For Kinetix 5700 system sizing examples, refer to Appendix C on page 395.
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.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Zero-stack Tab and Cutout Engaged
Kinetix 5700 Drive System DC-bus power supply is mounted leftmost followed by drive with
largest amp rating.
DC-bus Power Supply

Figure 48 - DC-bus Connector Example
DC-bus Link, 85 mm
DC-bus Link, 100 mm (seated)

Mount the Kinetix 5700 Drive System Chapter 3

End Caps (2) DC-bus Link, 55 mm

Align the DC-bus link lower pivots with the latches and push downward
until they latch.
Upper Pivot
Lower Pivot Latch

DC Link Latched (1)
Dual Axis Inverter, 55 mm
Single Axis Inverter, 85 mm
Single Axis Inverter, 100 mm
(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 mm2 (6 AWG) wire. The CP connectors that are included with each module accept up to 10 mm2 (12 AWG) or 6 mm2 (10 AWG), so the shared-bus input wiring connectors can provide the means to use larger gauge conductors for reduced voltage drop on long wire runs.

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Chapter 3 Mount the Kinetix 5700 Drive System Figure 49 - 24V Connector Example

24V Input Wiring

Zero-stack Tab and Cutout Engaged

24V Input Wiring Connector

100 mm Bus-bar

85 mm Bus-bar

55 mm Bus-bar

Bus-bar Connectors
24V T-connectors

Kinetix 5700 Drive System
DC-bus power supply is mounted leftmost followed by drive with
largest amp rating.

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 (midstream 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

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Mount the Kinetix 5700 Drive System Chapter 3

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 50 - Multiple 24V Input Wiring Connector Example

Kinetix 5700 Servo Drive System (top view)

First 24V Input Wiring Connector

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Shared DC-bus Power

19
SB+/NC S1A SCA S2A SBNC NC
NC
8 16

Second 24V Input Wiring Connector

1606-XLxxx

24V DC Control Power Allen-Bradley

1606-XL

(customer-supplied)

Power Supply

Input
AC Input Power

Dual-axis Inverters

MOD NET

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+ D-

MF-A

MF-B

Regenerative Bus Supply

MOD NET

I/O

Kinetix 5700 Servo Drive System (front view)

L1 L2 L3
21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Single-axis Inverter

MOD NET

I/O

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

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.

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Chapter 3 Mount the Kinetix 5700 Drive System

27.5 mm First Mounting Hole (typical) Upper and Lower
Mounting Hole (all drive modules)
00.0 mm Upper Mounting Holes
32.0 mm Module Top, reference

Drill-hole Pattern Calculations
Use Figure 51 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 and step 3 for the remaining holes.
Figure 51 - DC-bus Power Supply Mounting Hole Patterns 45.0 mm See Mounting Hole Pattern Calculations
45.0 mm See Mounting Hole Pattern Calculations 30.0 mm See Mounting Hole Pattern Calculations Ø 6.0 mm Typical
Module Top, reference
55 mm Wide Module

176 mm Lower Mounting Hole

100 mm Wide Module

85 mm

55 mm

Wide Module Wide Module

Applies to only 2198-CAPMOD-DCBUS-IN Extension Module
Ø 6.0 mm Typical

345 mm Lower Mounting Hole

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

420 mm Lower Mounting Hole

465 mm Lower Mounting Hole

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 only 2198T-W25K-ER iTRAK Power Supply

IMPORTANT Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

332 Module Height 345 Ground Stud 350 452 Module Height 465 Ground Stud 470

0.0 Upper Mounting Holes

Mount the Kinetix 5700 Drive System Chapter 3
Use Figure 52 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 52 - Regenerative Bus Supply Mounting Hole Patterns
176 (6.93) Lower Mounting Hole
345 (13.58) Lower Mounting Hole
420 (16.54) Lower Mounting Hole

2198-RP088 Regenerative Bus Supply
(165 mm module width)

110

2198-S263-ERSx 2198-S312-ERSx Single-axis Inverter (220 mm module width)

165

2198-RP200 Regenerative Bus Supply (275 mm module width)

110

IMPORTANT Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.

110

2198-RP312 2198-RP263 Regenerative Bus Supply (440 mm module width)

55.0 110 55.0 110 55.0

345 Lower Mounting Hole
465 Lower Mounting Hole

27.5 8.0 32.00

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Chapter 3 Mount the Kinetix 5700 Drive System

M4 thread-forming fasteners, 1.7 N·m (15 lb·in) 3x Ø4.50 (0.18)
10 (0.39)
2x 10 (0.39)

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 53 - Mounting Bar

100

Drill-hole Guide

Dimensions are in mm (in.)

Mounting Bar

43.2 (1.70) Ref

2x 190 (7.48)

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.

Mount Your Kinetix 5700 Drive Modules

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 Establish Noise Zones on page 68 for panel layout 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 beginning on page 85.

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Mount the Kinetix 5700 Drive System Chapter 3

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 HF Bond for Modules on page 65.
4. Attach the DC-bus supply (or supplies) or the regenerative bus supply to the cabinet panel.

Top Screws (bottom screws not shown)

Kinetix 5700 Drive System

(DC bus supply and dual-axis

inverter are shown)

Zero-stack Tab and Cutout Engaged
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 Zerostack Tab and Cutout Example on page 82.
6. Tighten all mounting fasteners. Apply 4.0 N·m (35.4 lb·in) maximum torque to each fastener.

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Chapter 3 Mount the Kinetix 5700 Drive System
Notes:

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

4 Chapter
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.

Topic

Page

Kinetix 5700 Connector Data

Understand Control Signal Specifications

106

Feedback Specifications

112

Functional Safety Features

120

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Chapter 4 Connector Data and Feature Descriptions
Kinetix 5700 Connector Data Use these illustrations to identify the connectors and indicators for the
Kinetix 5700 drive modules.
Figure 54 - DC-bus Power Supply Features and Indicators

MOD NET
5700

5 6 7

SH
13
DC+

DC+

L3 L2 L1

4
I/O DC
11

24V 24V+

Shared-bus 24V Input

Wiring Connector

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)

Item Description

Digital inputs (IOD) connector

Ethernet (PORT1) RJ45 connector

Ethernet (PORT2) RJ45 connector

Zero-stack mounting tab/cutout

Module status indicator

Network status indicator

Item Description

LCD display

Navigation pushbuttons

Link speed status indicators

Link/Activity status indicators

Contactor-enable (CED) connector

Ground terminal

Item Description

Shunt resistor (RC) connector

DC bus (DC) connector

24V control input power (CP) connector

AC Input power (IPD) connector

Cooling fan

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Connector Data and Feature Descriptions Chapter 4

Figure 55 - Regenerative Bus Supply Features and Indicators

6
5 4 3

MOD NET
5700

I/O

OK+ OK EN EN+

6 7
8 9 10
11 12 13

2198-RPxxx Regenerative Bus Supply
Front View (2198-RP088 is shown)
1

2198-RPxxx Regenerative Bus Supply
Top View (2198-RP088 is shown)

DC
16
DC+

DC+

24V 24V+

14 2
19

2198-RP088 and 2198-RP200 Regenerative Bus Supply Bottom View (2198-RP088 is shown)

2198-RP263 and 2198-RP312 Regenerative Bus Supply (bottom view)
20

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 5 Ethernet (PORT2) RJ45 connector

11 Link speed status indicators 12 Link/Activity status indicators

18 24V control input power (CP) connector 19 AC Input power (IPD) connector (1)

6 Zero-stack mounting tab/cutout

13 Contactor enable (CED) connector

20 Cooling fans

7 Module status indicator

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.

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Chapter 4 Connector Data and Feature Descriptions Figure 56 - Dual-axis Inverter Features and Indicators

11
MOD NET
5700

10 2
9 1

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

11 12
13
14

15
DC+

24V 24V+

6 18
4

8 16

SB+/NC S1A SCA S2A SBNC NC
NC

Dual-axis Inverter, Top View (2198-D006-ERS4 module is shown)

Dual-axis Inverter, Front View (2198-D006-ERS4 module is shown)

21 22 23 24 25
25
Dual-axis Inverter, Bottom View (2198-D006-ERS4 module is shown)

W-B V-B U-B MBRK+-B

W-A V-A U-A

MB+RK-A

Item Description

Motor cable clamp with spacers

Ground terminal

Motor feedback (MF) connector - A

Motor feedback (MF) connector - B

Universal feedback (UFB) connector - A

Universal feedback (UFB) connector - B

Digital inputs (IOD) connector - A

Digital inputs (IOD) connector - B

Ethernet (PORT1) RJ45 connector

Item Description

Ethernet (PORT2) RJ45 connector

Zero-stack mounting tab/cutout

Module status indicator

Network status indicator

LCD display

Navigation pushbuttons

Link speed status indicators

Link/Activity status indicators

Safe torque-off (STO) connector

Item Description

DC bus (DC) connector

24V control input power (CP) connector

Motor brake (BC) connector - A

Motor power (MP) connector - A

Motor power (MP) connector - B

Motor brake (BC) connector - B

Cooling fan

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Connector Data and Feature Descriptions Chapter 4 Figure 57 - Single-axis Inverter Features (2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx)

9
MOD NET
5700

I/O

UFB

D+ D-

MBRK

9 10 11 12
13
14 15

DC+
17

DC
24V 24V+

9 SB+/NC

10 S1A

11 SCA

12 S2A

13 SB-

14 NC

15 NC

16 NC

8 16

Single-axis Inverter, Top View (2198-S086-ERS4 module is shown)
Single-axis Inverter, Front View (2198-S086-ERS4 module is shown)

19
20
20 21 Single-axis Inverter, Bottom View (2198-S086-ERS4 module is shown)

Item Description

Motor cable clamp

LCD display

Tie-wrap bracket for feedback cable

Navigation pushbuttons

Motor brake (BC) connector

Link speed status indicators

Motor feedback (MF) connector

Link/Activity status indicators

Universal feedback (UFB) connector

Safe torque-off (STO) connector

Digital inputs (IOD) connector

DC bus (DC) connector

Ethernet (PORT1) RJ45 connector

24V control input power (CP) connector

Ethernet (PORT2) RJ45 connector

Motor power (MP) connector

Zero-stack mounting tab/cutout

Cooling fans

Module status indicator

Ground terminal

Network status indicator

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Chapter 4 Connector Data and Feature Descriptions

9
MOD NET
5700

I/O

UFB

Figure 58 - Single-axis Inverter Features (2198-S263-ERSx, 2198-S312-ERSx)

17 10 11 12 13 14 15
16

DC+

9 SB+/NC

10 S1A

11 SCA

12 S2A

13 SB-

14 NC

15 NC

16 NC

8 16

24V

24V+

Single-axis Inverter, Top View (2198-S263-ERSx and 2198-S312-ERSx modules)

MBRK

21mm2(4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Single-axis Inverter, Front View (2198-S263-ERSx and 2198-S312-ERSx modules)

Single-axis Inverter, Bottom View (2198-S263-ERSx and 2198-S312-ERSx modules)

Item Description

Motor cable clamp

Tie-wrap bracket for feedback cable

Motor brake (BC) connector

Motor feedback (MF) connector

Universal feedback (UFB) connector

Digital inputs (IOD) connector

Ethernet (PORT1) RJ45 connector

Ethernet (PORT2) RJ45 connector

Zero-stack mounting tab/cutout

Navigation pushbuttons

Link speed status indicators

Link/Activity status indicators

Ground jumper in operation

Safe torque-off (STO) connector

Lifting points

Motor power (MP) connector

Ground terminal

DC bus (DC) connector

Module status indicator

Network status indicator

LCD display

24V control input power (CP) connector

Cooling fans (replacement kits available)

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Connector Data and Feature Descriptions Chapter 4

Figure 59 - iTRAK Power Supply Features and Indicators

MOD NET

7 8

5700

11 12

DC+

1 I/O 6

iPS RDY

5 10

19 14

DC-

IN 24V IN 24V +

iTRAK Power Supply (top view)

iTRAK Power Supply (bottom view)

2 iTRAK® Power Supply
(left side view)

iTRAK Power Supply (front view)
2
1

Item Description

Power bus cable clamp

Ground lug (partially obscured behind output plugs)

Digital inputs (IOD) connector

Ethernet (PORT1) RJ45 connector

Ethernet (PORT2) RJ45 connector

Zero-stack mounting tab/cutout

Module status indicator

Item Description

Network status indicator

LCD display

10 Navigation push buttons 11 Link speed status indicators 12 Link/Activity status indicators 13 iTRAK power-supply ready (IR) connector 14 DC bus input (DC) connector

Item Description 15 24V control input power (CP) connector
16 24V control output power (ICP) connector -A
17 DC bus output (IDC) connector - A 18 24V control output power (ICP) connector - B 19 DC bus output (IDC) connector - B 20 Cooling fan 21 Power supply internal fuse

IMPORTANT For IOD, IR, IDC, and ICP connector pinouts, and internal fuse information see iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, or iTRAK 5730 System User Manual, publication 2198T-UM003.

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Chapter 4 Connector Data and Feature Descriptions

MOD

DC BUS

5700

MODULE STATUS

Figure 60 - Capacitor Module and DC-bus Conditioner Module Features and Indicators

11 12

2198-CAPMOD-2240 Capacitor Module and

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

(side view, lug cover removed)

6 9

2198-CAPMOD-2240 Capacitor Module and

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

(front view)

24V 24V+

2198-CAPMOD-2240 Capacitor Module and

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

(top views)

Item Description

Ground stud

Stud/lug cover with wires (1)

DC M8 stud (external DC-bus), shown with flexible bus-bar (2)

Module status (MS) connector

Stud cover without wires

DC+ M8 stud (external DC-bus), shown with wire lug

DC-bus status indicator

DC-bus (DC) connector

11 M8 hex nut

Module status indicator

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.

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Connector Data and Feature Descriptions Chapter 4

Figure 61 - Extension Module Features and Indicators

87
5700
2 2198-CAPMOD-DCBUS-IO Extension Module (side view, lug cover removed)
6

1 3
2198-CAPMOD-DCBUS-IO

Extension Module

(front view)

2198-CAPMOD-DCBUS-IO Extension Module (top views)

Item Description

Ground lug

DC M8 stud (external DC-bus)

Stud/lug cover with wires (1)

DC+ M8 stud (external DC-bus), shown with flexible bus-bar (2)

Stud cover without wires

M8 hex nut

DC-bus (DC) connector

Lug spacer

(1) This example shows the lug cover oriented for wires exiting to the left (module is on the far left of drive configuration). Rotate lug cover 180° when wires exit to the right (module is on the far right of drive configuration).
(2) Flexible bus-bars are included with only the 2198-CAPMOD-DCBUS-IO extension module.

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Chapter 4 Connector Data and Feature Descriptions

Safe Torque-off Connector Pinout
The hardwired safe torque-off (STO) connector pinouts apply to single-axis and dual-axis inverters. For feature descriptions and wiring information, refer to Chapter 9 beginning on page 316.

Input Power Connector Pinouts

Input power connectors include the AC input power (IPD) connector, contactor enable (CED) connector, and the 24V input power (CP) connector.

Table 30 - AC Input Power Connector

IPD Pin

Description

Chassis ground

Three-phase input power

Signal Module

· DC-bus power supply

· Regenerative bus supply

Table 31 - 24V Input Power Connector

CP Pin 1

Description 24V power supply, customer supplied

24V common

Signal 24V+
24V

Module
· DC-bus power supply · Regenerative bus supply · Inverters · Capacitor module · DC-bus conditioner module · iTRAK power supply

Table 32 - Contactor Enable Connector

CED Pin OK+
OK
EN EN+

Description

Signal

Relay-driven contact that provides a 24V signal to non-Kinetix 5700 inverters indicating that they can draw power from the regenerative power supply. This signal is intended for use with Kinetix 6000, Kinetix 7000, or PowerFlex® drive migration.

CONV OK+ CONV OK

Relay-driven contact that is used in the control CONT EN

string for a three-phase power contactor.

CONT EN+

Module
Regenerative bus supply
· DC-bus power supply · Regenerative bus supply

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DC Bus and Shunt Resistor Connector Pinouts

The 2198-Pxxx DC-bus power supply RC connector wires to an external passive shunt when the internal shunt capacity is exceeded. The 2198-RPxxx regenerative bus supply has no internal shunt and the RC connector wires to an external active shunt.

Table 33 - DC Bus Power Connector

DC Pin Description Bus bar DC bus connections

Signal DC
DC+

Module
· DC-bus power supply · Regenerative bus supply · Inverters · Accessory modules · iTRAK power supply

Table 34 - Shunt Connector

RC Pin 1 2 1 2

Description Passive shunt connections Active shunt connections

Signal SH DC+ DC DC+

Module DC-bus power supply Regenerative bus supply

Digital Inputs Connector Pinouts

The DC-bus power supply has two configurable digital inputs and four configurable functions to choose from in the Logix Designer application.

Table 35 - DC-bus Power Supply Digital Input Pinouts

Pin 1
Pin 4 Pin Orientation for 4-pin Digital Inputs (IOD) Connector

IOD Pin 1 2 3 4

Description 24V current sinking fast input #1 I/O common for customer-supplied 24V supply 24V current sinking fast input #2 I/O cable shield termination

Signal IN1 COM IN2 SHLD

Table 36 - DC-bus Power Supply Configurable Functions

Module DC-bus power supply

Default Configuration
Digital input1 = Enable Digital input2 = Unassigned

Description Unassigned Enable Bus Capacitor OK Shunt Thermal Switch OK Bus Conditioner OK

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Single-axis inverters, dual-axis inverters, and the regenerative bus supply have four configurable digital inputs with fast response times and ten configurable functions to choose from in the Logix Designer application.

Table 37 - Inverter and Regenerative Bus Supply Digital Input Pinouts

Pin Orientation for 10-pin Digital Inputs (IOD) Connector

IOD Pin 1 2 3 4 5 6 7 8 9 10

Description 24V current sinking fast input #1 I/O common for customer-supplied 24V supply 24V current sinking fast input #2 I/O common for customer-supplied 24V supply Chassis ground 24V current sinking fast input #3 I/O common for customer-supplied 24V supply 24V current sinking fast input #4 I/O common for customer-supplied 24V supply Chassis ground

Signal IN1 COM IN2 COM SHLD IN3 COM IN4 COM SHLD

Module
· Inverters · Regenerative bus supply

Table 38 - Inverter Configurable Functions

Default Configuration
Digital input1 = Enable Digital input2 = Home Digital input3 = Registration 1 Digital input4 = Registration 2

Description Unassigned Enable Home Registration 1 Registration 2 Positive overtravel Negative overtravel Regeneration OK Bus Capacitor OK Shunt Thermal Switch OK Bus Conditioner OK

Table 39 - Regenerative Bus Supply Configurable Functions

Default Configuration
Digital input1 = Enable Digital input2 = AC Line Contactor OK Digital input3 = Unassigned Digital input4 = Unassigned

Description Unassigned Enable Bus Capacitor OK Shunt Thermal Switch OK AC Line Contactor OK Bus Conditioner OK

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Ethernet Communication Connector Pinout

Description

Transmit+

Transmit

Receive+

Reserved

Receive

Reserved

Signal TD+ TD RD+ RD

Module
18 · DC-bus power supply · Regenerative bus supply · Inverters · iTRAK power supply

Motor Power, Brake, and Feedback Connector Pinouts

These connector pinouts apply to the single-axis and dual-axis inverter.

Table 40 - Motor Power Connector

MP Pin U V W

Description Three-phase motor power Chassis ground

Signal U V W

Color Brown Black Blue Green

ATTENTION: To avoid damage to the Kinetix 5700 system power supply and inverter, make sure the motor power signals are wired correctly. Refer to Figure 92 and Figure 93 beginning on page 148 for connector wiring examples.

IMPORTANT

Drive-to-motor power cables must not exceed 90 m (295 ft), depending on feedback type and overall system design. See Appendix D, beginning on page 405, for more information.
System performance was tested at this cable length. These limitations also apply when meeting CE requirements.

Table 41 - Motor Brake Connector

BC Pin 1 2

Description Motor brake connections

Signal MBRK+ MBRK

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Motor Feedback Connector Pinouts

These connector pinouts apply to the single-axis and dual-axis inverter.

Table 42 - DSL Feedback Connector

MF Pin 1 2
SHIELD

Description

Signal

D+
Bidirectional data and power for digital encoder interface D

Cable shield and grounding plate (internal to 2198-KITCON-DSL connector kit) termination point.
Cable shield and shield clamp (internal to 2198-H2DCK converter kit) termination point

SHIELD

IMPORTANT

Drive-to-motor power cables must not exceed 90 m (295 ft), depending on feedback type and overall system design. See Appendix D, beginning on page 405, for more information.
System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements.

Figure 62 - Pin Orientation for 2-pin DSL Feedback (MF) Connector

Pin 1 Pin 2

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Universal Feedback Connector Pinouts

These connector pinouts apply to the single-axis and dual-axis inverter.

Table 43 - Hiperface and TTL Sine/Cosine Universal Feedback Connector

UFB Pin Description

Signal

UFB Pin Description

Sine differential input + A differential input +

MTR_SIN+ MTR_AM+

Clock output +

Sine differential input A differential input

MTR_SIN MTR_AM

Data differential input/output Index differential input

Cosine differential input + B differential input +

MTR_COS+ MTR_BM+

Motor thermostat (normally closed) (2)

Cosine differential input B differential input

MTR_COS MTR_BM

Hall commutation S1 input

Data differential input/output + Index differential input +

MTR_DATA+ MTR_IM+

Hall commutation S2 input

Encoder common

Encoder 9V power output

MTR_ECOM MTR_EPWR9V (1)

Encoder 5V power output

Clock output

Hall commutation S3 input

MTR_S3

(1) Determine which power supply your encoder requires and connect to only the specified supply. Do not make connections to both supplies. (2) Not applicable unless motor has integrated thermal protection.

Signal MTR_CLK+ MTR_DATAMTR_IM MTR_TS
MTR_S1
MTR_S2 MTR_EPWR5V (1) MTR_CLK

Figure 63 - Pin Orientation for 15-pin Universal Feedback (UFB) Connector

Pin 15
Pin 11 Pin 6

Pin 10 Pin 5
Pin 1

Accessory Module Pinouts

The module status (MS) connector applies to capacitor modules and DC-bus conditioner modules.

Table 44 - Module Status Connector

MS Pin 1 2

Description Module status output

Signal MS MS

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Understand Control Signal Specifications

This section provides a description of the Kinetix 5700 digital inputs, Ethernet communication, power and relay specifications, encoder feedback specifications, and safe torque-off features.

Digital Inputs
Digital inputs are available for the machine interface on the IOD connector. Two for the DC-bus power supply, four for the single-axis inverter, four per axis for the dual-axis inverters, and four for the regenerative bus supply. Digital inputs require a 24V DC @ 15 mA supply. These are sinking inputs that require a sourcing device. A common connection is provided on the IOD connector for each of the digital inputs.
IMPORTANT To improve registration input EMC performance, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001.
Table 45 - Understand Digital Input Functions

2198-Pxxx 2198-xxxx-ERSx 2198-RPxxx

Functions

Description (2)

Enable

A 24V DC input is applied to this terminal as a condition to enable each module.

XXX

Home

An active state indicates to a homing sequence that the referencing sensor has been seen. Typically, a transition of this signal is used to establish a reference position for the machine axis.

Registration 1 Registration 2

An inactive-to-active transition (also known as a positive transition) or active-to-inactive transition (also known as a negative transition) is used to latch position values for use in registration moves.

X X

Positive Overtravel Negative Overtravel

The positive/negative limit switch (normally closed contact) inputs for each axis require 24V DC (nominal).

In the active state the inverters can be enabled. An inactive state indicates that the Bulletin 8720MC-RPS unit is not ready to supply DCbus power. The inverters cannot be enabled.

Regeneration OK (1)

When a bus group is supplied by an 8720MC-RPS unit, one inverter in the bus group must be configured in the Logix Designer application as Shared-DC Non-CIP MotionTM Converter and assigned to Regeneration OK. This signal is wired from RDY on the

8720MC-RPS unit and indicates to the Kinetix 5700 drive system that the 8720MC-RPS unit is ready to supply power. Enabled inverters

enumerate a Bus Power Sharing fault if the Regeneration OK input goes inactive.

Shunt Thermal Switch OK

When the 2198-R014, 2198-R031, or 2198-R127 external shunt resistor is wired to the DC-bus power supply, this input must be configured in the Logix Designer application to monitor the status of the external shunt module thermal switch and assigned to Shunt thermal switch OK. This function does not apply to the 2198-R004 shunt resistor. You can also use this input to monitor the status of an X X X active shunt module in DC-bus power supply systems that are connected via the capacitor module or extension module, or in regenerative bus supply systems that are connected via the RC connector or an accessory module.

Bus Capacitor OK

You can configure this input in the Logix Designer application and wire the module status (MS) output from the 2198-CAPMOD-2240 capacitor module to indicate to the DC-bus power supply, regenerative bus supply, or inverters that a major fault is present on the X X X capacitor module.

Bus Conditioner OK

You can configure this input in the Logix Designer application and wire the module status (MS) output from the 2198-DCBUSCONDRP312 DC-bus conditioner module to indicate to the DC-bus power supply, regenerative bus supply, or inverters that a major fault is present on the DC-bus conditioner module.

XXX

You can configure this input in the Logix Designer application to tell the 2198-RPxxx regenerative bus supply that the main AC line AC Line Contactor OK contactor has closed and is sending L1...L3 AC line voltage. This is accomplished by wiring an auxiliary Normally Open contact off the X
main M1 contactor into one of the regenerative bus supply digital inputs.

(1) For more information on configuring a Shared-bus Non-CIP Motion Converter, refer to step 1 on page 217. For more information on wiring the 8720MC-RPS unit, refer to Figure 170 on page 356. (2) The function is always inactive unless assigned to a digital input in the Logix Designer application. To configure your DC-bus power supply digital input for Shunt Thermal Switch OK or Bus capacitor
OK, refer to step 11 on page 201. To configure your regenerative bus supply digital input for Bus Conditioner OK or AC Line Contactor OK, refer to step 11 on page 205.

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Attribute

Table 46 - Digital Input Specifications Value

Connector Data and Feature Descriptions Chapter 4 Drive Module

2198-Pxxx 2198-xxxx-ERSx 2198-RPxxx

Digital input type Input current (with 24V applied) On-state input voltage Off-state input voltage Pulse reject filtering (applies to registration function only) Pulse reject filtering (debounce filter) Applies to all other input functions, Home, for example. Propagation delay (registration functions, inverters only) Registration accuracy (inverters only) Registration repeatability (inverters only) Windowed registration invalid-to-valid event delay (inverters only)

Optically isolated, active high, single-ended, current sinking (EN 61131-2 Type 1) 12 mA, typical 15...30V @ 15 mA, max -1.0...5.0V 12.0 s
20 ms, nom
0 (delay compensated) ±3 s 700 ns 125 s, min

XXX XXX XXX XXX X
XXX
X X X X

Figure 64 - Digital Input Circuitry

IOD-1 or IOD-3 INx

COM IOD-2

24V DC Kinetix 5700 Drive Module

INPUT

Ethernet Communication Specifications

The PORT1 and PORT2 (RJ45) Ethernet connectors provide communication with the Logix 5000TM controller.

Attribute

Value

Communication Cyclic update period (1)

The drive auto-negotiates speed and duplex modes. These modes can be forced through the Logix Designer application. 100BASETX, full duplex is recommended for maximum performance.
1.0 ms, min

Embedded switch features

Three-port, cut-through, time correction on IEEE-1588 packets, limited filtering, quality of service with four priority levels

Auto MDI/MDIX crossover detection/correction Yes

Port-to-port time synchronization variation 100 ns, max

Cabling

CAT5e shielded, 100 m (328 ft) max

(1) With CIP SecurityTM enabled on the 2198-Pxxx DC-bus power supply, the cyclic update period cannot be faster than 4.0 ms.

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Contactor Enable Relay

The contactor-enable circuitry includes a relay-driven contact within the 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus 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 power supply. In addition, the AC threephase contactor control string must be wired in series with the contactorenable relay at the contactor-enable (CED) connector. Refer to Power Wiring Examples on page 343 for wiring examples.

ATTENTION: Wiring the contactor-enable relay is required. To avoid personal injury or damage to the drive, 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.

Figure 65 - Contactor-enable Relay Circuit

Normally Open Relay
Power Supply

CONT EN+ CONT EN-

Surge suppression (diode, varistor module, RC module, or DC electronic interface) is required across the auxiliary and main contactor coils.

Table 47 - Regenerative Bus Supply (CED) Relay Output Specifications

Attribute

Value

Nominal

On-state current Current flow when the relay is closed.

On-state resistance Contact resistance when the relay is closed.

0.1

Off-state voltage Voltage across the contacts when the relay is open. 24V DC

Maximum 1 A 28V DC

Table 48 - DC-bus Power Supply (CED) Relay Output Specifications

Attribute

Value

Nominal

On-state current Current flow when the relay is closed.

On-state resistance Contact resistance when the relay is closed.

1.0

Off-state voltage Voltage across the contacts when the relay is open. 24V DC

Maximum 1 A 28V DC

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Converter OK Relay

The converter OK circuitry includes a relay-driven contact within the 2198-RPxxx regenerative bus supply. The relay provides a 24V signal to nonKinetix 5700 inverters indicating that they can draw power from the regenerative power supply and that the power supply is not faulted.
TIP This signal is intended for use with Kinetix 6000, Kinetix 6200, Kinetix 6500 Kinetix 7000, or PowerFlex drives when migrating from the 8720MC-RPS to the 2198-RPxxx regenerative bus supply.

Refer to Power Wiring Examples on page 343 for wiring examples.

Figure 66 - Converter OK Relay Circuit

24V PWR

Internally

Controlled

Relay

OK+

Regenerative

Resettable Fuse

Bus Supply

OK 24V COM

Current limited output with auto-resettable fuse.

Table 49 - Converter OK Relay Output Specifications

Attribute On-state current Off-state voltage On-state voltage

Value

Min

Current flow when the relay is closed.

Voltage across the contacts when the relay is open

or closed.

Max 0.8 A 0V DC 24V DC

Motor Brake Circuit
The brake option is a spring-set holding brake that releases when voltage is applied to the brake coil in the motor. The customer-supplied 24V power supply drives the brake output through a solid-state relay. The dual-axis inverters have separate brake circuits for each axis. The solid-state brake driver circuit provides the following:
· Brake current-overload protection · Brake over-voltage protection
For a detailed information on vertical loads and how the servo motor holdingbrake option can be used to help keep a load from falling, see the Vertical Load and Holding Brake Management Application Technique, publication MOTION-AT003.

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Two connections (BC-1 and BC-2) are required for the motor brake output (refer to Figure 67). Connections are rated for 2.0 A @ +24V (dual-axis inverters) and 5.0 A @ +24V (single-axis inverters).

Figure 67 - Motor Brake Circuit

Control Board

INT PWR

24V PWR

Kinetix 5700 Servo Drive

24V COM

Inductive Energy Clamp

MBRK+ (BC-1) MBRK (BC-2)

IMPORTANT Motor holding-brake switching frequency must not exceed 10 cycles/ min.
Control of the solid-state relay to release the motor brake is configurable in the Logix Designer application (refer to Configure SPM Motor Closed-loop Control Axis Properties on page 246). An active signal releases the motor brake. Turn-on and turn-off delays are specified by the MechanicalBrakeEngageDelay and MechanicalBrakeReleaseDelay settings.

IMPORTANT

Holding brakes that are available on Allen-Bradley® rotary motors are designed to hold a motor shaft at 0 rpm for up to the rated brakeholding torque, not to stop the rotation of the motor shaft, or be used as a safety device.
You must command the servo drive to 0 rpm and engage the brake only after verifying that the motor shaft is at 0 rpm.

These steps provide one method you can use to control a brake.
1. Wire the mechanical brake according to the appropriate interconnect diagram in Appendix A beginning on page 362.
2. Enter the MechanicalBrakeEngageDelay and Mechanical BrakeReleaseDelay times in the Logix Designer application.
Refer to Axis Properties>Parameter List. The delay times must be from the appropriate motor family brake specifications table in the Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001.
3. Use the drive stop-action default setting (Current Decel & Disable).
Refer to Axis Properties>Actions>Stop Action in the Logix Designer application.
4. Use the motion instruction Motion Axis Stop (MAS) to decelerate the servo motor to 0 rpm.
5. Use the motion instruction Motion Servo Off (MSF) to engage the brake and disable drive.

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Control Power
The Kinetix 5700 drive modules require 24V DC (21.6...26.4V) input power for control circuitry.

IMPORTANT

SELV or PELV rated power supplies must be used to energize external safety devices connected to the Kinetix 5700 safety inputs.
The National Electrical Code and local electrical codes take precedence over the values and methods provided. Implementation of these codes is the responsibility of the machine builder.

Table 50 - Control Power Current Specifications

Drive Module DC-bus Power Supplies

Drive Module Cat. No.
2198-P031 2198-P070 2198-P141 2198-P208

24V Current Per Module (non-brake motor)

24V Current, max (with maximum brake current)

24V Inrush Current (5)

ADC

0.8

4.0

1.9

2198-RP088

4.3

2198-RP200

5.4

Regenerative Bus Supplies

4.0

2198-RP263

9.1

2198-RP312

2198-D006-ERSx

2198-D012-ERSx

1.4 (2)

5.5 (3)

Dual-axis Inverters

2198-D020-ERSx

4.0

2198-D032-ERSx

1.7 (2)

7.7 (3)

2198-D057-ERSx

2.3 (2)

8.3 (3)

2198-S086-ERSx

2198-S130-ERSx

Single-axis Inverters

2198-S160-ERSx

4.6

9.6 (4)

4.0

2198-S263-ERSx

2198-S312-ERSx

iTRAK Power Supply (1) 2198T-W25K-ER

1.3

2.2

Capacitor Module

2198-CAPMOD-2240 0.1

7.0

Extension Module

2198-CAPMOD-DCBUS-IO

DC-bus Conditioner Module 2198-DCBUSCOND-RP312 0.1

7.0

(1) These values represent only the iTRAK power supply. They do not include the iTRAK motor modules that are connected to the iTRAK power supply and also draw current from this 24V control power input. For more information regarding 24V control power requirements, see iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, or iTRAK 5730 System User Manual, publication 2198T-UM003.
(2) Values are base current per module. (3) Values assume two brake motors, each drawing the maximum rating of 2 A, are attached to each module. (4) Values assume the maximum rated brake current of 5 A. (5) Inrush current duration is less than 30 ms.

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Feedback Specifications

The Kinetix 5700 drives accept motor feedback signals from Hiperface digitalservo-link (DSL) encoders on the motor feedback (MF) connector and Hiperface, incremental, and EnDat encoders on the universal feedback (UFB) connector.
IMPORTANT Auto-configuration in the Logix Designer application of intelligent absolute, high-resolution encoders, incremental, and EnDat encoders is possible with only Allen-Bradley motors.
The MF and UFB connectors can be used in the following applications: · Motor feedback · Auxiliary feedback-only axis · Dual-loop control applications

Encoder Feedback Supported on the DSL Feedback Connector
The Kinetix 5700 drives support Kinetix VPL, VPC-Q, VPF, VPH, and VPS servo motors with Hiperface digital-servo-link (DSL) encoders by using the 2-pin (MF) feedback connector.
Other Allen-Bradley motors and actuators with Hiperface single-turn or multi-turn high-resolution absolute encoders are also accepted. However, to connect these devices to the MF connector, you must also use the 2198H2DCK Hiperface-to-DSL (series B or later) converter kit for Hiperface-toDSL feedback conversion. Alternatively, you can use the universal (UFB) feedback connector for those motors and actuators.

Encoder Feedback Supported on the UFB Feedback Connector

The Kinetix 5700 drives also support multiple types of feedback devices by using the 15-pin (UFB) universal feedback connector and sharing connector pins in many cases. Use the 2198-K57CK-D15M universal feedback connector kit for terminating the feedback conductors.

Table 51 - Universal Feedback General Specifications

Attribute
Feedback device support
Power supply voltage (MTR_EPWR5V) Power supply current (MTR_EPWR5V) Power supply voltage (MTR_EPWR9V) Power supply current (MTR_EPWR9V) Thermostat

Motor Feedback
· Hiperface · Generic TTL Incremental · Generic Sine/Cosine Incremental · EnDat Sin/Cos (1) · EnDat Digital (2)
5.27...5.50V (3) 300 mA, max
8.30...9.90V (3) 150 mA, max
Single-ended, under 500 = no fault, over 10 k= fault

Auxiliary Feedback · Hiperface · Generic TTL Incremental · Generic Sine/Cosine Incremental · EnDat Sin/Cos (1) · EnDat Digital (2)
Single-ended, under 500 = no fault, over 10 k= fault

(1) EnDat sine/cosine encoders support only Kinetix RDB direct-drive motors. (2) EnDat digital encoders support VPC-Bxxxxx-Y motors and applicable third-party motors as described in Table 58 on page 115. (3) For 2198-Dxxx-ERSx (dual-axis) drives, these motor feedback voltage and current ratings are per axis.

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Table 52 - Universal Feedback Signals by Device Type

UFB Pin Hiperface

Generic TTL Incremental

Generic Sine/Cosine Incremental

EnDat Sine/Cosine

EnDat Digital

MTR_SIN+

MTR_AM+

MTR_SIN+

ENDAT_B+

MTR_SIN

MTR_AM

MTR_SIN

ENDAT_B

MTR_COS+

MTR_BM+

MTR_COS+

ENDAT_A+

MTR_COS

MTR_BM

MTR_COS

ENDAT_A

MTR_DATA+

MTR_IM+

MTR_DATA+

MTR_ECOM

MTR_EPWR9V (1)

MTR_S3

MTR_CLK+

MTR_DATA

MTR_IM

MTR_DATA

MTR_TS

MTR_S1

MTR_S2

MTR_EPWR5V (1)

MTR_EPWR5V

MTR_EPWR5V (1)

MTR_CLK

(1) Determine which power supply your encoder requires and connect to only the specified supply. Do not make connections to both supplies.

ATTENTION: To avoid damage to components, determine which power supply your encoder requires and connect to either the 5V or 9V supply, but not both.

Table 53 - Hiperface Specifications

Attribute Memory support Hiperface data communication Sine/cosine interpolation Input frequency (AM/BM) Input voltage (AM/BM) Line loss detection (AM/BM) Noise filtering (AM and BM)
Incremental position verification

Value Not programmed, or programmed with Allen-Bradley motor data 9600 baud, 8 data bits, no parity 4096 counts/sine period 250 kHz, max 0.6...1.2V, peak to peak, measured at the drive inputs Average (sin2 + cos2) > constant Two-stage coarse count pulse reject filter with rejected pulse tally Position compare between incremental accumulator and serial data performed every 50 ms or less

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Table 54 - Generic TTL Incremental Specifications

Attribute
TTL incremental encoder support
Quadrature interpolation
Differential input voltage (MTR_AM, MTR_BM, and MTR_IM)
DC current draw (MTR_AM, MTR_BM, and MTR_IM)
Input signal frequency (MTR_AM, MTR_BM, and MTR_IM)
Edge separation (MTR_AM and MTR_BM)
Commutation verification
Hall inputs (MTR_S1, MTR_S2, and MTR_S3)

Value 5V, differential A quad B 4 counts / square wave period 5V DC, differential line driver (DLD) output compatible
30 mA, max
5.0 MHz, max
42 ns min, between any two edges Commutation angle verification performed at the first Hall signal transition and periodically verifies thereafter Single-ended, TTL, open collector, or none

Table 55 - Generic Sine/Cosine Incremental Specifications

Attribute Sine/Cosine interpolation Input frequency (MTR_SIN and MTR_COS) Differential input voltage (MTR_SIN and MTR_COS)
Commutation verification
Hall inputs (MTR_S1, MTR_S2, and MTR_S3)

Value 2048 counts/sine wave period 250 kHz, max
0.6...1.2V, p-p Commutation angle verification performed at the first Hall signal transition and periodically verifies thereafter Single-ended, TTL, open collector, or none

Refer to Encoder Phasing Definitions on page 117 for encoder phasing alignment diagrams.

Table 56 - EnDat Sine/Cosine Interface Specifications

Attribute Protocol EnDat Sine/Cosine data communication Sine/Cosine interpolation Input frequency (MTR_SIN and MTR_COS) Differential input voltage (MTR_SIN and MTR_COS)
Incremental position verification

Value EnDat Sine/Cosine 2 Mbps, synchronous 2048 counts/sine wave period
250 kHz, max
0.6...1.2V, p-p
Position compare between incremental accumulator and serial data performed every 50 ms or less.

Table 57 - EnDat Digital Interface Specifications

Attribute EnDat Digital data communication

Value 4 Mbps, synchronous

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Table 58 - Support Requirements for EnDat Encoders

Requirement

EnDat Sine/Cosine

Supported models

LC 483 ECl 119 (1) ECN 113 ECN 1313/EQN 1325 ECN 413/EQN 425 ROQ 425

Position initialization

Digital

Position tracking

Uses sine/cosine signals

Data frequency

100 kHz

Sine/cosine frequency

0...250 kHz

(1) ECI119 can be procured as either EnDat Sin/Cos or EnDat Digital.

EnDat Digital
LIC 4000 ECl 119 (1) ROQ 437 ECN 1123/ EQN 1135 ECN 1325 / EQN 1337 ECI 1319/EQI 1331 ECI 1118/EQI 1130 ECN 125
Digital
4.125 MHz

IMPORTANT To properly support system EnDat feedback, the keying configuration in drive Module Properties of the Logix Designer application must be selected to use Kinetix 5700 drive firmware revision 5.0 or later.

IMPORTANT

Unprogrammed Smart feedback devices (Hiperface Sin/Cos, Hiperface DSL, EnDat Sin/Cos, and EnDat Digital) are not supported. Unprogrammed as load or feedback-only feedback types are supported, except unprogrammed Hiperface DSL encoders. Contact your local distributor or Rockwell Automation representative for support options.

Auxiliary Feedback Specifications

The Kinetix 5700 inverters support multiple types of feedback devices by using the 15-pin (UFB) connector and sharing connector pins in many cases. Refer to Configure Feedback-only Axis Properties on page 231 to use these in your application.

Table 59 - Auxiliary Feedback Signals by Device Type

UFB Pin Hiperface

Generic TTL Incremental

Generic Sine/Cosine Incremental

EnDat Sin/Cos

EnDat Digital

AUX_SIN+

AUX_AM+

AUX_SIN+

ENDAT_B+

AUX_SIN-

AUX_AM-

AUX_SIN-

ENDAT_B

AUX_COS+

AUX_BM+

AUX_COS+

ENDAT_A+

AUX_COS-

AUX_BM-

AUX_COS-

ENDAT_A

AUX_DATA+

AUX_IM+

AUX_DATA+

AUX_ECOM

AUX_EPWR9V (1)

AUX_CLK+

AUX_DATA-

AUX_IM-

AUX_DATA-

AUX_EPWR5V (1)

AUX_EPWR5V

AUX_EPWR5V (1)

AUX_CLK-

(1) Determine which power supply your encoder requires and connect to only the specified supply. Do not make connections to both supplies.

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ATTENTION: To avoid damage to components, determine which power supply your encoder requires and connect to either the 5V or 9V supply, but not both.

Specifications for the auxiliary feedback channel are identical to the motor feedback channel, except for specifications related to commutation and BLOB programming.

The 9.0V and 5.0V power supplies for auxiliary feedback devices are shared with the motor feedback channel, and the total current capability is outlined in the table on page 112.

Allen-Bradley Bulletin 842HR, 844D, 847H, and 847T encoders are the preferred encoders for auxiliary feedback connections.

Table 60 - Allen-Bradley Auxiliary Feedback Encoders

Cat. No. 842HR-MJDZ115FWYD (multi-turn) 842HR-SJDZ115FWYD (single-turn) 844D-B5CC1FW 844D-B5CC1CS 844D-B5CC1DR 847H-DN1A-RH01024 847H-DN1A-RH02048 847H-DN1A-RH05000 847T-DN1A-RH01024 847T-DN1A-RH02048

Description
Size 25, sine/cosine (serial), square flange, 3/8 in. solid shaft with flat, 5...12V DC, digital RS-485 interface, M23, 17-pin connector
HS35, hollow-shaft incremental encoders, rear (through-shaft), 5/8 inch, tether, 3/8 in. bolt on a 2.5...4.0 in. diameter, 5V DC in, 5V DC DLD out, MS connector, 10-pin
Size 25, incremental encoder, standard square flange, 3/8 inch diameter shaft with flat, 4.5...5.5V line driver, TTL (B-Leads-A, CW, Z gated with BN), MS connector, 10-pin
Size 20, incremental encoder, standard square flange, 3/8 inch diameter shaft with flat, 4.5...5.5V line driver, TTL (B-Leads-A, CW, Z gated with BN), MS connector, 10-pin

You can add and configure the Allen-Bradley Bulletin 842E-CM Integrated Motion on EtherNet/IPTM absolute encoder into your Studio 5000 Logix Designer® application to function as a feedback-only CIP Motion axis in the Logix 5000 controller.

Table 61 - Allen-Bradley 842E-CM Absolute Network Encoders

Cat. No.
842E-CM-Mxxxx (30-bit multi-turn) 842E-CM-Sxxxx (18-bit single-turn)

Description
· Support for the standard motion instruction set in the Studio 5000 Logix Designer application
· EtherNet/IP interface compliant with IEEE 1588 · Support for linear, ring, and star Ethernet topologies · IP67 environmental rating · Available with solid and hollow shaft

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The Allen-Bradley Bulletin 843ES CIP SafetyTM absolute network encoder is designed for safety applications that require speed, direction, or position monitoring safety functions.

Table 62 - Allen-Bradley 843ES Absolute Network Encoders

Cat. No.

Description

843ES-MIPxBAx (12-bit multi-turn) 843ES-SIPxBAx (18-bit standard, 15-bit safety resolution single-turn)

· Rated up to and including SIL 3 according to IEC 61800-5-2, IEC 620261, and IEC 61508-1
· Rated up to and including PLe, Cat. 3, according to ISO 13849-1 · Clamping, synchro, and square flange options for solid shaft · Blind-hollow shaft available with stator coupling · Feather-key solid shaft to prevent relative rotation · Dual Ethernet ports with embedded EtherNet/IP switch for linear
networks and Device Level Ring topologies · IP67 washdown rating

Refer to the Kinetix Motion Accessories Technical Data, publication KNX-TD004, for more information on these Allen-Bradley encoders.

Encoder Phasing Definitions
For TTL encoders, the drive position increases when A leads B. Clockwise motor rotation is assumed, when looking at the shaft.
Figure 68 - TTL Encoder Phasing 360°
90° 90° 90° 90°

A /A

B /B

Z /Z

For Sin/Cos encoders (Hiperface and EnDat), the drive position increases when Cosine (B) leads Sine (A). Clockwise motor rotation is assumed, when looking at the shaft.

Figure 69 - Sine/Cosine Encoder Phasing

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IMPORTANT The Sine/Cosine encoder signal phasing is different than the TTL encoder signal phasing.

IMPORTANT

When using an incremental Sine/Cosine feedback device, the drive cannot synthesize a marker signal, so a physical marker signal is required for the home-to-marker sequence (and the marker hookup test) to complete.
When using absolute feedback devices (for example, Hiperface) the drive synthesizes a marker signal because these devices don't have a marker signal required for the home-to-marker sequence (and the marker hookup test) to complete.

The drive UFB feedback connector uses Hall signals to initialize the commutation angle for permanent magnet motor commutation.

Figure 70 - Hall Encoder Phasing

VUN VWN VVN S1 S2 S3

300 0

60 120 180 240 300

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Encoder Type Hiperface DSL
Hiperface Hiperface (magnetic scale) EnDat

Absolute Position Feature

Cat. No. Designator -P
-W
-Q
-M
-V -xDx -7 -Y

The absolute position feature tracks the position of the motor, within the multi-turn retention limits, while the drive is powered off. The absolute position feature is available with only multi-turn encoders.

Table 63 - Absolute Position Retention Limits

Motor Cat. No.
VPL-A/Bxxxxx-P VPF-A/Bxxxxx-P VPS-Bxxxxx-P
VPL-A/Bxxxxx-W, VPF-A/Bxxxxx-W VPH-A/Bxxxxx-W
VPL-A/Bxxxxx-Q VPC-Bxxxxx-Q VPF-A/Bxxxxx-Q VPH-A/Bxxxxx-Q
VPC-B3004x-M MPL-A/Bxxxxx-M MPM-A/Bxxxxx-M MPF-A/Bxxxxx-M MPS-A/Bxxxxx-M
MPL-A/Bxxxxx-V

RDB-Bxxxxxx-7
VPC-Bxxxxx-Y

Actuator Cat. No.
VPAR-A/Bxxxxx-P
VPAR-Bxxxxx-W
VPAR-Bxxxxx-Q
MPAR-A/B3xxxx-M MPAI-A/BxxxxxM
MPAS-A/Bxxxx1-V05, MPAS-A/Bxxxx2-V20 MPAR-A/B1xxxx-V, MPAR-A/B2xxxx-V MPAI-A/BxxxxxV LDAT-Sxxxxxx-xDx

Retention Limits Turns (rotary) mm (linear) 4096 (±2048)
4096 (±2048)

512 (±256)

2048 (±1024)

4096 (±2048)
1024 (±512) 128 (±64)

960 (37.8)

Figure 71 - Absolute Position Limits (measured in turns) 4096 Turns 2048 Turns 1024 Turns 512 Turns 128 Turns

-2048

-1024

-512

-256

-128

-64

+64

+128

+256

+512

+1024

+2048

Position at Power Down

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Functional Safety Features

Kinetix 5700 servo drives have safe torque-off (STO) capability and can safely turn off the inverter power transistors in response to the removal of the STO digital inputs, resulting in Stop Category 0 behavior. Hardwired and integrated safety options are available on all Kinetix 5700 servo drives.

Hardwired STO Mode
Hardwired safe torque-off (STO) mode supports parallel input terminals for cascading to adjacent drives over duplex wiring. For applications that do not require the safety function you must install jumper wires to bypass the safe torque-off feature. This applies to 2198-xxxx-ERS3 and 2198-xxxx-ERS4 inverters.
Refer to Hardwired Safe Torque-off on page 312 for the STO connector pinout, installation, and wiring information.

Integrated Mode
For 2198-xxxx-ERS3 inverters in integrated STO mode, when any GuardLogix® or Compact GuardLogix safety controller issues the safe torqueoff (STO) command over the EtherNet/IP network and the Kinetix 5700 drives execute the STO commands.
Refer to Integrated Safe Torque-off on page 322 for integrated safety drive specifications, configuring motion and safety connections, direct motion commands, and the STO bypass feature.
For 2189-xxxx-ERS4 inverters in integrated mode, the GuardLogix 5580 or Compact GuardLogix 5380 safety controller activates the Monitored SS1 stopping function or any of the Drive Safety instructions providing controllerbased safety functions over the EtherNet/IP network.
For 2189-xxxx-ERS4 and 2189-xxxx-ERS3 (series B) drives, Timed SS1 and STO are drive-based safety functions that are activated by the GuardLogix 5580 or Compact Guardlogix 5380 controller over the EtherNet/IP network.
Refer to the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001, for a description and configuration examples of the integrated stopping functions in the Studio 5000 Logix Designer application.

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5 Chapter
Connect the Kinetix 5700 Drive System

This chapter provides procedures for wiring your Kinetix® 5700 system components and making cable connections.

Topic

Page

Basic Wiring Requirements

122

Input Power Configurations for Kinetix 5700 Power Supplies

123

Ground Screw/Jumper Settings

129

Remove/Install the Ground Screw/Jumper

131

Ground the Drive System

134

Wiring Requirements

136

Wiring Guidelines

140

Wire the Power Connectors

140

Wire the Digital Input Connectors

144

Wire Motor Power and Brake Connectors

147

Connect Single Cables

154

Connect Power/Brake and Feedback Cables

158

Customer-supplied Motor Power Cables

173

Accessory Module Connections

176

External Passive-shunt Connections

177

External Active-shunt Connections

178

Ethernet Cable Connections

181

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Basic Wiring Requirements This section contains basic wiring information for the Kinetix 5700 drive
system power supplies, servo drives, the iTRAK® power supply, and accessories.
ATTENTION: 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 components.

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2198 drive modules prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use.

IMPORTANT

This section contains common PWM servo system wiring configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.

Routing the Power and Signal Cables
Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic devices can be induced into I/O communication, or other sensitive low voltage signals. This can cause system faults and communication anomalies.
The Bulletin 2090 single motor cable contains the power, brake, and feedback wires, but is properly shielded to protect the noise-sensitive feedback signals.
Refer to Electrical Noise Reduction on page 65 for examples of routing high and low voltage cables in wireways. Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001, for more information.

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Input Power Configurations for Kinetix 5700 Power Supplies

The Kinetix 5700 drive system power supply can be either the 2198-Pxxx DC-bus power supply or the 2198-RPxxx regenerative bus supply. The input power components and wiring depend on which power supply is used.

DC-bus Power Supply
Before wiring input power to your 2198-Pxxx DC-bus power supply, you must determine the type of input power within your facility. The drive modules are designed to operate in both grounded and ungrounded environments.

IMPORTANT

For IEC 61800-3 category C3 compliance, use the appropriate 2198-DBRxx-F line filter with a grounded WYE configuration. The use of a line filter in an ungrounded, corner-grounded, or impedance-grounded configuration can affect the line filter components and result in equipment damage.
2198-DBxx-F line filters also provide compliance, but are not the preferred solution because they require inverter ground jumpers installed manually.

Grounded Power Configurations
The grounded (WYE) power configuration grounds your three-phase power at a neutral point. This type of grounded power configuration is preferred.
Figure 72 - Grounded Power Configuration (WYE Secondary)

2198-Pxxx DC-bus Power Supply (bottom view)

L3 L2 L1

Three-phase Input VAC

Transformer (WYE) Secondary L3
Transformer L2
L1

Circuit

Protection Contactor

Three-phase (1) AC Line Filter (required for CE)

Phase Ground

Bonded Cabinet Ground
Ground Grid or Power Distribution Ground

Connect to drive module ground stud.

(1) When using 2198-DBxx-F line filter, 2198-Pxxx power supply has the ground jumper installed and 2198-xxxx-ERSx inverters have the ground jumpers installed. When using 2198-DBRxx-F line filter, 2198-Pxxx power supply has the ground jumper installed, 2198-xxxx-ERSx inverters have the ground jumpers removed.

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L3 L2 L1

Chapter 5 Connect the Kinetix 5700 Drive System

Figure 73 - Impedance-grounded Power Configuration (WYE secondary)

Three-phase Input VAC

2198-Pxxx DC-bus Power Supply (1) (bottom view)

Transformer (WYE) Secondary L3
Transformer L2
L1

Circuit

Protection Contactor

Phase Ground

Bonded Cabinet Ground
Ground Grid or Power Distribution Ground

Connect to drive module ground stud.

(1) 2198-Pxxx power supply has the ground jumper removed. 2198-xxxx-ERSx inverters have the ground jumpers removed.

Figure 74 - Corner-grounded Power Configuration (Delta secondary)

2198-Pxxx DC-bus Power Supply (1) (bottom view)

Transformer (Delta) Secondary

Transformer

L3 L2 L1

Circuit

Protection Contactor

Bonded Cabinet Ground
Ground Grid or Power Distribution Ground

Connect to drive module ground stud.

(1) 2198-Pxxx power supply has the ground jumper removed. 2198-xxxx-ERSx inverters have the ground jumpers removed.

Refer to Power Wiring Examples beginning on page 343 for input power interconnect diagrams.

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Ungrounded Power Configurations
The ungrounded power configuration (Figure 75), corner-grounded (Figure 74), and impedance-grounded (Figure 73) power configurations do not provide a neutral ground point.

IMPORTANT

If you determine that you have ungrounded, corner-grounded, or impedance-grounded power distribution in your facility, you must remove the ground screw in each of your DC-bus power supplies, iTRAK power supplies, and dual-axis inverters, and the ground jumper in each of your single-axis inverters.
Refer to Ground Screw/Jumper Settings on page 129 for more information.

Figure 75 - Ungrounded Power Configuration

2198-Pxxx DC-bus Power Supply (1) (bottom view)

L3 L2 L1

Three-phase Input VAC

Transformer

Circuit

Protection Contactor

Chassis Ground

Bonded Cabinet Ground
Ground Grid or Power Distribution Ground

Connect to drive module ground stud.

(1) 2198-Pxxx power supply has the ground jumper removed. 2198-xxxx-ERSx inverters have the ground jumpers removed.

ATTENTION: Ungrounded and corner-grounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground. Drive-to-motor cable lengths are limited with these AC power source types. See Appendix D, beginning on page 405, for more information.

Refer to Power Wiring Examples beginning on page 343 for input power interconnect diagrams.

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Regenerative Bus Supply
Before wiring input power to your 2198-RPxxx regenerative bus supply, you must determine the type of input power within your facility. The regenerative bus supply is designed to operate in grounded-wye and impedance grounded environments. Corner-grounded and ungrounded power can be used, but you must add an isolation transformer to the input power circuit to provide grounded-wye power.
ATTENTION: For IEC 61800-3 category C3 compliance, use the appropriate 2198-DBRxx-F AC line filter with a grounded WYE configuration. Use of the AC line filter in an ungrounded or corner-grounded configuration (without an isolation transformer) or in an impedance-grounded configuration can affect the line filter components and result in equipment damage. 2198-DBxx-F line filters are not compatible with regenerative bus supplies.
Grounded Power Configurations
This grounded (WYE) power configuration (Figure 76) grounds the threephase input power at a neutral point. This is the preferred grounded power configuration.
Figure 76 - Grounded Power Configuration (WYE secondary)

Three-phase Input VAC
Phase Ground

Transformer (WYE) Secondary

2198-RPxxx (1) Regenerative Bus Supply
(bottom view)

Transformer L2

AC Line Filter (required for CE)

L3 L2

Circuit

Protection Contactor

Bonded Cabinet Ground

Connect to drive module ground stud.

Ground Grid or Power Distribution Ground

(1) 2198-RPxxx power supply has the ground jumper installed. 2198-xxxx-ERSx inverters have the ground jumpers removed.

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This impedance-grounded power configuration (Figure 77) does not provide a neutral ground point.
ATTENTION: Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground.
Figure 77 - Impedance-grounded Power Configuration (WYE secondary)

Transformer (WYE) Secondary

2198-RPxxx (1) Regenerative Bus Supply
(bottom view)

Transformer

Three-phase Input VAC

Circuit

Protection Contactor

Phase Ground

Bonded Cabinet Ground

Connect to drive module ground stud.

Ground Grid or Power Distribution Ground

(1) 2198-RPxxx power supply has the ground jumper removed. 2198-xxxx-ERSx inverters have the ground jumpers removed.

IMPORTANT

If you determine that you have impedance-grounded power distribution in your facility, you must remove the ground screw in your regenerative power supply, iTRAK power supplies, and dual-axis inverters, and the ground jumper in each of your single-axis inverters.
Refer to Ground Screw/Jumper Settings on page 129 for more information.

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This corner-grounded power configuration (Figure 78) includes an isolation transformer that results in grounded-wye power distribution.
Figure 78 - Corner-grounded Power Configuration (with isolation transformer)

Transformer (Delta) Secondary

Isolation Transformer

2198-RPxxx (1) Regenerative Bus Supply
(bottom view)

Transformer

AC Line Filter

(required for CE)

Circuit M1 Protection Contactor
L2

Bonded Cabinet Ground
Ground Grid or Power Distribution Ground

Connect to drive module ground stud.
(1) 2198-RPxxx power supply has the ground jumper installed. 2198-xxxx-ERSx inverters have the ground jumpers removed.
Refer to Power Wiring Examples beginning on page 343 for input power interconnect diagrams.
Ungrounded Power Configurations
This ungrounded power configuration (Figure 79) includes an isolation transformer that results in grounded-wye power distribution.
Figure 79 - Ungrounded Power Configuration (with isolation transformer)

Three-phase Input VAC
Chassis Ground

Transformer

Isolation Transformer

2198-RPxxx (1) Regenerative Bus Supply
(bottom view)

AC Line Filter

(required for CE)

Circuit M1

Protection Contactor

Bonded Cabinet Ground

Connect to drive module ground stud.

Ground Grid or Power Distribution Ground
(1) 2198-RPxxx power supply has the ground jumper installed. 2198-xxxx-ERSx inverters have the ground jumpers removed.

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Ground Screw/Jumper Settings

Connect the Kinetix 5700 Drive System Chapter 5
Determine the ground screw/jumper setting for your Kinetix 5700 drive system power supply, iTRAK power supply, and Kinetix 5700 inverters.

Kinetix 5700 Drive System Power Supply

The Kinetix 5700 drive system power supply can be either 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply.

DC-bus Power Supply

The 2198-Pxxx DC-bus power supply has a factory-installed ground screw for grounded-wye power distribution. Table 64 summarizes the ground screw/ jumper settings for the 2198-Pxxx DC-bus power supply.

Table 64 - Ground Screw Setting for the DC-bus Power Supply

Ground Configuration

Example Diagram

Grounded (wye)

Figure 72 on page 123

· Impedance grounded · Corner grounded · AC-fed ungrounded

Figure 73 on page 124 Figure 74 on page 124 Figure 75 on page 125

(1) Ground screw is factory installed.

2198-Pxxx DC-bus Power Supply Ground screw installed (default setting) (1)
Remove ground screw/jumper

IMPORTANT If you have grounded-wye power distribution in your facility, do not remove the ground screw from the DC-bus power supply. Remove the ground screw when using ungrounded, corner-grounded, or impedance-grounded power.

Regenerative Bus Supply

The 2198-RPxxx regenerative bus supply includes a factory-installed ground jumper for grounded-wye power distribution. Table 65 summarizes the ground jumper settings for the 2198-RPxxx regenerative bus supply.

Table 65 - Ground Jumper Setting for the Regenerative Bus Supply

Ground Configuration

Example Diagram

2198-RPxxx Regenerative Bus Supply

· Grounded (wye) · Corner-grounded with isolation transformer · Ungrounded with isolation transformer
Impedance grounded

Figure 76 on page 126 Figure 78 on page 128 Figure 79 on page 128
Figure 77 on page 127

Ground jumper is factory installed (default setting)
Remove ground jumper (1)

(1) When the regenerative bus supply ground jumper is removed, it can be permanently stored in threaded holes at the bottom of the chassis.

IMPORTANT

If you have grounded-wye power distribution in your facility, or cornergrounded or ungrounded power with an isolation transformer, do not remove the ground jumper from the regenerative bus supply. Remove the ground jumper when using impedance-grounded power.

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Kinetix 5700 Inverters

The 2198-Dxxx-ERSx dual-axis and 2198-Sxxx-ERSx single-axis inverters also have a ground screw/jumper setting that depends on the input-power ground configuration and whether a 2198-DBxx-F or 2198-DBRxx-F filter is used.

Table 66 summarizes the ground screw/jumper default settings for the 2198-xxxx-ERSx inverters.

Table 66 - Ground Screw/Jumper Setting for 2198-xxxx-ERSx Inverters

2198-xxxx-ERS3 (series A)
Ground screw is factory installed (default setting)

2198-xxxx-ERS3 (series B)

2198-xxxx-ERS4

Ground screw/jumper is not installed (1) (default setting)

(1) Ground screw/jumper is included with the drive, but not installed.

Table 67 summarizes the ground screw/jumper settings required for the 2198-xxxx-ERSx inverters depending on the Kinetix 5700 power supply in use.

Table 67 - Ground Screw/Jumper Setting for 2198-xxxx-ERSx Inverters

AC Power Source Type

Inverter Ground Jumper Setting Based on Selected Power Supply

2198-Pxxx (1) DC-bus Power Supply

· 2198-Pxxx DC-bus Power Supply (2) · 2198-RPxxx Regenerative Bus Supply · 8720MC-RPS Regenerative Power Supply
· Any Other Active Converter

Grounded (wye)
· AC-fed ungrounded · Corner grounded · Impedance grounded

Inverter ground screw/ jumper installed.
Inverter ground screw/ jumper not installed.

Inverter ground screw/jumper not installed (3).

(1) 2198-Pxxx DC-bus power supply when 2198-DB20-F, 2198-DB42-F, 2198-DB80-F, or 2198-DB290-F AC line filter is used. (2) 2198-Pxxx DC-bus power supply when 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filter is used. (3) When the 2198-S263-ERSx or 2198-S312-ERSx inverter ground jumper is removed, it can be permanently stored in threaded
holes at the bottom of the chassis.

IMPORTANT

If you have grounded-wye power distribution and the 2198-Pxxx DC-bus power supply with:
· 2198-DB20-F, 2198-DB42-F, 2198-DB80-F, or 2198-DB290-F AC line filters, install the ground jumper in the inverters. EMC performance can be affected if the ground jumper is not installed.
· 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filters, remove the ground jumper in the inverters. Ground jumper removed is preferred when using the 2198-DBRxx-F AC line filters. EMC performance is achieved with or without the ground jumper installed.

IMPORTANT If you are using the 2198-RPxxx regenerative bus supply, always remove the ground jumper in the inverters.

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Kinetix 5700 iTRAK Power Supply

The 2198T-W25K-ER iTRAK power supply has a factory-installed ground screw for grounded-wye power distribution.

Table 68 summarizes the ground screw settings required for the 2198T-W25K-ER iTRAK power supply depending on the AC power source.

Table 68 - Ground Screw Setting for 2198T-W25K-ER iTRAK Power Supply

AC Power Source Type

2198-Pxxx (1) (2) DC-bus Power Supply

Grounded (wye)

Ground screw installed (default setting).

· AC-fed ungrounded

· Corner grounded

Ground screw not installed.

· Impedance grounded

(1) 2198-Pxxx DC-bus power supply when 2198-DB20-F, 2198-DB42-F, 2198-DB80-F, or 2198-DB290-F AC line filter is used. (2) L16 motor modules are compatible with only the grounded-wye configuration.

IMPORTANT

If you have grounded-wye power distribution and the 2198-Pxxx DC-bus power supply with:
· 2198-DB20-F, 2198-DB42-F, 2198-DB80-F, or 2198-DB290-F AC line filters, install the ground jumper in the iTRAK power supply. EMC performance can be affected if the ground jumper is not installed.
· 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filters, remove the ground jumper in the iTRAK power supply. Ground jumper removed is preferred when using the 2198-DBRxx-F AC line filters. EMC performance is achieved with or without the ground jumper installed.

Remove/Install the Ground Screw/Jumper

We recommend that you remove or install the ground screw/jumper when the drive module is removed from the panel and placed on its side on a solid work surface (does not apply to catalog numbers 2198-RPxxx, 2198-S263-ERSx, or 2198-S312-ERSx).

IMPORTANT To determine if you need to remove or install the ground screw/jumper, see Ground Screw/Jumper Settings on page 129.

ATTENTION: When the ground screw/jumper is not installed on DC-bus power supplies, the risk of equipment damage exists because the unit no longer maintains line-to-neutral or line-to-line voltage protection.
To access or remove/install the ground screw on DC-bus power supplies, dualaxis inverters, and the iTRAK power supply, open the small plastic door on the right side of the module.

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Figure 80 - Remove/Install the Ground Screw

DC-bus Power Supply, Dual-axis Inverter, or iTRAK Power Supply (side view)
(DC-bus power supply is shown)

Ground Screw Access Door

Ground Screw

To determine if you need to remove or install the ground screw, see Ground Screw/Jumper Settings on page 129.

ATTENTION: To avoid personal injury, the ground screw/jumper 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/ jumper. This applies to the DC-bus power supply, regenerative bus supply, dual-axis inverters, and single-axis inverters.

Single-axis inverters (catalog numbers 2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx) have a ground-jumper access door on the back of the unit. Two captive screws secure the jumper.

Figure 81 - Remove/Install the Single-axis Inverter Ground Jumper

2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx Single-axis Inverter (rear view)

Captive Screws (2)

Jumper
TIP Hold the jumper with needle-nose pliers and remove/install the
captive screws.

Ground Jumper Access Door

To determine if you need to remove or install the ground jumper, see Ground Screw/Jumper Settings on page 129.

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Regenerative bus supplies (catalog numbers 2198-RPxxx) and single-axis inverters (catalog numbers 2198-S263-ERSx and 2198-S312-ERSx) have a ground-jumper access door on the front of the unit. Two captive screws secure the jumper.
Figure 82 - Remove/Install the Ground Jumper

2198-RPxxx Regenerative Bus Supply

MOD NET

or 2198-S263-ERSx and 2198-S312-ERSx Single-axis Inverter

(single-axis inverter, front view is shown) 2

I/O

Captive Screws (2)

TIP Hold the jumper with needle-nose pliers and remove/install the
captive screws.
Ground Jumper (1) Access Door

Jumper

Jumper Storage

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

To determine if you need to remove or install the ground jumper, see Ground Screw/Jumper Settings on page 129.

(1) When the regenerative bus supply or 2198-S263-ERSx or 2198-S312-ERSx inverter ground jumper is removed, it can be permanently stored in threaded holes at the bottom of the chassis.

ATTENTION: Risk of equipment damage exists. The module ground configuration must be accurately determined. See Ground Screw/Jumper Settings on page 129.

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Ground the Drive System

All equipment and components of a machine or process system must have a common earth-ground point that is connected to chassis. A grounded system provides a ground path for protection against electrical shock. Grounding your drive modules and panels minimize the shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.
ATTENTION: The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system. For CE grounding requirements, refer to Agency Compliance on page 37.

Ground the System Subpanel
Ground Kinetix 5700 power supplies, inverters, and accessory modules to a bonded cabinet ground bus with a braided of at least 10 mm2 (0.0155 in2) in cross-sectional area. Keep the braided ground strap as short as possible for optimum bonding.
Figure 83 - Connect the Ground Terminal

DC-bus Power Supply (typical example)

Kinetix 5700 Drive System (typical system)

MBRK
+

Braided Ground Straps Provide at least 10 mm2 (0.0155 in2)

in cross-sectional area.

Keep straps as short as possible.

3 4

Item Description

Ground screw (green) 2.0 N·m (17.7 lb·in), max

Braided ground strap (customer supplied)

Ground grid or power distribution ground

Bonded cabinet ground bus (customer supplied)

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

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Ground Multiple Subpanels
In this figure, the chassis ground is extended to multiple subpanels.
Figure 84 - Subpanels Connected to a Single Ground Point

Bonded Ground Bus

Follow NEC and applicable local codes.

Ground Grid or Power Distribution Ground
High-frequency (HF) bonding is not illustrated. For HF bonding information, refer to HF Bond for Multiple Subpanels on page 67.

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Wiring Requirements

Wires must be copper with 75 °C (167 °F) minimum rating. Phasing of main AC power is arbitrary and earth ground connection is required for safe and proper operation.
Refer to Power Wiring Examples on page 343 for interconnect diagrams.

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

Table 69 - DC-bus Power Supply Wiring Requirements

DC-bus Power Supply Cat. No.
2198-P031
2198-P070
2198-P141 2198-P208

Description
Mains input power

Connects to Terminals

Signal

Wire Size mm 2 (AWG)
6...10 (1) (10...8)
6...10 (2) (10...8)
10...35 (8...2)

Strip Length mm (in.)
10.0 (0.39)
20.0 (0.79)

Torque Value N·m (lb·in)
0.5...0.8 (4.4...7.1)
2.5...4.5 (22...40)

PELV/SELV 24V power (connector plug)

CP-1 CP-2

24V+

0.5...4

24V

(20...12)

7.0 (0.28)

0.22...0.25 (1.9...2.2)

DC Bus power Bus bar

DC DC+

N/A (3)

2198-Pxxx

Contactor enable

EN EN+

CONT EN CONT EN+

0.14...2.5 (26...12)

7.0 (0.28)

0.4...0.5 (3.5...4.4)

Shunt resistor

RC-1 RC-2

SH DC+

1.5...6 (16...10)

12.0 (0.47)

0.5...0.6 (4.5...5.3

IOD-1

IN1

Digital inputs

IOD-2 IOD-3

COM IN2

0.14...1.5 (26...16)

10.0 (0.39)

N/A (4)

IOD-4

SHLD

(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 one drive module to another over the bus-bar connection system. These terminals do not receive discrete wires. (4) This connector uses spring tension to hold wires in place.

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Table 70 - Regenerative Bus Supply Wiring Requirements

Regen Bus Supply Cat. No.
2198-RP088

Description

Connects to Terminals

Signal

Wire Size mm 2 (AWG)
6...10 (1) (10...8)

Strip Length mm (in.)
10.0 (0.39)

Torque Value N·m (lb·in)
0.5...0.8 (4.4...7.1)

2198-RP200
2198-RP263 2198-RP312

Mains input

power

10...35

(8...2)

20.0 (0.79)

2.5...4.5 (22...40)

21.1...120 (4...250 kcmil)

27.0 (1.06)

15...20 (132...177)

2198-RP088 2198-RP200
2198-RP263 2198-RP312

PELV/SELV
24V power (connector plug)

CP-1 CP-2

0.5...4 (20...12)

24V+

1.5...4

24V

(16...12)

6 (10)

7.0 (0.28) 10.0 (0.39)

0.22...0.25 (1.9...2.2)
0.5...0.6 (4.4...5.3)
0.7...0.8 (6.1...7.0)

DC Bus power Bus bar

DC DC+

N/A (2)

N/A (3)

OK+

Contactor enable

OK EN

EN+

CONV OK+ CONV OK CONT EN CONT EN+

0.14...2.5 (26...12)

7.0 (0.28)

0.4...0.5 (3.5...4.4)

2198-RPxxx

Active shunt

RC-2 RC-1

DC+ DC

IOD-1

IN1

IOD-2

COM

IOD-3

IN2

IOD-4

COM

Digital inputs

IOD-5 IOD-6

SHLD IN3

IOD-7

COM

IOD-8

IN4

IOD-9

COM

IOD-10

SHLD

1.5...6 (16...10)
0.14...1.5 (26...16)

12.0 (0.47) 10.0 (0.39)

0.5...0.6 (4.5...5.3)
N/A (3)

(1) Applies to solid wire. If using stranded wire, the maximum wire size is 6 mm2 (10 AWG). To meet CE requirements above 40 °C (104 °F) for 6 mm2 stranded wires, single-core copper conductors must be used with 90 °C minimum rating.
(2) Shared DC-bus power connections are always made from drive to drive over the bus-bar connection system. These terminals do not receive discrete wires. (3) This connector uses spring tension to hold wires in place.

Table 71 - iTRAK Power Supply Wiring Requirements

iTRAK Power Supply Cat. No.

Description

Connects to Terminals

Signal

Wire Size mm2 (AWG)

Strip Length mm (in.)

Torque Value N·m (lb·in)

2198T-W25K-ER

DC-bus input power

Bus bar

DC DC+

SELV/PELV rated 24V power (connector plug)

CP-1 CP-2

24V+ 24V

N/A (1)
1.5...4 (2) (16...12)
6 (10) (2)

N/A (1) 10.0 (0.39)

N/A (1)
0.5...0.6 (4.4...5.3) 0.7...0.8 (3) (6.1...7.0)

(1) Shared DC-bus power connections are always made from power supply to power supply over the bus-bar connection system. These terminals do not receive discrete wires.
(2) Use sufficient wire size to support the complete control power load, including the Kinetix 5700 drive modules and pass-through current for the attached motor modules. (3) Depending on 24V current demand, 6 mm2 (10 AWG) wire can be required. When 6 mm2 (10 AWG) wire is used, these torque specifications apply.

TIP For iTRAK power supply wiring requirements not shown here, see iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, or iTRAK 5730 System User Manual, publication 2198T-UM003.

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Table 72 - Single-axis Inverter Wiring Requirements

Single-axis Inverter Cat. No.

Description

Connects to Terminals

Signal

Wire Size mm 2 (AWG)

Strip Length mm (in.)

Torque Value N·m (lb·in)

2198-S086-ERSx 2198-S130-ERSx
2198-S160-ERSx

Motor power

Motor power cable depends on motor/ drive combination.

U V W

6...25 (1) (10...4)

20.0 (0.79)

2.5...4.5 (22...40)

10...35 (1)

(8...2)

2198-S263-ERSx 2198-S312-ERSx

21.1...120 (4...250 kcmil)

27.0 (1.06)

15...20 (132...177)

2198-S086-ERSx 2198-S130-ERSx
2198-S263-ERSx 2198-S312-ERSx

PELV/SELV
24V power (connector plug)

CP-1 CP-2

0.5...4 (20...12)

24V+

1.5...4

24V-

(16...12)

6 (10)

7.0 (0.28) 10.0 (0.39)

0.22...0.25 (1.9...2.2)
0.5...0.6 (4.4...5.3)
0.7...0.8 (6.1...7.0)

Brake power

BC-1 BC-2

MBRK+ MBRK-

N/A (2)

7.0 (0.28)

0.22...0.25 (1.9...2.2)

DC Bus power Bus bar

DCDC+

N/A (3)

Safety 2198-Sxxx-ERSx

ST0-1 ST0-9 SB+/NC ST0-2 ST0-10 S1A ST0-3 ST0-11 SCA ST0-4 ST0-12 S2A ST0-5 ST0-13 SBST0-6 ST0-14 NC ST0-7 ST0-15 NC ST0-8 ST0-16 NC

0.14...1.5 (26...16)

10.0 (0.39)

N/A (4)

Digital inputs

IOD-1 IOD-2 IOD-3 IOD-4 IOD-5 IOD-6 IOD-7 IOD-8 IOD-9 IOD-10

IN1

COM

IN2

COM

SHLD IN3

0.14...1.5 (26...16)

10.0 (0.39)

N/A (4)

COM

IN4

COM

SHLD

(1) Building your own single cables or using third-party single cables for Kinetix VP motors and actuators is not an option. Use 2090-CSxM1DE/DG single motor cables. Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004, for cable specifications.
(2) Motor brake wires are included in the Bulletin 2090 motor cable. (3) Shared DC-bus power connections are always made from one drive module to another over the bus-bar connection system. These terminals do not receive discrete wires. (4) This connector uses spring tension to hold wires in place.

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Table 73 - Dual-axis Inverter Wiring Requirements

Dual-axis Inverter Cat. No.

Description

Connects to Terminals

Signal

Wire Size mm 2 (AWG)

Strip Length mm (in.)

Torque Value N·m (lb·in)

2198-D006-ERSx 2198-D012-ERSx 2198-D020-ERSx 2198-D032-ERSx
2198-D057-ERSx

Motor power

(axis A and B)

Motor power cable

depends on motor/

U V W

drive combination. 0.75...2.5 (1)

10.0 (0.39)

0.5...0.6 (4.4...5.3)

(18...14)

2.5...6 (1) (14...10)

10.0 (0.39)

0.5...0.8 (4.4...7.1)

PELV/SELV
24V power (connector plug)

CP-1 CP-2

Brake power BC-1 (axis A and B) BC-2

24V+ 24V
MBRK+ MBRK

0.5...4 (20...12)
N/A (2)

7.0 (0.28)

0.22...0.25 (1.9...2.2)

DC Bus power Bus bar

DC DC+

N/A (3)

ST0-1 ST0-9 SB+ /NC

ST0-2 ST0-10 S1A

ST0-3 ST0-11 SCA

2198-Dxxx-ERSx

Safety

ST0-4 ST0-12 S2A ST0-5 ST0-13 SB-

0.14...1.5 (26...16)

10.0 (0.39)

N/A (4)

ST0-6 ST0-14 S1B

ST0-7 ST0-15 SCB

ST0-8 ST0-16 S2B

Digital inputs

IOD-1 IOD-2 IOD-3 IOD-4 IOD-5 IOD-6 IOD-7 IOD-8 IOD-9 IOD-10

IN1

COM

IN2

COM

SHLD IN3

0.14...1.5 (26...16)

10.0 (0.39)

N/A (4)

COM

IN4

COM

SHLD

ATTENTION: To avoid personal injury and/or equipment damage, observe
the following:
· Make sure 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 for connection purposes only. Do not use them to turn the motor on and off.
· Ground shielded power cables to prevent potentially high voltages on the shield.

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Wiring Guidelines

Use these guidelines as a reference when wiring the power connectors on your Kinetix 5700 drive modules.

IMPORTANT

For connector locations of the Kinetix 5700 drive modules, refer to Kinetix 5700 Connector Data on page 92.
When removing insulation from wires and tightening screws to secure the wires, refer to the table on page 136 for strip lengths and torque values.

IMPORTANT To improve system performance, run wires and cables in the wireways as established in Establish Noise Zones on page 68.
Follow these steps when wiring the connectors for your Kinetix 5700 drive modules.
1. Prepare the wires for attachment to each connector plug by removing insulation equal to the recommended strip length. Some cables come prepared with wires appropriately stripped.
IMPORTANT Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.
2. Route the cable/wires to your Kinetix 5700 drive module connector. 3. Insert wires into connector plugs.
Refer to the connector pinout tables in Chapter 4 or the interconnect diagrams in Appendix A. 4. Tighten the connector screws. 5. Gently pull on each wire to make sure it does not come out of its terminal; reinsert and tighten any loose wires. 6. Insert the connector plug into the drive module connector.

Wire the Power Connectors

This section provides examples and guidelines to assist you in making connections to the input power connectors.
Refer to Power Wiring Examples on page 343 for interconnect diagrams.

Wire the 24V Control Power Input Connector
The 24V power (CP) connector requires 24V DC input for the control circuitry. The connector plug ships with the drive module and shared-bus connector kits are purchased separately.
IMPORTANT Mount the 24V power supply as close to the drive system as possible to minimize voltage drop on the 24V input power wiring.

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Figure 85 - CP Connector Wiring - Connector Plug

24V (CP) Connector Plug

24V24V+

2198-Pxxx DC-bus Power Supply or 2198-RPxxx Regenerative Bus Supply, Top View (DC-bus power supply is shown)

1 2

Table 74 - CP Connector Plug Wiring Specifications

Drive Module Cat. No.

CP Pin

Signal

Recommended Wire Size mm2 (AWG)

Strip Length mm (in.)

Torque Value N·m (lb·in)

2198-Pxxx, 2198-RP088, 2198-RP200, 2198-Dxxx-ERSx, 2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx, 2198-CAPMOD-2240 and 2198-DCBUSCOND-RP312

CP-1 CP-2

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

CP-1 CP-2

24V+

0.5...4 (1)

24V-

(20...12)

1.5...4 (1)

24V+

(16...12)

24V6 (10)

7.0 (0.28) 10.0 (0.39)

0.22...0.25 (1.9...2.2)
0.5...0.6 (4.4...5.3)
0.7...0.8 (6.1...7.0)

(1) Use sufficient wire size to support the complete control power load, including the Kinetix 5700 drive modules and pass-through current for the attached motor modules. See 24V Control Power Evaluation on page 47 for more information.

24V DC Input Wiring Connector

Figure 86 - CP Connector Wiring - Shared Bus
24V2-4V+

Kinetix 5700 Drive System (top view)

Wiring Connector for 2198-Pxxx, 2198-Dxxx-ERSx, 2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx, 2198-RP088, 2198-RP200, 2198-CAPMOD-2240, and 2198-DCBUSCOND-RP312 modules: Catalog Number 2198-TCON-24VDCIN36

Wiring Connector for 2198-RP263, 2198-RP312, 2198-S263-ERSx, 2198-S312-ERSx, and 2198T-W25K-ER modules: Catalog Number 2198T-W25K-P-IN

Table 75 - CP Shared-bus Wiring Specifications

Drive Module (1) (2) Cat. No.

CP Pin

Signal

Input Current, max A rms

Recommended Wire Size mm2 (AWG)

Strip Length mm (in.)

Torque Value N·m (lb·in)

2198-RPxxx and 2198-Pxxx 2198-Dxxx-ERSx, 2198-Sxxx-ERSx, 2198-CAPMOD-2240, 2198-DCBUSCOND-RP312, 2198T-W25K-ER

CP-1 CP-2

24V+ 24V-

10 (6)

11.0 (0.43)

1.7...1.8 (15.0...15.9)

(1) Catalog numbers 2198T-W25K-ER, 2198-RP263, 2198-RP312, 2198-S263-ERSx, and 2198-S312-ERSx, use a slightly larger input wiring connector than the other Kinetix 5700 drive modules. (2) Bus-bars and T-connectors can be added only to the right of the 24V DC input wiring connector.

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Wire the Input Power Connector
The input power (IPD) connector applies to the 2198-Pxxx DC-bus power supply and 2198-RPxxx regenerative bus supply.

ATTENTION: Make sure the input power connections are correct when wiring the IPD connector plug. Insert the plug into the module connector and tighten screws to the specified torque value. Incorrect wiring/polarity or loose wiring can cause damage to equipment.

Figure 87 - IPD Connector Wiring

Connector Screws (2) 0.8 N·m (7.1 lb·in)

2198-Pxxx DC-bus Power Supply or 2198-RP088 and 2198-RP200 Regenerative Bus Supply, Bottom View (DC-bus power supply is shown)

Input Power (IPD) Connector Plug

L3 L2 L1
L3 L2 L1

Front View
L1 L2 L3
21mm2(4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Bottom View L1 L2 L3

L1 L2 L3

Input Power (IPD) Connector Screws (3x): 6 mm Hex Driver Torque: 15...20 N·m (132...177 lb·in)

Input Power Ground Terminal Screw: 8 mm Hex Driver Torque: 5.6 N·m (50 lb·in)

The IPD connector on 2198-RP263 and 2198-RP312 power supplies is
not removable.

Table 76 - Input Power (IPD) Connector Specifications

Regenerative Bus Supply DC-bus Power Supply

Cat. No.

2198-RP088

2198-P031 2198-P070

2198-RP200

2198-P141 2198-P208

L3 L2

2198-RP263 2198-RP312

Signal
L3 L2 L1

Recommended Wire Size mm2 (AWG)
6...10 (10...8)
10...35 (8...2)
21.1...120 (4...250 kcmil)

2198-RP263 and 2198-RP312 Regenerative Bus Supply, Bottom View

Strip Length mm (in.)
10.0 (0.39)
20.0 (0.79)
27.0 (1.06)

Torque Value N·m (lb·in)
0.8 (7.1)
15...20 (132...177)

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Wire the Contactor Enable Connector
The contactor enable (2-pin CED) connector applies to the DC-bus power supply. The regenerative bus supply has a 4-pin CED connector and includes wiring to the Converter OK relay.
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 or regenerative
bus supply is protected under various fault conditions. · three-phase power is never applied to the Kinetix 5700 drive system before
control power is applied.
Figure 88 - CED Connector Wiring - Connector Plug

2198-Pxxx MOD NET
DC-bus Power Supply
(front view)

2-pin Contactor Enable

4 I/O

EN+

(CED) Connector Plug

MOD

2198-RPxxx

NET

5700

Regenerative Bus Supply

(front view)

I/O

OK+ 4-pin Contactor Enable

EN EN+

(CED) Connector Plug

OK+ OK EN EN+

Regenerative Bus Supply Cat. No.
2198-RP088 2198-RP200 2198-RP263 2198-RP312

Table 77 - CED Connector Plug Specifications

DC-bus Power Supply Cat. No.

2198-P031

2198-P070

2198-P141

EN+

2198-P208

OK+ OK

Signal
CONT EN CONT EN+
CONV OK+ CONV OK

Recommended Wire Size mm2 (AWG)
0.14...2.5 (26...12)

Strip Length mm (in.)
7.0 (0.28)

Torque Value N·m (lb·in)
0.4...0.5 (3.5...4.4)

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Wire the Digital Input Connectors

This section provides guidelines to assist you in making digital input connections. The digital inputs (IOD) and safety (STO) connector plugs for all 2198-xxxx-ERS3 and 2198-xxxx-ERS4 drives require special attention to
help keep the plugs seated properly during normal operation.

IMPORTANT

When replacing 2198-xxxx-ERS3 (series A) single-axis and dual-axis inverters with 2198-xxxx-ERSx (series B) inverters, you must use the series B (safety and digital input) connector plugs that are included with your series B inverter.

2198-xxxx-ERS3 (series A) Connector Plugs
The right side of the safety and digital-input connector plugs require an offcenter push when inserting them into their respective connectors. This applies to 2198-xxxx-ERS3 (series A) single-axis and dual-axis inverters.

IMPORTANT

An off-center push is required to engage the locking features on the bottom of the safety and digital-input connector plugs and seat properly with the drive (STO and IOD) connectors. Failure to do this can result in the connector plugs pulling out of the drive connector during normal operation.

Kinetix 5700 Inverter Safety or Digital Inputs Connector Plug
(safety connector plug is shown)

Figure 89 - 2198-xxxx-ERS3 (series A) Connector Plugs

Off-center Push

Push the Right-hand Side

Locking Features

Safety (STO) Connector Plug

MOD

NET

Digital Inputs Plug

Safety Plug

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Kinetix 5700 Inverter Safety or Digital Inputs Connector Plug
(safety connector plug is shown)
Safety (STO) Connector Plug

Connect the Kinetix 5700 Drive System Chapter 5

2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Connector Plugs
The safety and digital-input connector plugs have two locking leavers that you push in a clockwise direction as you insert the plugs into the drive connector. This is the locked position. Rotate the leavers counter-clockwise (open position) to release the connector plugs. This applies to 2198-RPxxx regenerative bus supply and 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) single-axis and dual-axis inverters.

IMPORTANT

Push the locking leavers clockwise into the locked position as you insert the (STO and IOD) connector plugs. Failure to do this can result in the connector plugs pulling out of the drive connector during normal operation.

Figure 90 - 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Connector Plugs Push to Lock

Push to Lock Push to Unlock

Locking Leavers in Locked Position

Open Position (rotated counter-clockwise)
MOD NET

Locked Position (rotated clockwise)

Wire the Safe Torque-off Connector
For the hardwired safe torque-off (STO) connector pinouts, feature descriptions, and wiring information, refer to Chapter 9 beginning on page 303.

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Wire the Digital Inputs Connector
The digital inputs (IOD) connector applies to the DC-bus power supply, 2198-RPxxx regenerative bus supply, single-axis inverter, and dual-axis inverters and use spring tension to hold wires in place.
Figure 91 - IOD Connector Wiring

2198-RPxxx

MOD

NET

Regenerative Bus Supply

(front view)

I/O

4-pin Digital Inputs (IOD) Connector Plug

2198-Pxxx DC-bus Power Supply (front view)

MOD NET
5700

I/O

OK+ OK EN EN+

2198-Sxxx-ERSx MOD Single-axis Inverters or
NET
2198-Dxxx-ERSx Dual-axis Inverters Front View (2198-xxxx-ERS4 is shown)

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

5 10

10-pin Digital Inputs (IOD) Connector Plug

Table 78 - Digital Inputs (IOD) Connector Specifications

Drive Module Cat. No.

IOD Pin

Signal

Recommended Wire Size mm2 (AWG)

IOD-1

IN1

2198-Pxxx

IOD-2 IOD-3

COM IN2

0.14...1.5 (26...16)

IOD-4

SHLD

IOD-1

IN1

IOD-2

COM

IOD-3

IN2

2198-RPxxx 2198-Dxxx-ERSx 2198-Sxxx-ERSx

IOD-4 IOD-5 IOD-6 IOD-7

COM SHLD IN3 COM

IOD-8

IN4

IOD-9

COM

IOD-10

SHLD

0.14...1.5 (26...16)

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

Strip Length mm (in.) 10.0 (0.39)
10.0 (0.39)

Torque Value N·m (lb·in) N/A (1)
N/A (1)

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Wire Motor Power and Brake Connectors

Motor power connections are made at the MP connector on the bottom of the dual-axis and single-axis inverters. Motor brake connections are made at the BC connector. On dual-axis inverters, the BC connectors are on either side of the MP connectors on the bottom of the drive. On single-axis inverters, the BC connector is on the front of the drive.
· On 2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx singleaxis inverters, the motor power connector and shield clamp are mounted to a separate bracket that plugs into the bottom of the drive and has mounting screws to hold it secure.

Motor Power Connector
Bracket (side view)

2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx Single-axis Inverter Clamp Bracket

Clamp

· On 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters, the motor power connector is part of the drive. The clamp bracket is included with the drive, but requires some assembly.

Hole for M8 Stud
Bracket (front view)

2198-S263-ERSx and 2198-S312-ERSx Single-axis Inverter Clamp Bracket

Clamp

IMPORTANT The clamp included with 2198-S263-ERSx and 2198-S312-ERSx inverters is compatible with Bulletin 2090 (4 and 2 AWG) motor power cable. Do not use the clamp for smaller or larger cables.

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Figure 92 - MP and BC Connector Wiring (dual-axis inverters)

MOD NET

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

2198-Dxxx-ERSx Dual-axis Inverters (2198-D006-ERS4 drive is shown)

Motor Brake (BC) Connector Plugs

MB+RK-A

W-A V-A U-A

W-B V-B U-B MBRK+-B

Motor Power (MP) Connector Plugs

2 1
W V U W V U
2 1

Motor Cable Shield Clamp

Bulletin 2090 Motor Power Cable (2090-CSxM1DE/DG cable is shown)

ATTENTION: Make sure the motor power connections are correct when wiring the MP connector plug and that the plug is fully engaged in the module connector. Incorrect wiring/polarity or loose wiring can cause damage to equipment.

Table 79 - Motor Power (MP) Connector Specifications (dual-axis inverters)

Dual-axis Inverter Cat. No.

Recommended Signal/Wire Color Wire Size
mm2 (AWG)

Strip Length Torque Value

mm (in.)

N·m (lb·in)

2198-D006-ERSx

2198-D012-ERSx

2198-D020-ERSx

2198-D032-ERSx

2198-D057-ERSx

Motor power cable

depends on motor/

U Brown

drive combination.

V Black W Blue

0.75...2.5 (1)

Green/Yellow (18...14)

2.5...6 (1) (14...10)

10.0 (0.39) 10.0 (0.39)

0.5...0.6 (4.4...5.3)
0.5...0.8 (4.4...7.1)

(1) Building your own single cables or using third-party single cables with Kinetix VP motors and actuators is not an option. Use 2090-CSxM1DE/DG single motor cables. Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004, for cable specifications.

Table 80 - Motor Brake (BC) Connector Specifications

Drive Module Cat. No.

Signal/ Wire Color

Recommended Wire Size

Strip Length

(AWG)

mm (in.)

2198-Dxxx-ERSx BC-1 2198-Sxxx-ERSx BC-2

MBRK+/Black MBRK-/White

N/A (1)

7.0 (0.28)

(1) Motor brake wires are part of the Bulletin 2090 motor power cable.

Torque Value N·m (lb·in)
0.22...0.25 (1.9...2.2)

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Figure 93 - MP and BC Connector Wiring (single-axis inverters)

MOD

2198-S086-ERSx

NET

2198-S130-ERSx or

2198-S160-ERSx

Single-axis Inverters

2
(front view)

I/O

(2198-S086-ERS4 drive is shown)

5 10 UFB

MBRK

Motor Brake (BC) Connector Plug

Tie Wrap

MBRK +

W V U

Motor Power Connector
Motor Cable Bracket
Motor Cable Shield Clamp

Motor Power (MP) Connector Plug

Motor Cable Shield Clamp

Bulletin 2090 Motor Power Cable (2090-CSxM1DE/DG cable is shown)

Connector Flange Screws (2) 0.8 N·m (7.1 lb·in)

Attach the motor power wires to the motor power connector, plug in the motor feedback and brake connectors, and then connect the bracket to the drive.

ATTENTION: Make sure the motor power connections are correct when wiring the MP connector plug. Insert the plug into the module connector and tighten flange screws to 0.8 N·m (7.1 lb·in). Incorrect wiring/polarity or loose wiring can cause damage to equipment.

Table 81 - Motor Power (MP) Connector Specifications (single-axis inverters)

Drive Module Cat. No.

Recommended Signal/Wire Color Wire Size
mm2 (AWG)

Strip Length

Terminal Flange Torque Value Torque Value, max

mm (in.)

N·m (lb·in) N·m (lb·in)

2198-S086-ERSx

2198-S130-ERSx

2198-S160-ERSx

Motor power cable

depends on motor/

U Brown

drive combination.

V Black W Blue

6...16 (1)

Green/Yellow (10...6)

20.0 (0.79)

2.5...4.5 (22...40)

0.8 (7.1)

10...35 (8...2)

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2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverters
(side view)
Motor Cable Bracket

2198-K57CK-D15M Motor Feedback Connector Kit

Motor Power (MP) Connector (bottom view)

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverters (front view)

Motor Brake (BC) Connector Plug

MBRK

Motor Power Ground Terminal Screw: 8 mm Hex Driver
Torque: 5.6 N·m (50 lb·in)
Motor Cable Connections

Motor Power (MP) Connector Screws (3x): 6 mm Hex Driver Torque: 15...20 N·m (132...177 lb·in)
Bulletin 2090 Motor Power Cable (2090-CPBM7DF cable is shown)

Install the motor cable bracket (see page page 165), then attach motor power and ground wires to the motor power connector and ground terminal. Plug in motor feedback and brake connectors.

Table 82 - Motor Power and Brake Connector Specifications (single-axis inverters)

Drive Module Cat. No.

U 2198-S263-ERSx V 2198-S312-ERSx W

Recommended Signal/Wire Color Wire Size
mm2 (AWG)

U Brown

V Black

21.1...120

W Blue

(4...250 kcmil)

Green/Yellow

Strip Length

Terminal Torque Value

mm (in.)

N·m (lb·in)

27.0 (1.06)

15...20 (132...177)

Maximum Cable Lengths
There are maximum cable length limitations that apply to the DC-bus cables (cluster to cluster) and motor power/brake and feedback cables (drive to motor).
DC Bus Cluster-to-Cluster Cable Lengths
In this example, the power supply (center) feeds two extended clusters. The following DC-bus cable length limitations apply:
· The maximum DC-bus cable length (power supply cluster to extended cluster) is 70 m (230 ft)
· The maximum total DC-bus cable length is 140 m (459 ft)

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IMPORTANT These examples feature the 2198-RPxxx regenerative bus supply, however, they also apply to the 2198-Pxxx DC-bus power supply.

M M

Figure 95 - Regenerative Bus Supply Example/Center Power Supply Cluster/104 A, max

DC Bus

Single-axis Capacitor DC-bus Conditioner

Inverters Module

Module

DC+

Extension Regenerative Capacitor Module Bus Supply Module

Circuit (1) Protection (optional)

DC-bus Conditioner Capacitor Single-axis

Module

Module Inverters

DC+

DC Bus

90 m (295 ft) x 2 axes = 180 m (591 ft)

70 m (230 ft),
max

Motor Array

70 m (230 ft),
max

90 m (295 ft) x 2 axes = 180 m (591 ft) Motor Array M

(1) The National Electrical Code and local electrical codes take precedence over the values and methods provided.

When the power supply is positioned right or left of the extended clusters, the maximum total DC-bus cable length is 70 m (230 ft).

Figure 96 - Regenerative Bus Supply Example/Two Extended Clusters/208 A, max

Regenerative Capacitor Extension Bus Supply Module Module
DC Bus

Extension Module
DC+ DC Bus

DC-bus Conditioner Module

Single-axis Inverters

Capacitor Module

Extension Module

DC-bus Conditioner Capacitor Single-axis

Module

Module Inverters

DC+

DC Bus

Circuit (1) DC Protection (optional)

35 m (115 ft)

90 m (295 ft) x 2 axes = 180 m (591 ft)

Motor Array

(1) The National Electrical Code and local electrical codes take precedence over the values and methods provided.

IMPORTANT

It is important to use low-inductance DC cable routing to help reduce the risk of voltage oscillations between clusters.
Low-inductance DC cable routing can be achieved by means of positive and negative cables routed in parallel and as close to one another as possible, less than 0.3 m (1.0 ft).
Size the DC cable in accordance with UL or applicable agency guidelines. The voltage drop across the DC cable can be further reduced by using a bigger cable size because voltage drop is directly proportional to cable resistance (see Recommended DC-bus Cable Gauge on page 152).

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Table 83 - Recommended DC-bus Cable Gauge

Regenerative Bus Supply Cat. No.
2198-RP088 2198-RP200 2198-RP263 2198-RP312 DC-bus Power Supply Cat. No. 2198-P031 2198-P070 2198-P141 2198-P208 2198-P208 x 2 2198-P208 x 3

Recommended DC-bus Cable Gauge mm2 (AWG/MCM) 53.5 (1/0)
152 (300 MCM) Recommended DC-bus Cable Gauge mm2 (AWG/MCM)
53.5 (1/0)
152 (300 MCM)

Observe the following guidelines when installing DC-bus cable:
· Use only unshielded cable for DC-bus voltage
· Use 1000V rated insulation cable in this application
· Make the DC+ and DC- cable distance as short as possible to help reduce cable inductance
· Twisting the DC-bus cable together is not required, but we recommend twisting to make sure the DC cables are routed close to each other
· The maximum Bus Voltage Set Point reduces linearly from 750V DC to 715V DC as the DC-bus cable length per cluster increases from 0 to 70 m (230 ft) respectively
· To prevent nuisance bus-overvoltage faults, the maximum Bus Voltage Set Point reduces linearly from 750V DC to 715V DC as the DC-bus cable length per cluster increases from 0 to 70 m (230 ft) respectively.

Maximum Bus Voltage Set Point (Volts DC)

0 750
745
740
735
730
725
720
715 0

DC-bus Cable Length per Cluster (ft) 32.8 65.6 98.4 131 164

DC-bus Cable Length per Cluster (m)

197 230

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Drive to Motor Cable Lengths

Combined motor-power cable length for all axes on the same DC bus depends on the Kinetix 5700 system power supply in use.
· For applications that include the 2198-Pxxx DC-bus power supply and 2198-DBxx-F AC line filter, the maximum length is up to 400 m (1312 ft)
When 2198-P070, 2198-P141, and 2198-P208 DC-bus power supplies are used with 2198-DBRxx-F AC line filters, the maximum length is up to 1200 m (3937 ft)
When 2198-P031 DC-bus power supplies are used with 2198-DBxx-F or 2198-DBRxx-F line filters, the maximum length is up to 400 m (1312 ft)
· For applications that include the 2198-RPxxx regenerative bus supply and 2198-DBRxx-F AC line filter, the maximum length is up to 1200 m (3937 ft)

The maximum drive-to-motor cable length for Kinetix 5700 drives and motor/actuator combinations with 2090-CSxM1Dx cables is up to 90 m (295 ft), depending on the feedback type and overall system design.

Table 84 - Drive-to-Motor Feedback Cable Length

Feedback Type

Cable Length, max (1) m (ft)

Single-turn or multi-turn absolute

up to 90 (295)

Incremental

up to 30 (98)

EnDat

up to 90 (295)

(1) See Appendix D on page 405 for the maximum motor-to-drive cable length for specific motor and actuator families.

IMPORTANT For more information on maximum motor cable lengths, see Appendix D beginning on page 405.

This cable length example is based on the Kinetix 5700 system in Figure 95 on page 151.

Table 85 - Combined Cable Length Example

Cluster
Extended Cluster #1 Power Supply Cluster #2 Extended Cluster #3 Total

Total Motor Power Cable Length m (ft)
180 (591)

180 (591)
360 (1182)

Total DC-bus Cable Length m (ft)
70 (230)

70 (230)
140 (460)

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Connect Single Cables

Kinetix 5700 inverters and Kinetix VPL, VPC-Q, VPF, VPH, VPS servo motors and Kinetix VPAR electric cylinder combinations use single motorcable technology with motor power, feedback, and brake wires (when specified) housed in a single cable. Feedback wires are shielded separately and provide a shield braid for grounding in the connector kit.

IMPORTANT

Due to the unique characteristics of single cable technology, designed for and tested with Kinetix 5700 inverters and Kinetix VP motors and actuators, you cannot build your own single cables or use third-party single cables.

Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004, for cable specifications.

Table 86 - Single Cable Catalog Numbers

Motor /Actuator Feedback Kit

Cat. No.

VPL-A/Bxxxx VPF-A/Bxxxx VPH-A/Bxxxx VPS-Bxxxxx VPC-Bxxxxx-Q VPAR-Bxxxxx

2198-KITCON-DSL

Motor Cable Cat. No. (with brake wires)
2090-CSBM1DE-xxxAxx (standard) cables 2090-CSBM1DE-xxxFxx (continuous-flex) cables
2090-CSBM1DG-xxxAxx (standard) cables 2090-CSBM1DG-xxxFxx (continuous-flex) cables

Motor Cable Cat. No. (without brake wires)

Feedback Connections

2090-CSWM1DE-xxxAxx (standard) cables

2198-KITCON-DSL kit is pre-wired to feedback conductors

Flying-lead feedback conductors. 2090-CSWM1DG-xxxAxx (standard) cables 2198-KITCON-DSL connector kit is
purchased separately

Table 87 - Kinetix VPL, VPF, VPH, VPS, VPC-Q, and VPAR Motor/Actuator Compatibility

Drive Module (1) Cat. No.

Kinetix VPL

Kinetix VPF

Kinetix VPH

Kinetix VPS

VPC-Bxxxxx-Q (2) Kinetix VPAR

2198-Dxxx-ERSx X

2198-Sxxx-ERSx

(1) For wiring to compatible motors with 2198-S160-ERSx drives, see Single-axis Inverter Power/Brake Cable Installation on page 163. For wiring to compatible motors with 2198-S263-ERSx, 2198-S312-ERSx drives, see Customer-supplied Motor Power Cables on page 173.
(2) Due to the motor power conductor size, VPC-B3004 motors do not support single cable technology. See the Motor Power Cable Compatibility table on page 158 for VPC-Bxxxxx-S, VPC-B3004x-M, and VPC-Bxxxxx-Y motor cables intended for use with Kinetix 5700 drives.

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2198-Sxxx-ERSx

MOD

NET

Single-axis Inverters

(2198-S086-ERS4 drive is

shown) 2

I/O

Motor Feedback

Connector Kits

UFB

MBRK
+

Connect the Kinetix 5700 Drive System Chapter 5

Motor Feedback Connections
ATTENTION: When routing 2090-CSxM1DE cables through tight spaces, we recommend removing the 2198-KITCON-DSL feedback connector kit to avoid causing damage to the kit.
Single motor-cable feedback connections are made by using the 2198-KITCON-DSL feedback connector kit.
· 2090-CSxM1DE cables include the connector kit pre-wired to the feedback conductors.
· 2090-CSxM1DG cables have flying-lead feedback conductors. The 2198-KITCON-DSL feedback connector kit must be purchased separately and installed.
Figure 97 - MF Connector Wiring Example

MOD NET

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+ D-

2198-Dxxx-ERSx Dual-axis Inverters (2198-D006-ERS4 drive is shown)
Mounting Screws (2)

Refer to Kinetix 5500 Feedback Connector Kit Installation Instructions, publication 2198-IN002, for connector kit specifications.

Connector Housing

2198-KITCON-DSL Cover Feedback Connector Kit
Exposed Shield

Feedback Cable (EPWR+, EPWR-)

Internal Grounding Plate

Clamp Screws (2)

Motor Cable Shield Clamp

Table 88 - Motor Feedback (MF) Connector Specifications

Drive Module Cat. No.

2198-Dxxx-ERSx MF-1 2198-Sxxx-ERSx MF-2

Signal/ Wire Color
D+/Blue
D-/White/Blue

Wire Size AWG
22

Strip Length Torque Value

mm (in.)

N·m (lb·in)

10.0 (0.39)

0.4 (3.5)

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Apply the Single Motor Cable Shield Clamp
Factory-supplied 2090-Series single motor cables are shielded, and the braided cable shield must terminate at the drive during installation. A small portion of the cable jacket has been removed to expose the shield braid. The exposed area must be clamped (with the clamp provided) at the bottom front of the drive.
SHOCK HAZARD: To avoid hazard of electrical shock, make sure shielded power cables are grounded according to recommendations.

These procedures assume you have completed wiring your motor power, brake, and feedback connectors and are ready to apply the cable shield clamp.
Dual-axis Inverter Shield Clamp Installation
Follow these steps to apply the dual-axis inverter cable shield clamp.
1. Loosen the clamp knob and determine if you need the clamp spacers. Clamp spacers are included with the dual-axis inverters for cable diameters that are too small for a tight fit within the drive clamp alone. The spacers are held captive by nylon rivets. Remove the rivets and spacers when your cable shield is of sufficient diameter for the clamp to hold the cable secure.

IMPORTANT Use clamp spaces (supplied with drive) when the cable shield diameter is too small for a tight fit within the shield clamp. Remove the clamp spacers when not needed.

Figure 98 - Dual-axis Inverter Shield Clamp Installation

2198-KITCON-DSL

D+

Motor Feedback Connector Kits D- D-

MF-A

MF-B

2090-CSxM1DE/DG Single Motor Cables

Service Loops

Motor Power (MP) and Motor Brake (BC) Connectors

2198-Dxxx-ERSx Dual-axis Inverter, (side view)

Exposed Shield Braid Under Clamp

Clamp Rivets (2) Spacers (2)

Clamp Knob (hand tighten)

Clamp Screw and Nut

Bulletin 2090-CSBM1DE/DG Single Motor Cables

Motor Cable Shield Clamp

2. Position the exposed portion of each cable braid directly in line with the clamp.
3. Hand tighten the clamp knob.

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Make sure the cable clamp tightens around the cable shield and provides a good bond between the cable shield and the drive chassis.
Only finger-tight torque on the clamp knob is required. The cable should not move within the clamp under its own weight or when slight pressure is applied by hand.

IMPORTANT

If the power/brake cable shield on the dual-axis inverter has a loose fit inside the shield clamp, use a clamp spacer to reduce the clamp diameter. When the clamp knob is tightened, the result must be a high-frequency bond between the cable shield and the drive chassis.
Make sure the clamp is aligned with the shield braid and not heat shrink.

4. Repeat step 1 through step 3 for each dual-axis inverter.
Single-axis Inverter Shield Clamp Installation
Single-axis inverters include a two-position cable-shield clamp. Use which ever clamp holds your cable shield firmly. Replacement clamps are available.
Follow these steps to apply the single-axis inverter motor-cable shield clamp. 1. Remove the larger (lower position) clamp. 2. Loosen the clamp screw.
Figure 99 - Cable Installation Example

2198-KITCON-DSL Motor Feedback Connector Kit
Exposed Shield Braid Under Clamp

Clamp Screw (M10)

2198-Sxxx-ERSx Single-axis Inverter (front view)

MBRK

Motor Brake

(BC) Connector

Motor Power Wires
Small Cable Clamp (10, 8, 6 AWG) Large Cable Clamp (4 and 2 AWG)

Small Cable Clamp

Motor Power (MP) Connector

Motor Cable Shield Clamp

Bulletin 2090-CSxM1DE/DG Single Motor Cable

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3. Position the exposed portion of the cable braid directly in line with the clamp.
IMPORTANT Make sure the clamp is aligned with the shield braid and not the heat shrink.
4. Tighten the clamp screw. Make sure the cable clamp tightens around the overall cable shield and provides a good bond between the cable shield and the drive chassis. Torque value 5.6 N·m (50 lb·in), max.
5. Repeat step 1 through step 4 for each drive in multi-axis configurations.

Connect Power/Brake and Feedback Cables

Kinetix 5700 drives are also compatible with many other Allen-Bradley® motors and actuators that have separate power/brake and feedback cables. Follow these guidelines when 2090-CPxM7DF (power/brake) cables and 2090-CFBM7DF (feedback) cables are used in a new installation or reused in an existing installation with Kinetix 5700 servo drives.

Motor Power and Brake Cables

The motors and actuators in Table 89 have separate power/brake and feedback cables. The motor power/brake cable attaches to the cable clamp on the drive and the power/brake conductors attach to the MP and BC connectors, respectively.

Table 89 - Motor Power Cable Compatibility

Motor/Actuator Cat. No.

Motor Power Cables (1) Motor Power Cables (1)

(with brake wires)

(without brake wires)

MPL-A/B15xxx-xx7xAA, MPL-A/B2xxx-xx7xA MPL-A/B3xxx-xx7xAA...MPL-A/B9xxx-xx7xAA

MPM-A/Bxxxx, MPF-A/Bxxxx, MPS-A/Bxxxx

MPAS-Bxxxx1-V05SxA, MPAS-Bxxxx2-V20SxA MPAI-Bxxxx, MPAR-B3xxx (series B) MPAR-B1xxx and MPAR-B2xxx (series B and C)
VPC-Bxxxxx-S VPC-B3004x-M, VPC-Bxxxxx-Y

2090-CPBM7DF-xxAAxx (standard) or 2090-CPBM7DF-xxAFxx (continuous-flex)

2090-CPWM7DF-xxAAxx (standard) or 2090-CPWM7DF-xxAFxx (continuous-flex)

RDB-Bxxxx-7/3

MPAS-Bxxxxx-ALMx2C

LDAT-Sxxxxxx-xDx LDAT-Sxxxxxx-xBx

N/A

LDC-xxxxxx-xHTxx

HPK-Bxxxx, HPK-Exxxx

Customer-supplied

(1) Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004, for cable specifications.

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Table 90 - Legacy Motor Power Cables Motor Cable Standard
Continuous-flex

Description Power/brake, threaded Power-only, bayonet Power/brake, threaded Power-only, threaded Power-only, bayonet

Cat. No. 2090-XXNPMF-xxSxx 2090-XXNPMP-xxSxx 2090-CPBM4DF-xxAFxx 2090-CPWM4DF-xxAFxx 2090-XXTPMP-xxSxx

Table 91 - Induction Motor Power Cable Specifications

Cable Manufacturer Belden Lapp Group SAB

Cable Series 29500-29507 ÖLFEX VFD XL VFD XLPE TR

Voltage Rating 600V

Temperature Rating 90 °C (194 °F)

Motor Power/Brake Cable Series Change

Compatible Motors and Actuators

Motor power and brake conductors on 2090-CPBM7DF (series A) cables have the following dimensions from the factory. If your cable is reused from an existing application, the actual conductor lengths could be slightly different.

Figure 100 - 2090-CPBM7DF (series A) Power/brake Cable Dimensions

Dimensions are in mm (in.)

Edge of Cable Jacket

102 (4.0)

150 (5.9)

Power Conductors

Overall Cable Shield

Brake Shield (remove) 635 (25)

Brake Conductors

Dimensions are in mm (in.)
Compatible Motors and Actuators

Motor power and brake conductors on 2090-CPBM7DF (series B) 12 and 10 AWG standard, non-flex cables provide (drive end) shield braid and conductor preparation designed for compatibility with multiple Kinetix servo-drive families, including Kinetix 5700 drives.

Figure 101 - 2090-CPBM7DF (series B, 10 or 12 AWG) Power/brake Cable Dimensions

71 (2.80)

305 (12.0)

234 (9.20)

15.0 (0.59)

12.7 (0.50) 5.0 (0.20)

Power Conductors

Overall Cable Shield Heat Shrink

5.0 (0.20)

Brake Conductors
8.0 (0.31)

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Dual-axis Inverter Power/Brake Cable Installation
Dual-axis inverters are compatible with several Allen-Bradley motor families that require 16, 14, 12, and 10 AWG power/brake cables. Refer to Table 92 for the proper procedure designed for your 2090-CPxM7DF cable.
SHOCK HAZARD: To avoid hazard of electrical shock, make sure shielded power cables are grounded according to recommendations.

Table 92 - Cable Preparation for 2090-CPxM7DF Cables

Cable Power Conductor Size AWG
16 and 14
12 and 10

Go to:
Cable Preparation for 16 and 14 AWG Cables Cable Preparation for 12 and 10 AWG Cables

Cable Preparation for 16 and 14 AWG Cables

For dual-axis inverters, the 2090-CPBM7DF power conductor length, 102 mm (4.0 in.), is sufficiently long to reach the MP connector plug and provides adequate stress relief. However, you must remove additional insulation from the power conductors to achieve a strip length of 10 mm (0.39 in.).

The brake conductor length, 635 mm (25 in.), is much longer than necessary. We recommend that you measure 188 mm (7.4 in.) from the edge of the cable jacket (that is covered by heat shrink) and trim off the rest.

Refer to Figure 102 and on page 162 for a typical installation example. For strip lengths and torque values, refer to Table 79 and Table 80 on page 148.

Cable Preparation for 12 and 10 AWG Cables

2090-CPBM7DF (series B) 12 and 10 AWG cables are designed for use with Kinetix 5700 dual-axis inverters and do not require any modifications.

For dual-axis inverters, 2090-CPBM7DF (series A) 12 and 10 AWG conductors are too short and stiff to reach the MP connector plug and provide adequate stress relief.

Follow these steps to prepare your existing (series A) 12 and 10 AWG cables.
1. Remove any heat shrink or small sections of cable jacket from your existing cable.
2. Remove additional cable jacket and shield braid from your cable following the diagram below.

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Compatible Motors and Actuators

Include a new 12 mm (0.5 in.) section of cable jacket and slide it down to the end of the shield braid.

Dimensions are in mm (in.)

Edge of Cable Jacket

221 (8.7)

10.0 (0.39)

12 (0.50)

Power Conductors

71 (2.8) 305 (12)

Brake Shield (trimmed back)

3. Apply heat shrink to the small section of cable jacket.

Brake Conductors
7.0 (0.28)

Refer to Figure 103 for typical installation examples for series A and series B cables. For strip lengths and torque values, refer to Table 79 and Table 80 on page 148.

Dual-axis Inverter Shield Clamp Installation

Follow these steps to apply the dual-axis inverter cable shield clamp.

1. Loosen the clamp knob and determine if you need the clamp spacers.
The power/brake cable shield attaches to the dual-axis inverter cable clamp. Clamp spacers are included with the dual-axis inverters for cable diameters that are too small for a tight fit within the drive clamp alone.
The spacers are held captive by nylon rivets. Remove the rivets and spacers when your cable shield is of sufficient diameter for the clamp to hold the cable secure.

IMPORTANT Most 2090-CPxM7DF power/brake cables require the spacers. Only 10 AWG cables with brake conductors have a diameter large enough to fit in the clamp without the spacers.

2. Position the exposed portion of each cable braid directly in line with the clamp.
3. Hand tighten the clamp knob.
Make sure the cable clamp tightens around the cable shield and provides a good bond between the cable shield and the drive chassis.

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Only finger-tight torque on the clamp knob is required. The cable should not move within the clamp under its own weight or when slight pressure is applied by hand.

IMPORTANT

Figure 102 - Dual-axis Inverter Cable Installation (16 and 14 AWG cable)

UFB-A

UFB-B

Universal Feedback

(UFB) Connectors

D+ D-

MF-A

MF-B

Dual-axis Inverter (front view)

2198-K57CK-D15M Motor Feedback Connector Kit
Nylon Rivet

Dual-axis Inverter (side view)
Motor Power (MP) and Motor Brake (BC) Connectors

Clamp Knob

Clamp Spacer

Stress Relief Bends

Conductors enter into the motor and brake connectors at approximately 90° (between 75° and 105° is acceptable).

Clamps Compressed Around Shields Close to the Heat Shrink
Bulletin 2090-CPBM7DF Power/Brake Cables

12 and 10 AWG (series A) cables, prepared as shown on page 160, and series B cables have longer conductors that support service loops.
Figure 103 - Dual-axis Inverter Cable Installation (series A and B, 12 and 10 AWG cable)

75°...105° Entry Into Connectors

Motor Power (MP) and Motor Brake (BC) Connectors

Dual-axis Inverter (side view)

Service loops provide stress relief and the conductors enter into the motor and
brake connectors at approximately 90° (between 75 and 105° is acceptable).

Bulletin 2090-CPBM7DF Power/Brake Cables

Clamps Compressed Around Shields Close to the Heat Shrink

4. Repeat step 1 through step 3 for each dual-axis inverter.

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IMPORTANT

Avoid sharp bends in the power and brake conductors. You must route the power and brake conductors from where they exit the clamp and enter the motor and brake connectors so that stress-relief bends or service loops are formed.

Single-axis Inverter Power/Brake Cable Installation
All single-axis inverters include a cable-shield clamp bracket that is designed to ground (bond) 2090-CPBM7DF cable shields with the drive chassis.
· 2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx single-axis inverters include a two-position cable-shield clamp that accommodates 10, 8, 6, 4, and 2 AWG power conductors. The clamp bracket is connected to the motor power connector and ships with the drive.
· 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters include a single-position cable-shield clamp that accommodates 4 and 2 AWG power conductors. The clamp bracket ships with the drive, but requires some assembly.
2090-CPBM7DF (series B) 10 AWG cables are designed for use with Kinetix 5700 single-axis inverters and do not require any modifications.

SHOCK HAZARD: To avoid hazard of electrical shock, make sure shielded power cables are grounded according to recommendations.

For single-axis inverters, the 2090-CPBM7DF (series A) cable power conductors, 102 mm (4.0 in.), require adjustment only when the smaller (upper position) clamp is used. The upper position is for smaller cables (10, 8, and 6 AWG). The lower position is for larger cables (4 and 2 AWG). We recommend that you measure from the edge of the cable jacket (that is covered with heat shrink) and trim the power conductors as shown in Table 93.

Table 93 - Power Conductor Trimmed Length

Power Conductor Size AWG 6 and 8 10 2 and 4

Power Conductor Length mm (in.) 75 (2.9) No trimming required 85 (3.3)

The (series A) 2090-CPBM7DF brake conductor length, 635 mm (25 in.) is longer than necessary. Measure from the edge of the heat shrink and trim the brake conductors as shown in Table 94.

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Table 94 - Brake Conductor Trimmed Length

Power Conductor Size AWG
6, 8, 10
2 and 4

Brake Conductor Length mm (in.)
315 (12.4)
375 (14.7)

See Figure 104 on page 165 for a typical series-A installation example. For strip lengths and torque values, see Table 80 and Table 81 on page 148 and Table 82 on page 150.

Single-axis Inverter Shield Clamp Installation

Follow these steps to apply the 2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx single-axis inverter motor-cable shield clamp when using 2090-CPBM7DF motor power cables.

1. Remove the larger (lower position) clamp or small (upper position) clamp, depending on the power conductor size used in your application.

IMPORTANT Make sure to use the proper size clamp depending on cable diameter.

2. Loosen the clamp screw.
3. Position the exposed portion of the cable braid directly in line with the clamp.

IMPORTANT Make sure the clamp is aligned with the shield braid and not heat shrink.

4. Tighten the clamp screw. Make sure the cable clamp tightens around the overall cable shield and provides a good bond between the cable shield and the drive chassis. Torque value 5.6 N·m (50 lb·in), max.
In Figure 104, 10 AWG (series A) cables are prepared per Table 93 and Table 94 on page 164, and series B cables do not require preparation.

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2198-K57CK-D15M Motor Feedback Connector Kit
Overall Cable Shield Under Clamp

Clamp Screw (M10)

2198-Sxxx-ERSx Single-axis Inverter (front view)

MBRK

Motor Brake

(BC) Connector

Motor Power Wires
Small Cable Clamp (10, 8, and 6 AWG) Large Cable Clamp (4 and 2 AWG)

Motor Power (MP) Connector

Small Cable Clamp

Motor Cable Shield Clamp

Bulletin 2090-CPBM7DF Power/Brake Cable

5. Repeat step 1 through step 4 for each drive in multi-axis configurations.

Follow these steps to apply the 2198-S263-ERSx and 2198-S312-ERSx singleaxis inverter motor-cable shield clamp when using 2090-CPBM7DF motor power cables.

1. Install the clamp bracket. a. Remove the M8 hex nut by using a 13 mm socket. b. Remove the termination block. c. Insert the cable clamp bracket over the M8 stud. d. Replace the termination block and hex nut. e. Tighten the hex nut to 5.6 N·m (50 lb·in), max.

Ground Conductor M8 Hex Nut Termination Block
M8 Stud

2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverter (front/side view)

Cable Clamp

Cable Clamp Bracket

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2. Align the clamp-bracket captive screw with hole in chassis and tighten to 1.6 N·m (14 lb·in).

Captive Screw

2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverter (bottom view)

Ground Conductor Termination Block

Cable Clamp

Cable Clamp Bracket
3. Loosen the clamp screw. 4. Position the exposed portion of the cable braid directly in line with the
clamp.
IMPORTANT Make sure the clamp is aligned with the shield braid and not the heat shrink.
5. Tighten the clamp screw. Make sure the cable clamp tightens around the overall cable shield and provides a good bond between the cable shield and the drive chassis. Torque value 5.6 N·m (50 lb·in), max.
In Figure 105, the Bulletin 2090 (4 and 2 AWG) cable requires no preparation.
Figure 105 - Single-axis Inverter Cable Installation (4 and 2 AWG cables)

2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverter
(side view)
Cable Clamp Bracket
166

2198-K57CK-D15M Motor Feedback Connector Kit
Overall Cable Shield Under Clamp

Clamp Screw (M10)

2198-S263-ERSx or

2198-S312-ERSx

Single-axis Inverter

(front view)

Motor Brake

MBRK

(BC) Connector

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Motor Power (MP) Connector

Motor Power Conductors

Cable Clamp

Motor Cable Shield Clamp

Bulletin 2090-CPBM7DF Power/Brake Cable

6. Repeat step 1 through step 5 for each drive in multi-axis configurations.

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Motor Feedback Connections

You can connect motor feedback to the 2-pin motor feedback (MF) connector or the 15-pin universal feedback (UFB) connector with the associated feedback connector kit.

Table 95 - Feedback Connector Kit Options

Connector Kit Cat. No.

Kinetix 5700 Drive Feedback Connectors

Encoder Feedback Type

Description

2198-H2DCK (series B or later)

Motor feedback (MF)

Single-turn or multi-turn absolute

Converts the 15-pin Hiperface feedback signals from the encoder to 2-pin DSL feedback signals at the drive.

2198-K57CK-D15M

Universal feedback (UFB)

Single-turn/ multi-turn absolute, incremental, or EnDat

Feedback signals pass straight through encoder to drive for motor feedback or auxiliary feedback.

Feedback cables attach to the connector kit and are wired to the connector inside the connector kit. Bulletin 2090 feedback cables require preparation to make sure the shield clamp attaches properly and conductors route smoothly to the connector terminals.

All of the current and legacy feedback cables listed below are compatible with the 2198-H2DCK converter kit and 2198-K57CK-D15M connector kit.

Motor/Actuator Families
Kinetix MPL servo motors Kinetix MPM servo motors Kinetix MPF servo motors Kinetix MPS servo motors
Kinetix VPC servo motors
Kinetix HPK servo motors Kinetix MPAS/MPMA integrated linear stages Kinetix MPAR electric cylinders Kinetix MPAI heavy-duty electric cylinders LDAT-Series integrated linear thrusters LDC-SeriesTM iron-core linear motors Kinetix RDB direct-drive motors

Table 96 - Compatible Motors and Actuators

Single-turn or Multi-turn Absolute Encoders

Incremental Encoders

Motor /Actuator Cat. No.

Feedback Cable Cat. No.

Motor/Actuator Cat. No.

Feedback Cable Cat. No.

MPL-A/B15xxx...MPL-A/B2xxx-V/E MPL-A/B3xxx...MPL-A/B9xxx-M/S

MPL-A/B15xxx...MPL-A/B2xxx-H MPL-A/B3xxx...MPL-A/B45xxx-H

MPM-A/Bxxxxx-M/S

N/A

MPF-A/Bxxxx-M/S

N/A

MPS-A/Bxxxx-M/S
VPC-Bxxxxx-S VPC-B3004x-M VPC-Bxxxxx-Y
HPK-Bxxxxxx-M/S
MPAS-Bxxxxx-VxxSxA (ballscrew)

2090-CFBM7DF-CEAAxx 2090-CFBM7DD-CEAAxx 2090-CFBM7DF-CERAxx (standard) or 2090-CFBM7DF-CEAFxx 2090-CFBM7DD-CEAFxx 2090-CFBM7DF-CDAFxx (continuous-flex)

N/A
N/A
N/A MPAS-Bxxxxx-ALMx2C (direct drive)

2090-XXNFMF-Sxx (standard) 2090-CFBM7DF-CDAFxx (continuous-flex)

MPAR-Bxxxxx

N/A

MPAI-Bxxxxx

N/A

LDAT-Sxxxxxx-xDx

LDAT-Sxxxxxx-xBx

N/A

LDC-xxxxxx-xHTxx

RDB-Bxxxx-7/3

2090-XXNFMF-Sxx 2090-CFBM7DF-CDAFxx

N/A

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14 11 10 7 6 5 4 3 2 1

10-pin Connector
16-pin Connector

Table 97 - Legacy Motor Feedback Cables

Motor Cable Standard Continuous-flex

Description Encoder feedback, threaded
Encoder feedback, bayonet Encoder feedback, bayonet Encoder feedback, threaded

Cable Cat. No.
2090-XXNFMF-Sxx 2090-UXNFBMF-Sxx
2090-UXNFBMP-Sxx 2090-XXNFMP-Sxx
2090-XXTFMP-Sxx
2090-CFBM4DF-CDAFxx

Figure 106 - 2198-H2DCK Converter Kit Pinout

Terminal 1

Signal SIN+

Wire Color Black

Strip Length mm (in.)

Torque Value N·m (lb·in)

SIN

White/Black

COS+

Red

COS

White/Red

5 6

DATA+ ECOM (1)

Green White/Gray

5.0 (0.2)

0.22...0.25 (1.9...2.2)

EPWR_9V (2)

Orange

DATA

White/Green

White/Orange

EPWR_5V (2)

Gray

(1) The ECOM and TS- connections are tied together and connect to the cable shield. (2) The converter kit generates 9V and 5V from a 12V supply coming from the drive. The 9V supply is used by 9V encoders in 460V
motors and actuators.

Figure 107 - 2198-K57CK-D15M Connector Kit Pinout

Terminal Signal

Wire Color

Strip Length mm (in.)

SIN+ AM+ Black

SIN

White/Black

COS+ BM+ Red

COS BM White/Red

DATA+ IM+

Green

ECOM (1)

White/Gray

EPWR_9V

Orange

CLK+

White/Yellow Brown

5.0 (0.2)

DATA IM

White/Green

White/Orange

White/Blue

Yellow

EPWR_5V

Gray

CLK

White/Brown

Drain

N/A

(1) The ECOM and TS- connections are tied together and connect to the cable shield.

Torque Value N·m (lb·in)
0.22...0.25 (1.9...2.2)

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

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Motor Feedback Cable Preparation
Observe the lead preparation guidelines for each of the connector kits.

IMPORTANT This length of wire is needed to provide a service loop for the longest wires terminated at the terminal block. However, most wires need to be trimmed shorter, depending on the terminal they are assigned to.

Figure 108 - Lead Preparation for 2198-H2DCK Converter Kit

Cable Jacket

Cable Shield

Dimensions are in mm (in.) 5.0 (0.2)

12.0 (0.5)

103 (4.0)

115 (4.5)

Figure 109 - Lead Preparation for 2198-K57CK-D15M Connector Kit

Dimensions are in mm (in.)

Cable Jacket

Cable Shield

5.0 (0.2)

12.0 (0.5)

Drain Wire 97 (3.8)

110 (4.3)

IMPORTANT For the 2198- K57CK-D15M universal connector kit, if your 2090-Series motor cable does not include a drain wire, you must create one from the overall shield during wire preparation and connect it to pin 16.

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Apply the Converter Kit/Connector Kit Shield Clamp
Follow these steps to apply the shield clamp. 1. Apply the shield clamp to the 12 mm (0.5 in.) of exposed cable shield.

IMPORTANT

Cable preparation and positioning/wiring that provides a highfrequency bond between the shield braid/drain wire and ground is required to optimize system performance.
Also, make sure that the cable is positioned where the cover clamps onto the jacket for added stress relief.

a. For the 2198- H2DCK converter kit, the shield clamp achieves a high-frequency bond between the shield braid and ground. Apply 0.30 N·m (2.6 lb·in) torque to the clamp screws.
Shield Clamp

Cable Positioned Where Cover Clamps Onto the Cable Jacket
b. For the 2198- K57CK-D15M connector kit, you must attach the drain wire to pin 16 to achieve a high-frequency bond.

IMPORTANT If your 2090-Series motor cable does not include a drain wire, you must create one from the overall shield braid.

Apply 0.34 N·m (3.0 lb·in) torque to the clamp screws.

Drain Wire

16 15 14 13 12 11 10

Cable Positioned Where Cover Clamps Onto the Cable Jacket
2. Route and insert each wire to its assigned terminal.
Include a service loop, as shown on page 172, and refer to the connector pinout on page 168.
3. Tighten each terminal screw.
Apply 0.22...0.25 N·m (1.9...2.2 lb·in) torque to each screw.
4. Gently pull on each wire to make sure it does not come out of its terminal; reinsert and tighten any loose wires.
5. Attach the tie wrap for added stress relief.

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Table 98 - 2090-CFBM7DF-CEAxxx Feedback Cables

Rotary Motors

MPL-A/B15xxx...MPL-A/B2xxx-V/Ex4/7xAA MPL-A/B3xxx...MPL-A/B9xxx-M/Sx7xAA MPF-A/Bxxx-M/S, MPS-A/Bxxx-M/S MPM-A/Bxxxxx-M/S, VPC-Bxxxxx-S, VPC-B3004x-M HPK-Bxxxxx-M/S, HPK-Exxxxx-M/S

Linear Actuators

MPAS-Bxxxxx-VxxSxA MPAR-Bxxxx MPAI-Bxxxx LDAT-Sxxxxxx-xDx

2198-H2DCK Converter Kit Pin

SIN+

SIN

COS+

COS

DATA+

DATA

EPWR_5V

ECOM

6 (1)

EPWR_9V

ECOM

(1) The ECOM and TS- connections are tied together and connect to the cable shield.

2198-K57CK-D15M Connector Kit Pin
1 2 3 4 5 10 14 6 (1) 7 6 11

Rotary Motors

VPC-Bxxxxx-Y

Linear Actuators

CLK+

CLK

DATA+

DATA

EPWR_5V

ECOM

2198-K57CK-D15M Connector Kit Pin
1 2 9 15 5 10 14 6 (1) 6 11

Table 99 - 2090-XXNFMF-Sxx or 2090-CFBM7DF-CDAxxx Feedback Cables

Rotary Motors
Linear Actuators
1 2 3 4 5 6 9 10 12 13 15 16 17

MPL-A/B15xxx...MPL-A/B2xxx-Hx4/7xAA MPL-A/B3xxx...MPL-A/B45xxx-Hx4/7xAA
MPAS-Bxxxxx-ALMx2C LDAT-Sxxxxxx-xBx LDC-xxxxxx-xHTxx

RDB-Bxxxx-7/3

2198-K57CK-D15M Connector Kit Pin

AM+

SIN+

SIN

BM+

COS+

COS

IM+

DATA+

DATA

EPWR_5V ECOM

EPWR_5V

ECOM

6 (1)

ECOM

(1) The ECOM and TS- connections are tied together and connect to the cable shield.

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A mounting bracket is included with the 2198-H2DCK converter kit to secure the kit to the drive. Install the mounting bracket in the bottom mounting position on the kit, and the kit mounting holes on the drive.
Figure 110 - Wiring the 2198-H2DCK Feedback Converter Kit

D+

D-

Mounting Screws (2)

MF-A

MF-B

Converter Kit Mounting Holes (2198-Dxxx-ERSx example is shown)

The bottom mounting position applies to all dual-axis and single-axis inverters.

Mounting Bracket

10-pin Connector
Exposed Shield Aligned in the Cable Channel

14 11 10 7 6 5 4 3 2 1

Service Loops
Tie Wrap for Stress Relief and Wire Management
Clamp Screws (2)
1. Place exposed cable shield in the channel.
2. Place the shield clamp over the exposed shield.
3. Tighten screws, torque 0.3 N·m (2.6 lb·in).
Shield Clamp

Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006, for converter kit specifications.

Figure 111 - Wiring the 2198-K57CK-D15M Feedback Connector Kit

Mounting Screws

UFB
Pin 15 Pin 11 Pin 6

Pin 10 Pin 5
Pin 1

2198-K57CK-D15M Connector Kit
16-pin Connector
Exposed Shield Aligned on the Ground Pad Shield Clamp

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Service Loops

Tie Wrap is recommended for Stress Relief and Wire Management

Clamp Screws (2) Bulletin 2090 Feedback Cable

1. Place exposed cable shield in the channel.
2. Place the shield clamp over the exposed shield.
3. Tighten screws, torque 0.34 N·m (3.0 lb·in).

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

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Customer-supplied Motor Power Cables

Connect the Kinetix 5700 Drive System Chapter 5
For 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters that are paired with motors that require power cables greater than 2 AWG and up to 250 kcmil, customer supplied cable is necessary.
IMPORTANT The cable clamp bracket and shield clamp, included with your drive, does not apply to customer supplied cables larger than 2 AWG.
We recommend six conductor cables with three conductors for power and another three conductors that can be twisted together to form a suitable ground wire. Follow these steps to prepare customer-supplied motor power cables.
1. Remove 279 mm (11.0 in.) of the cable jacket. In addition, remove the same amount of shield braid, copper foil, or other overall shielding.
279 mm (11.0 in.)

Typical End View

Remove Overall Cable Shield

2. Separate the power conductors from the ground conductors.

In this example, the power conductors are insulated and the ground conductors are not.
3. Twist the three ground conductors together to form a single ground conductor.

4. Apply heat shrink to the ground conductor.

27 mm (1.06 in.)

Edge of Cable Jacket

25 mm (0.98 in.)
5. Apply heat shrink over the cable jacket and the four insulated conductors.
6. Trim the insulation to leave a strip length of 27 mm (1.06 in.)

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Chapter 5 Connect the Kinetix 5700 Drive System Figure 112 - MP and BC Connector Wiring (single-axis inverters)

2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverters
(side view)

2198-K57CK-D15M Motor Feedback Connector Kit

Motor Power (MP) Connector (bottom view)

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

2198-S263-ERSx or 2198-S312-ERSx Single-axis Inverters (front view)

Motor Brake (BC) Connector Plug

MBRK

Customer-supplied Motor Brake Cable

Motor Power Ground Terminal Screw: 8 mm Hex Driver
Torque: 5.6 N·m (50 lb·in)
Motor Cable Connections

Motor Power (MP) Connector Screws (3x): 6 mm Hex Driver Torque: 15...20 N·m (132...177 lb·in)
Customer-supplied Motor Power Cable

Prepare the customer-supplied motor power cable (see page 173), then attach motor power and ground wires to the motor power connector and ground terminal. Plug in motor feedback and brake connectors, as required for your application.

IMPORTANT

The supplied ground terminal is suitable for use with 16...120 mm2 (6 AWG...250 kcmil) Class B and C power cables and all Allen-Bradley Bulletin 2090 motor cables. A customer-supplied lug is required for all other applications.

Table 100 - Motor Power Connector Specifications (single-axis inverters)

Drive Module Cat. No.

Recommended Pin Signal/Wire Color Wire Size
mm2 (AWG)

Strip Length

Terminal Torque Value

mm (in.)

N·m (lb·in)

U 2198-S263-ERSx V 2198-S312-ERSx W

U Brown

V Black

21.1...120

W Blue

(4...250 kcmil)

Green/Yellow

27.0 (1.06)

15...20 (132...177)

If you replace the ground-conductor termination block with a lug, the lug size must not exceed these maximum dimensions.
Figure 113 - Maximum Customer-supplied Lug Dimensions

25.4 mm (1.00 in.)

8 mm (0.315 in.) (inside diameter hole)

Lug size according to cable size and classification. Flexible wires (Class K...G) must use flex-rated lugs.

11.43 mm (0.45 in.)

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Motor brake conductors are customer supplied. We recommend unshielded cable up to 90 m (295 ft).

Table 101 - Motor Brake (BC) Connector Specifications

Drive Module Cat. No.

Pin Signal

2198-S263-ERSx 2198-S312-ERSx

BC-1 MBRK+ BC-2 MBRK-

Recommended Wire Size (AWG)
16

Strip Length Torque Value

mm (in.)

N·m (lb·in)

7.0 (0.28)

0.22...0.25 (1.9...2.2)

TIP Motors used with 2198-S263-ERSx and 2198-S312-ERSx inverters typically use a brake coil that is not 24V DC. In this case, use a customer-supplied auxiliary relay to power the customer-supplied brake coil.

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Accessory Module Connections

Follow these guidelines when wiring the 2198-CAPMOD-2240 capacitor module, 2198-CAPMOD-DCBUS-IO extension module, and 2198-DCBUSCOND-RP312 DC-bus conditioner module:
· Wire module status (MS) output connections to digital input Bus Capacitor OK, Bus Conditioner OK, or the Logix 5000TM controller (optional).
· Flexible bus-bars (included with 2198-CAPMOD-DCBUS-IO extension modules) are required whenever two accessory modules are mounted side-by-side in 208 A systems. If your system does not include the extension module, order the 2198-KITCON-DCBUSCOND or 2198-KITCON-CAPMOD2240 replacement kit.
· Refer to DC-bus Power Supply with Capacitor Module wiring example on page 345.
· Refer to Regenerative Bus Supply with DC-bus Conditioner Module wiring example on page 349.
· Refer to Kinetix 5700 Accessory Module Status Indicators on page 277 for troubleshooting the module status indicators and relay output.
IMPORTANT To improve system performance, run wires and cables in the wireways as established in Chapter 2. Connections to the DC bus must be made with the shared-bus connection system.
Figure 114 - MS Connector Wiring (capacitor module and DC-bus conditioner module)

MOD DC BUS

2198-CAPMOD-2240 Capacitor Module or

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

Module Status

(MS) Connector Plug

MODULE STATUS

Table 102 - Accessory Module Connector Specifications

Connector Description

Signal

Recommended Wire Size mm2 (AWG)

Strip Length Torque Value

mm (in.)

N·m (lb·in)

Module Status

MS-1 MS-2

MS MS

0.14...1.5 (28...16)

7.0 (0.28)

0.22...0.25 (1.9...2.2)

PELV/SELV

CP-1

24V+

24V power (plug) CP-2

24V-

DC-bus power Bus-bar

0.5...4 (20...12)
N/A (1)

7.0 (0.28) N/A (1)

0.22...0.25 (1.9...2.2)
N/A (1)

Bus-bar

DC-

DC-bus studs

DC+

Lugs

N/A

53.5 (1/0 AWG) 104 A 152 (300 kcmil) 208 A

N/A (2)

18 (156)

(1) DC bus connections are always made from one drive module to another over the shared-bus connection system. These terminals
do not receive discrete wires. (2) Strip length for the DC-bus studs depend on the customer-supplied lugs.

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External Passive-shunt Connections

Passive shunts attach to only 2198-Pxxx DC-bus power supplies. See Passive Shunt Considerations on page 49 for shunts compatible with your DC-bus power supply.
Follow these guidelines when wiring your 2198-Rxxx passive shunt: · Refer to External Passive Shunt Modules on page 72 for noise zone considerations. · Refer to Passive Shunt Wiring Examples on page 359. · Refer to the installation instructions provided with your Bulletin 2198 shunt module, publication 2198-IN011.

IMPORTANT To improve system performance, run wires and cables in the wireways as established in Chapter 2.

Figure 115 - RC Connector Wiring

2198-Pxxx DC-bus Power Supply Top View

Shunt Resistor (RC) Connector Plug

1 2

Table 103 - Shunt Resistor (RC) Connector Specifications

DC-bus Power Supply Cat. No.

2198-Pxxx

RC-1 RC-2

Signal
SH DC+

Recommended Wire Size mm2 (AWG)
1.5...6 (16...10)

Strip Length mm (in.)
12.0 (0.47)

Torque Value N·m (lb·in)
0.5...0.6 (4.4...5.3)

IMPORTANT You must disconnect the internal shunt wires at the RC connector before connecting the Bulletin 2198 passive shunt resistor wires.

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External Active-shunt Connections

Active shunts are available from the Rockwell Automation EncompassTM partner Powerohm Resistors, Inc. See Active Shunt Considerations on page 50 for Powerohm shunts compatible with your Kinetix 5700 power supply.

Rockwell Automation Encompass Partners Powerohm Resistors, Inc.

Contact Information
5713 13th Street Katy, Texas 77493 Tel: (800) 838-4694 http://www.powerohm.com

Follow these guidelines when wiring your Powerohm active shunt:
· Refer to External Active Shunt Modules on page 74 for noise zone considerations.
· Refer to Active Shunt Wiring Examples on page 360.
· Refer to the installation instructions provided with your Bulletin PWBxxx and PKBxxx Powerohm shunt module.

IMPORTANT To improve system performance, run wires and cables in the wireways as established in Chapter 2.

DC-bus Power Supply Active Shunt Connections
Make active shunt connections in drive systems that include the DC-bus power supply and Powerohm PKBxxx or PWBxxx active shunts at the external DC-bus studs on accessory modules.
Refer to Wire the External DC-bus Connections on page 179.
Regenerative Bus Supply Active Shunt Connections
Make active shunt connections to the 2198-RPxxx regenerative bus supply at the active shunt (RC) connector or the external DC-bus studs on accessory modules, depending on the shunt type.

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Connections at the Active Shunt (RC) Connector
You can make active shunt connections in drive systems that include the regenerative bus supply and Powerohm PKBxxx-800 active shunts at the Active Shunt (RC) connector.
Figure 116 - RC Connector Wiring
2198-RPxxx Regenerative Bus Supply Top View

Active Shunt (RC) Connector Plug

1 2

Table 104 - Active Shunt (RC) Connector Specifications

Regenerative Bus Supply Pin Cat. No.

Signal

Continuous (1) Current, max

Recommended Wire Size mm2 (AWG)

Strip Length mm (in.)

2198-RPxxx

RC-1 RC-2

DC DC+

10 A

2.5...6 (14...10)

12.0 (0.47)

(1) This connector applies to only Powerohm PKBxxx-xxx active shunts rated at 7 kW or less.

Torque Value N·m (lb·in)
0.5...0.6 (4.4...5.3)

IMPORTANT

Due to the 10 A connector current rating, connections to the RC connector are limited to only Powerohm PKBxxx-xxx active shunts rated at 7 kW or less. All other PKBxxx-xxx and PWBxxx-xxx active shunt connections must be made to the 2198-CAPMOD-2240 capacitor module.

Connections at the External DC-bus Studs

You can make active shunt connections in drive systems that include the regenerative bus supply and Powerohm PKBxxx-800 or PWBxxx-800 active shunts at the external DC-bus studs on accessory modules.
Refer to Wire the External DC-bus Connections.

Wire the External DC-bus Connections
Accessory modules are equipped with spacers that slide onto the M8 studs. When the system configuration includes external DC-bus and active shunt connections, external DC-bus connections are made below the spacer and active shunt connections are made above the spacer.

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Figure 117 - Active Shunt Connections

Active Shunt Lug Connections
(above spacer)
DC-bus Lug Connections and Flexible Bus-bars (2)
(below spacer)

Spacer

2198-DCBUSCOND-RP312 2198-CAPMOD-2240 or 2198-CAPMOD-DCBUS-IO (1) Accessory Modules (2198-CAPMOD-2240 capacitor module is shown)

(1) An external active shunt can be wired to any of the accessory modules. See Mount Accessory Modules on page 81 for more information on mounting and accessory module example configurations. The 2198-CAPMOD-2240 capacitor module is preferred because it provides additional system capacitance.
(2) Position flexible bus-bars (when two accessory modules are used) below the DC-bus lug connections. The flexible bus-bars are used to parallel the extended DC-bus with another accessory module in 208 A systems (not required when only one accessory module is used in 104 A systems). Flexible bus-bars are included with 2198-CAPMOD-DCBUS-IO extension modules or you can order 2198-KITCON-CAPMOD2240 or 2198-KITCON-DCBUSCOND replacement kits.

Kinetix VPC Motors and the Extended Speed Feature
The extended speed feature is implemented in the Logix Designer application to prevent accidental motor operation at unsafe speeds. See Field Weakening Mode on page 462 for a description of this feature.
WARNING: Kinetix VPC motor operation at speeds exceeding the busovervoltage speed limit can result in personal injury and/or damage to the drive. To avoid equipment damage and personal injury, an active shunt must be configured in the Logix Designer application to protect the DC-bus system from an overvoltage condition.
IMPORTANT Refer to Motion Analyzer software to verify drive/shunt system sizing. Access the tool at https://motionanalyzer.rockwellautomation.com.
Powerohm Bulletin PKB and PWB active-shunt modules are required for DCbus system protection when Kinetix VPC motors are expected to operate in the extended speed region at speeds exceeding the bus-overvoltage speed limit.

Considerations for Powerohm Shunt Installation
Refer to the Powerohm documentation included with your Bulletin PKB or PWB shunt module to install, wire, and configure the module.
· To avoid nuisance thermal overload trips, configure Bulletin PKB and PWB active-shunt modules to the highest shunt turn-on voltage setting. The recommended setting for Line Voltage Level Jumper is JP5.
· Configure Bulletin PKB and PWB active-shunt modules in Internal (automatic) mode. Unless an external enable signal is provided, configure the Brake Enable Jumper in Internal (automatic) mode ( JP6 is in the downward position).

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Ethernet Cable Connections This procedure assumes that you have your Logix 5000 controller and
Kinetix 5700 modules mounted and are ready to connect the network cables.
The EtherNet/IPTM network is connected by using the PORT 1 and PORT 2 connectors. Refer to page 92 to locate the Ethernet connectors on your drive module. Refer to Figure 118 to locate the connectors on your Logix 5000 controller.
Shielded Ethernet cable is required for EMC compliance and is available in several standard lengths. Ethernet cable lengths connecting drive-to-drive, drive-to-controller, or drive-to-switch must not exceed 100 m (328 ft). Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004, for more information.
Figure 118 - ControlLogix and CompactLogix Ethernet Port Locations

ControlLogix® 5570 Controller with Bulletin 1756 EtherNet/IP Communication Module
LNK1 LNK2 NET OK

CompactLogixTM 5370 Controller, Compact GuardLogix® 5370 Controller (CompactLogix 5370 controller is shown)

ControlLogix Ethernet Ports 2
The 1756-EN2T modules have only one port,
1756-EN2TR and 1756-EN3TR modules have two. 1

Front Views

00:00:BC:2E:69:F6
1 (Front) 2 (Rear)

Front View

ControlLogix 5580 and GuardLogix 5580 Controller

Logix5585 TM
SAFETY ON
0 0 0 0 NET LINK
RUN FORCE SD OK

CompactLogix 5380 Controller, or Compact GuardLogix 5380 Controller (CompactLogix 5380 controller is shown)

Front View 1 GB Ethernet Port

Bottom View

Port 1, Front Port 2, Rear

The Logix 5000 controllers accept linear, ring (DLR), and star network configurations. Refer to Typical Communication Configurations on page 29 for linear, ring, and star configuration examples.

IMPORTANT

When using an external Ethernet switch for routing traffic between the controller and the drive, switches with IEEE-1588 time synchronization capabilities (boundary or transparent clock) must be used to make sure switch delays are compensated.

IMPORTANT

When configured for standalone operation, the iTRAK power supply requires an Ethernet connection for firmware upgrades that use ControlFLASHTM or ControlFLASH PlusTM software. This connection can also be used to access real-time data, for example, event logging.

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Notes:

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6 Chapter
Configure and Start the Kinetix 5700 Drive System

This chapter provides procedures for configuring your Kinetix® 5700 drive system with a Logix 5000TM controller by using the Logix Designer application.

Topic

Page

Understand the Kinetix 5700 Display

184

Configure the Drive

194

Studio 5000 Logix Designer

194

Configure the Kinetix 5700 Drive Modules

199

Configure the Motion Group

224

Configure Regenerative Bus Supply Axis Properties

225

Configure Vertical Load Control Axis Properties

230

Configure Feedback-only Axis Properties

231

Configure Induction-motor Frequency-control Axis Properties

233

Configure IPM Motor Closed-loop Control Axis Properties

242

Configure SPM Motor Closed-loop Control Axis Properties

246

Configure Induction-motor Closed-loop Control Axis Properties

251

Configure Feedback Properties

258

Download the Program

263

Apply Power to the Kinetix 5700 Drive System

264

Understand Bus-sharing Group Configuration

265

Test and Tune the Axes

268

TIP Before you begin, make sure that you know the catalog number for each drive module, the Logix module and /or controller, and the motor used in your motion control application.

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Understand the Kinetix 5700 Display

The Kinetix 5700 drives have two status indicators and an LCD status display. The indicators and display are used to monitor the system status, set network parameters, and troubleshoot faults. Four navigation buttons, directly below the display, are used to select items from a soft menu.

Figure 119 - Kinetix 5700 Drive LCD Display and Status Indicators

PRECHARGE 192.168.1.1 DC BUS: 0.3V
Soft Menu

MOD NET
5700
PRECHARAGE 192.168.1.1 DC BUS: 0.3V

Status Indicators (see page 276) Navigation Buttons

This is the Home screen.

· The setup selections are tied to the Setup (left-side) buttons and the
menu selections are tied to the Menu (right-side) buttons. · For dual-axis inverters, the Drive (center) buttons toggle the display
between drive A and B (A is the default drive).

DC-bus Power Supplies and Single-axis Inverters

Dual-axis Inverters

PRECHARAGE 192.168.1.1 DC BUS: 0.3V

PRECHARAGE 192.168.1.1 DC BUS: 0.3V
AB

Setup Menu

Setup Drive Menu

Each soft menu item is executed by pressing the navigation button directly below the item, as
shown in this example.
MAIN MENU MODULE INFO MOTOR INFO

The soft menu provides a changing selection that corresponds to the current screen. Use the navigation buttons to perform the following.

Press to go back. Pressing enough times results in the Home screen.
Pressing either arrow moves the selection to the next (or previous) item. When changing values, pressing the up arrow increments the highlighted value. Values rollover after reaching the end of the list.
Press to select values to change, moving from right to left. Values rollover when reaching the end of the list.
Press to select a menu item.

Press to return to the Home screen.

Press to display the fault help (possible solutions in troubleshooting tables). (1)

(1) For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes.

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Menu Screens

The menu screens provide information about the drives, motors, diagnostics, and the fault log. Parameters cannot be updated in the menu screens. Press one of the menu buttons to access the menu.

You can use the soft menu items and navigation buttons to view the information.

MAIN MENU
MODULE INFO MOTOR INFO

Table 105 - Navigating the Inverter Menu

Menu/Sub Menu Selections Drive Info
Motor Info Diagnostics> Drive Diagnostics
Diagnostics> Motor Diagnostics
Diagnostics> Encoder Diagnostics
Diagnostics> Safety Inputs
Diagnostics> Safety Diagnostics

Attributes
Catalog number Firmware revision Hardware revision Serial number Model number Serial number
Bus diagnostics
Inverter diagnostics
Motor speed Motor current Motor utilization Motor temperature Serial number Resolution Number of turns Encoder temperature Supply voltage
Link quality
Remote signal strength indicator Accumulated position errors Channel position errors Hardwired input status
Safety state
Input connections
Output connections

Description

Example Values

2198-Dxxx-ERSx or 2198-Sxxx-ERSx

FW REV: 1.1.450167

HW REV: 1.1

SERIAL#: xxxxxxxxxxx

MODEL: VPL-B1306F

SERIAL#: xxxxxxxxxxx

BUS VOLT: 0.0V

BUS CUR: 0.0A

INV UTIL: 0.0%

INV TEMP: 31.7C

SPEED:0.0 RPM

MTR CUR:0.0A RMS

MTR UTIL:0.0%

MTR TEMP:0.00C

SERIAL#xxxxxxxxxxx

RESOLUTION: 262144

NO OF TURNS: 1

ENC TEMP:33.7C

SUPP VOLT:11.3V

The link quality attribute indicates how noisy a communication link is and also indicates if there is a communication link already established at the drive end. The LINK QUAL value must always be 100%. Persistent values below 100% indicates a poor feedback ground connection.

LINK QUAL: 100.0%

Similar to Link Quality, RSSI reports the quality of link as seen at the motor end by the encoder. Maintain the RSSI value between 80 and 100%. Persistent values below 80% indicates a poor feedback ground connection.

RSSI: 100.0%

This is an aggregated number of errors in the primary position feedback channel of DSL feedback.

POS ERRORS: 1

This is an aggregated number of errors on a secondary communication channel of the DSL feedback.

CHNL ERRORS: 5

12 OFF OFF

12 ON ON

This attribute indicates the state of the safety supervisor object (refer to Safety Supervisor State on page 310.

This attribute indicates the number of safety controllers that have an input connection established. The input connection provides the controller with the drive's safety status. The drive supports up to three input connections.
This attribute indicates the number of safety controllers that have an output connection established. The output connection provides a controller with the ability to control the drive's STO function. The drive allows only one output connection.

SAFETY STATE:CONFIGURING
INPUT CONNECTIONS:1 OUTPUT CONNECTIONS:1

SAFETY STATE:RUNNING
INPUT CONNECTIONS:1 OUTPUT CONNECTIONS:1

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Table 105 - Navigating the Inverter Menu (continued)

Menu/Sub Menu Selections

Attributes Fault text

Description Fault code as listed in the Kinetix 5700 Fault Codes.xlsx file. (1)

Example Values FLT S20 - CONV OVERLOAD FL

Fault Log

Fault details

The problem as reported in the Kinetix 5700 Fault Codes.xlsx file. (1)

The converter thermal model indicates that the temperature has exceeded the factory set capacity rating of 110%.

Fault help

The Possible Solution as reported in the Kinetix 5700 Fault Codes.xlsx file. (1)

· Reduce the number of drives in the same bus group · Reduce duty-cycle of commanded motion

(1) For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes.

Table 106 - Navigating the DC-bus Power Supply Menu

Menu/Sub Menu Attributes Selections

Description

Example Values

Catalog number

2198-Pxxx

Module Info

Firmware revision Hardware revision

FW REV: 1.1.450167 HW REV: 1.1

Serial number

SERIAL#: xxxxxxxxxxx

Diagnostics> Converter Diagnostics

Bus diagnostics Converter diagnostics

BUS VOLT: 0.0V BUS CUR: 0.0A CONV UTIL: 0.7% CONV TEMP: 31.7C

Shunt utilization Fault text

Fault code as listed in the Kinetix 5700 Fault Codes.xlsx file. (1)

SHUNT UTIL: 0.0% FLT S18 - CONV OVERTEMP FL

Fault Log

Fault details Fault help

The problem as reported in the Kinetix 5700 Fault Codes.xlsx file. (1) The Possible Solution as reported in the Kinetix 5700 Fault Codes.xlsx file. (1)

The measured converter temperature has exceeded the factory set temperature limit.
Reduce the number of drives in the same bus group.

(1) For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes.

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Table 107 - Navigating the Regenerative Bus Supply Menu

Menu/Sub Menu Attributes Selections

Description

Example Values

Catalog number

2198-RPxxx

Module Info

Firmware revision Hardware revision

FW REV: 10.1.10500409 HW REV: 2.1

Serial number

SERIAL#: xxxxxxxxxxx

CONV UTIL: 0.7%

CONV TEMP: 31.7C

SHUNT UTIL: 0.0%

DC BUS: 0.0V

IBUS: 0.0A

CONV UTIL: 0.0%

CONV TEMP: 22.6C

PWR OUT: 0.0kW

IGND:0.0A RMS

AC FREQ: 0.1Hz

IL1: 0.0A RMS

IL2: 0.0A RMS

Converter diagnostics

IL3: 0.0A RMS VL1-2: 0.0V RMS

VL2-3: 0.0V RMS

Diagnostics> Converter Diagnostics

VL3-1: 0.0V RMS VL1-N: 0.0V RMS

VL2-N: 0.0V RMS

VL3-N: 0.0V RMS

VBUS REF: 690V

SYNC STS: 0

ACT PWR: 0.0kW

PF: 0.0

VAC UNBAL: 0.0%

IAC UNBAL: 0.0%

PHASE SEQ: 0.0

IN1: OFF

Digital Inputs

IN2: OFF IN3: OFF

IN4: OFF

Digital Outputs Fault text

Fault code as listed in the Kinetix 5700 Fault Codes.xlsx file. (1)

CONT ENABLE: 0 PWR SUP OK: 0 FLT S23 AC PHASE LOSS

Fault Log

Fault details Fault help

The problem as reported in the Kinetix 5700 Fault Codes.xlsx file. (1) The Possible Solution as reported in the Kinetix 5700 Fault Codes.xlsx file. (1)

One AC phase has been lost on the AC line to the converter.
Check AC input voltage on all phases.

(1) For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes.

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Table 108 - Navigating the iTRAK Power Supply Menu

Menu/Sub Menu Attributes Selections

Description

Example Values

Catalog number

2198T-W25K-ER

Module Info

Firmware revision Hardware revision

FW: 6.1.7100254 HW REV: 1.1

Serial number

SERIAL#: xxxxxxxxxxx

Bus diagnostics

BUS VOLT: 0.0V

OUT1 VOLT: 0.0V

Output 1 diagnostics

OUT1 AMPS: 0.0A OUT1 PWR: 0.0kW

Diagnostics> Converter Diagnostics

OUT1 UTIL: 0.0% OUT2 VOLT: 0.0V

Output 2 diagnostics

OUT2 AMPS: 0.0A OUT2 PWR: 0.0kW

OUT2 UTIL: 0.0%

Fault Log

Converter diagnostics Fault text Fault details Fault help

Fault code as listed in the Kinetix 5700 Fault Codes.xlsx file. (1) The problem as reported in the Kinetix 5700 Fault Codes.xlsx file. (1) The Possible Solution as reported in the Kinetix 5700 Fault Codes.xlsx file. (1)

TOTAL PWR: 0.0kW FLT S38 - FUSE BLOWN The internal DC-bus power fuse is blown Return drive for repair if fault continues

(1) For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes.

Setup Screens

The setup screens provide the means of changing drive settings, for example, the IP address. Press one of the setup buttons to access the setup screens.

You can use the soft menu items and navigation buttons to view the information and make changes.
Press to validate your changes: · If the change is invalid, the value doesn't change. · If the change is valid, an asterisk appears next to the changed attribute.

SETTINGS NETWORK DISPLAY
STATIC IP IP ADDRESS* SUBNET MASK

IMPORTANT

You must cycle control power to make network configuration changes persistent. In this example, the IP address was changed. The change takes affect and the asterisk disappears after control power is cycled.
Display configuration changes take effect immediately.

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Table 109 - Navigating the Inverter Settings Menu

Settings Menu Selections Sub Menu Selections

Attributes

Default

Description

Protected Mode

Network Config Device Config

ENABLED DISABLED
ENABLED DISABLED

ENABLED ENABLED

When Enabled (default), network configuration changes are not possible when a controller connection is open.
When Enabled (default), only attribute writes are possible when a controller connection is open.

->Static IP (1)

IP address Subnet mask

192.168.1.1

Indicates current IP address

255.255.255.000 Indicates current subnet mask

Network

Gateway

192.168.001.254 Indicates current gateway

On DHCP
Off

Turns DHCP on Turns DHCP off

Backlight Timeout

30 sec...NEVER (NEVER=no timeout period, the backlight is always on)
->DC BUS (1)

-> 3 min (1)

Sets backlight timeout period of the display DC bus voltage

INV UTIL

Inverter utilization in percent

Display

Cyclic Data Select (2)

INV TEMP MOTOR UTIL SPEED

Inverter temperature in °C Motor utilization in percent RPM

OUT PWR

Output power in watts

OUT FREQ

Output frequency in hertz

OUT CUR

Output current in amps

Set Contrast

-10...+10

Contrast setting of the display

Factory Reset

Reset Defaults?

Are you sure?

Resets drive to factory default state

Safety

Reset Ownership

Are you sure?

Resets safety ownership (reset fails after 30 seconds)

Enabled Web
->Disabled

Enables the web server Disables the web server

(1) An arrow (->) appears in front of the chosen attribute indicating that this attribute is currently configured. This is also the factory default setting. (2) The DC bus voltage is one of several cyclic data attributes. You can select any of the Cyclic Data Select attributes to be displayed on the Home screen.

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Table 110 - Navigating the DC-bus Power Supply Settings Menu

Settings Menu Selections Sub Menu Selections

Attributes

Default

Description

Reset

ENABLED DISABLED

ENABLED

When Enabled (default), identity object or safety resets are not possible when a controller connection is open.

Protected Mode

Network Config Flash Update

ENABLED DISABLED
ENABLED DISABLED

ENABLED ENABLED

When Enabled (default), network configuration changes are not possible when a controller connection is open.
When Enabled (default), firmware updates are not possible when a controller connection is open.

Device Config

ENABLED DISABLED

ENABLED

When Enabled (default), only attribute writes are possible when a controller connection is open.

->Static IP (1)

IP address Subnet mask

192.168.1.1

Indicates current IP address

255.255.255.000 Indicates current subnet mask

Network

Gateway

192.168.001.001 Indicates current gateway

On DHCP
Off

Turns DHCP on Turns DHCP off

Backlight Timeout

30 sec...NEVER (NEVER=no timeout period, the backlight is always on)
->DC BUS (1)

-> 3 min (1)

Sets backlight timeout period of the display DC bus voltage

Display

Cyclic Data Select (2)

CONV UTIL CONV TEMP SHUNT UTIL

Converter utilization in percent Converter temperature in °C Shunt utilization in percent

OUT PWR

Output power in watts

DC BUS CUR

Output current in amps

Set Contrast

-10...+10

Contrast setting of the display

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Table 111 - Navigating the Regenerative Bus Supply Settings Menu

Settings Menu Selections Sub Menu Selections

Attributes

Default

Description

Reset

ENABLED DISABLED

ENABLED

When Enabled (default), identity object or safety resets are not possible when a controller connection is open.

Protected Mode

Network Config Flash Update

ENABLED DISABLED
ENABLED DISABLED

ENABLED ENABLED

Device Config

ENABLED DISABLED

ENABLED

When Enabled (default), only attribute writes are possible when a controller connection is open.

->Static IP (1)

IP address Subnet mask

192.168.1.1

Indicates current IP address

255.255.255.000 Indicates current subnet mask

Network

Gateway

192.168.001.001 Indicates current gateway

On DHCP
Off

Turns DHCP on Turns DHCP off

Backlight Timeout

30 sec...NEVER (NEVER=no timeout period, the backlight is always on)

-> 3 min (1)

Sets backlight timeout period of the display

-> DC BUS

DC bus voltage

CONV UTIL

Converter utilization in % Rated

CONV TEMP

Converter temperature in °C

PWR OUT

Output power in Watts

IBUS

Output current in Amps

Display

Cyclic Data Select (2)

AC FREQ IAC LINE VAC LINE

Input frequency in Hz AC Line current in Amps AC Line voltage in Volts

VBUS REF

Bus Voltage Reference in Volts

ACTV PWR

Active power in Watts

REACT PWR

Reactive power in kVAR

Power Factor

ACTV IREF

Active Current reference in % Rated

REACT IREF

Reactive current reference in % Rated

Set Contrast

-10...+10

Contrast setting of the display

Web

ENABLED DISABLED

ENABLED

When Enabled (default), the drive's diagnostic webpage is accessible.

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Table 112 - Navigating the iTRAK Power Supply Settings Menu

Settings Menu Selections Sub Menu Selections

Attributes

Default

Description

Static IP (3)

IP address Subnet mask

192.168.1.1

Indicates current IP address

255.255.255.000 Indicates current subnet mask

Network

->DHCP (4)

Gateway ->On (4) (3) Off (3)

192.168.001.254

Indicates current gateway Turns DHCP on Turns DHCP off

Backlight Timeout

30 sec...NEVER (NEVER=no timeout period, the backlight is always on)
-> BUS VOLT (4)

-> 3 min (4)

Sets backlight timeout period of the display DC bus voltage in volts

OUT1 VOLT

Output 1 voltage in volts

OUT1 AMPS

Output 1 current in amps

Display

Cyclic Data Select (5)

OUT1 PWR OUT1 UTIL OUT2 VOLT

Output 1 power in kilowatts Output 1 utilization in percent Output 2 voltage in volts

OUT2 AMP

Output 2 current in amps

OUT2 PWR

Output 2 power in kilowatts

OUT2 UTIL

Output 2 utilization in percent

TOTAL PWR

Total power in kilowatts

Set Contrast

-10...+10

Contrast setting of the display

Enabled

Web

->Disabled (4)

Enables the web server Disables the web server

Disabled

Reset

->Enabled (4)

Disables drive reset protection Enables drive reset protection

Protect (1) (2)

Network Config Flash Update

Disabled ->Enabled (4)
Disabled ->Enabled (4)

Disables network configuration protection Enables network configuration protection Disables flash update protection Enables flash update protection

Device Config

Disabled ->Enabled (4)

Disables device configuration protection Enables device configuration protection

Standalone (1)

->Disabled Enabled (4)

Disables standalone operation Enables standalone operation

(1) Settings menu items available for the iTRAK power supply in drive firmware revision 12.001 and later. (2) Protected mode settings prevent the corresponding operation from being performed when Class 1 CIPTM connections are open. (3) The default network setting was changed from Static IP to DHCP in drive firmware revision 12.001 to comply with EtherNet/IPTM standards (4) An arrow (->) appears in front of the chosen attribute indicating that this attribute is currently configured. This is also the factory default setting. (5) The DC bus voltage is one of several cyclic data attributes. You can select any of the Cyclic Data Select attributes to be displayed on the Home screen.

IMPORTANT

Standalone mode was added to the iTRAK® power supply in drive firmware revision 12.001 to provide backward compatibility with iTRAK medium frame systems. Enable Standalone operation only when providing power to iTRAK medium frame systems.

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Startup Sequence
On initial powerup, the drive performs a self test. Upon successful completion, the drive firmware revision is displayed.

Kinetix 57 until Kinetix 5700 is spelled out... Kinetix 5700

then...
SELF-TEST FW REV: 3.1
75%

until the test is complete...

SELF-TEST FW REV: 3.1
100%

Next, the CIP axis state, the IP address, and the default cyclic data attribute (in this example DC-bus voltage) appears. In addition, the setup and menu soft keys are displayed. This is the Home screen.

PRECHARAGE 192.168.1.1 DC BUS: 0.3V

<-- Axis State <-- IP Address <-- Cyclic Data Attribute

In this example PRECHARGE is the axis state attribute. Table 113 lists the other axis states and their descriptions.

Table 113 - CIP Axis States on the Home Screen

Axis State

Description

STANDBY

The drive is waiting to receive configuration information from the controller.

CONNECTING The drive is trying to establish communication with the EtherNet/IP controller.

CONFIGURING The drive is receiving configuration information from the controller.

SYNCING

The drive is waiting for a successful Group Sync service.

STOPPED

The drive has DC bus ready, but the control loops are not enabled.

PRECHARGE

The drive is ready for mains input power.

STARTING

The drive is enabled and checking various conditions before entering the RUNNING or TESTING state. For example, the drive checks the Brake Release delay time during the STARTING state.

RUNNING

· The drive is enabled, configured with an active control mode, and actively tracking a command.
· The drive is configured for No Control and is fully operational.

TESTING

The drive is actively executing a test procedure, for example, a hookup test.

STOPPING

The drive is decelerating to a stop as the result of a disable.

ABORTING

The drive is decelerating to a stop as the result of a fault or an abort request.

MAJOR FAULTED The drive is faulted due to an existing or past fault condition.

START INHIBITED The drive has an active condition that inhibits it from being enabled.

SHUTDOWN

The drive has been shut down.

For more information on the 2198-RPxxx regenerative bus supply CIP axis states, see Regenerative Bus Supply Sequence Operation on page 413.

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Configure the Drive

You can include the drive in your Studio 5000 Logix Designer® application by adding it to a configured EtherNet/IP module or controller under the I/O configuration tree. After setting network parameters, you can view the drive status information in Studio 5000® environment and use it in your Logix Designer application.

Set the Network Parameters
You must program network parameters by using the LCD display.
1. From the LCD display, select SETUP>NETWORK and choose between STATIC IP and DHCP. The default setting is STATIC IP.
2. If STATIC IP, then press to configure the following parameters: · IP address · Gateway · Subnet mask
Settings are stored in nonvolatile memory. IP addressing can also be changed through the Module Configuration dialog box in RSLinx® software. Changes to the IP addressing take effect after power is cycled. The drive is factory programmed to static IP address of 192.168.1.1.
Refer to Setup Screens on page 188 for help setting the network parameters.

Studio 5000 Logix Designer

For help using the Studio 5000 Logix Designer application as it applies to configuring the ControlLogix® or CompactLogixTM controllers, refer to Additional Resources on page 13.

Version History

Each release of the Studio 5000 Logix Designer application makes possible the configuration of additional Allen-Bradley® motors, actuators, power supplies, and drive features not available in previous versions.

IMPORTANT

To configure additional motors, actuators, and drive features with your Kinetix 5700 servo drive, you must have drive firmware 4.001 or later. Refer to Table 114 to determine if you need to install the Kinetix 5700 Add-on Profile.

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Table 114 - AOP Installation Requirement

Drive Module Cat. No.

Drive Firmware Revision

Logix Designer Application Version

Kinetix 5700 AOP Needed?

26.00 or 27.00

Yes

4.001

28.00 or later

2198-xxxx-ERS3 (series A)

5.001 7.001 or later (2)

26.00, 27.00, 28.00

Yes

29.00 or later

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

9.001 or later (2)

31.00 or later

2198-RPxxx

10.001 or later (2)

32.00 or later

CIP SecurityTM (1) for:

2198-Pxxx, 2198-RPxxx 2198-xxxx-ERS3 (series B)

11.001 or later

32.00

Yes

2198-xxxx-ERS4

2198T-W25K-ER

12.001 or later

33.00

Yes

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

13.001 or later (2)

33.00 or later

(1) For information on CIP Security, see CIP Security on page 12. (2) These firmware enhancements are available only with the applicable Studio 5000 Logix Designer, version. There is no AOP
available for download.

Install the Kinetix 5700 Add-On Profile
Download Add-On profiles (AOP) from the Product Compatibility Download Center (PCDC) website: http://compatibility.rockwellautomation.com/Pages/home.aspx.
Follow these steps to download the Kinetix 5700 Add-On profile.
1. Go to the Product Compatibility Download Center. The Compatibility & Downloads webpage appears.
2. Click Download.

3. Enter Kinetix 5700 in the Search PCDC window.

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4. Click the appropriate firmware revision and follow prompts to download.
5. Extract the AOP zip file and run Setup.

Configure the Logix 5000 Controller

These procedures assume that you have wired your Kinetix 5700 drive system. In this example, the GuardLogix® 5580 safety controller and Compact GuardLogix 5380 controller dialog boxes are shown.
Follow these steps to configure the controller.
1. Apply power to your controller and open your Logix Designer application.

2. From the Create menu, choose New Project. The New Project dialog box appears.

IMPORTANT

If you are configuring a safety application, you must use a GuardLogix or Compact GuardLogix safety controller.
If you are configuring a 2198-xxxx-ERS4 inverter in a safety application, you must use a GuardLogix 5580 or Compact GuardLogix 5380 safety controller.

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In this example, the typical dialog boxes for ControlLogix and GuardLogix 5580 controllers and CompactLogix 5380 controllers with embedded Ethernet are shown.
Follow these steps to configure your Logix 5000 controller.
1. Expand the Logix 5000 controller family and select your controller. 2. Type the file Name. 3. Click Next.
The New Project dialog box appears.

4. From the Revision pull-down menu, choose your software revision.
IMPORTANT To configure Kinetix 5700 drive systems, you must be using the Logix Designer application, version 26.00 or later.
5. Click Finish. The new controller appears in the Controller Organizer under the I/O Configuration folder. Controller Organizer with Compact GuardLogix 5380 controller.
Controller Organizer with GuardLogix 5580 controller.

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6. Configure the Logix 5000 controller. Your new Logix 5000 controller appears under the I/O Configuration folder in the Controller Organizer. In this example, a GuardLogix 5580 controller with 1756-EN2TR communication module is used.
7. From the Edit menu, choose Controller Properties. The Controller Properties dialog box appears.
8. Click the Date/Time tab.

9. Check Enable Time Synchronization.
The motion modules set their clocks to the module you assign as the Grandmaster.

IMPORTANT

Check Enable Time Synchronization for all controllers that participate in CIP SyncTM. The overall CIP Sync network automatically promotes a Grandmaster clock, unless the priority is set in Advanced.

10. Click OK.

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IMPORTANT To configure Kinetix 5700 drive systems, you must be using the Logix Designer application, version 26.00 or later.
IMPORTANT When the iTRAK power supply is configured for Standalone operation, the Logix Designer application is not used. For more information, see iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002.

Configure the DC-bus Power Supply
Follow these steps to configure the DC-bus power supply.
1. Below the controller you just created, right-click Ethernet and choose New Module. The Select Module Type dialog box appears.

Enter 2198 here to further limit your search.

2. By using the filters, check Motion and Allen-Bradley, and select your 2198-Pxxx DC-bus power supply as appropriate for your hardware configuration.
3. Click Create.

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The New Module dialog box appears.
4. Configure the new module. a. Type the module Name. b. Select an Ethernet Address option. In this example, the Private Network address is selected. c. Enter the address of your 2198-Pxxx DC-bus power supply. In this example, the last octet of the address is 1.
5. Click the Power category.
IMPORTANT The Logix Designer application enforces shared-bus configuration rules for Kinetix 5700 drives.

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6. From the pull-down menus, choose the power options appropriate for your hardware configuration.

Attribute Bus Configuration

Menu Shared AC/DC (1)

Description Applies to 2198-Pxxx DC-bus power supply (converter) modules.

Bus Sharing Group (2)

· Group1 · Group2 · Group3...

Applies to any bus-sharing configuration.

Bus Regulator Action

Disabled Shunt Regulator

Disables the internal shunt resistor and external shunt option. Enables the internal and external shunt options.

Internal
Shunt Regulator Resistor Type External

Enables the internal shunt (external shunt option is disabled). Enables the external shunt (internal shunt option is disabled).

External Shunt (3)

· None · 2198-R004, 2198-R014 · 2198-R031, 2198-R127

Selects external shunt option. Only the shunt catalog number intended for the specific DC-bus power supply is shown.

(1) Shared AC/DC bus configuration is the default selection for DC-bus power supplies. (2) For more information on bus-sharing groups, refer to Understand Bus-sharing Group Configuration on page 265. (3) Refer to the Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003, for more information on the Bulletin 2198 external passive shunt resistors.

ATTENTION: To avoid damage to equipment all modules physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application.
7. Click OK to close the New Module dialog box.
8. Your 2198-Pxxx DC-bus power supply appears in the Controller Organizer under the Ethernet network in the I/O Configuration folder.

9. Click Close to close the Select Module Type dialog box. 10. Right-click the DC-bus power supply you just created in the Controller
Organizer and choose Properties. The Module Properties dialog box appears.
TIP To configure the remaining DC-bus power supply properties, you must close the New Module dialog box and reopen it as the Module Properties dialog box.
11. Click the Digital Input category.

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12. From the Digital Input pull-down menu choose Bus Capacitor OK or Shunt Thermal Switch OK to monitor your capacitor module status or the shunt thermal switch, respectively, depending on your application. In this example, Bus Capacitor OK is chosen.
13. Click the Associated Axes category.
14. Click New Axis. The New Tag dialog box appears.

15. Type the axis Name. AXIS_CIP_DRIVE is the default Data Type.
16. Click Create.

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The axis (Axis_1 in this example) appears in the Controller Organizer under Motion Groups> Ungrouped Axes and is assigned as Axis 1.
17. Click Apply. 18. Repeat step 1 through step 17 if you have more than one 2198-P208
DC-bus power supply.
Configure the Regenerative Bus Supply
Follow these steps to configure the regenerative bus supply. 1. Below the controller you just created, right-click Ethernet and choose New Module. The Select Module Type dialog box appears.
Enter 2198-RP here to further limit your search.

2. By using the filters, check Motion and Allen-Bradley, and select your 2198-RPxxx regenerative bus supply as appropriate for your hardware configuration.
3. Click Create.

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The New Module dialog box appears.

4. Configure the new module.
a. Type the module Name. b. Select an Ethernet Address option.
In this example, the Private Network address is selected. c. Enter the address of your 2198-RPxxx regenerative bus supply.
In this example, the last octet of the address is 1. 5. Click the Power category.

IMPORTANT The Logix Designer application enforces shared-bus configuration rules for Kinetix 5700 drives.

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6. From the pull-down menus, choose the power options appropriate for your hardware configuration.

Attribute Bus Configuration

Menu Shared AC/DC (1)

Description Applies to 2198-RPxxx regenerative bus supply modules.

· Group1 Bus Sharing Group (2) · Group2
· Group3...

Applies to any bus-sharing configuration.

(1) Shared AC/DC bus configuration is the default selection for regenerative bus supplies. (2) For more information on bus-sharing groups, refer to Understand Bus-sharing Group Configuration on page 265.

ATTENTION: To avoid damage to equipment all modules physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application.

7. Click OK to close the New Module dialog box.
8. Your 2198-RPxxx regenerative bus supply appears in the Controller Organizer under the Ethernet network in the I/O Configuration folder.

9. Click Close to close the Select Module Type dialog box. 10. Right-click the regenerative bus supply you just created in the Controller
Organizer and choose Properties. The Module Properties dialog box appears.
TIP To configure the remaining regenerative bus supply properties, you must close the New Module dialog box and reopen it as the Module Properties dialog box.
11. Click the Digital Input category.

12. From the Digital Input pull-down menu choose Bus Conditioner OK or AC Line Contactor OK to monitor your DC-bus conditioner module status or the M1 contactor status, respectively, depending on your application.
In this example, Bus Capacitor OK is chosen.

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13. Click the Associated Axes category.
14. Click New Axis. The New Tag dialog box appears.

15. Type the axis Name. AXIS_CIP_DRIVE is the default Data Type.
16. Click Create.

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The axis (Axis_1 in this example) appears in the Controller Organizer under Motion Groups> Ungrouped Axes and is assigned as Axis 1.
17. Click Apply. 18. Repeat step 1 through step 17 if you have more than one 2198-RPxxx
regenerative bus supply.
Configure the iTRAK Power Supply
Follow these steps to configure the iTRAK power supply. 1. Below the controller you just created, right-click Ethernet and choose New Module. The Select Module Type dialog box appears.
Enter 2198 here to further limit your search.

2. Select your 2198T-W25K-ER power supply. 3. Click Create.

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The New Module dialog box appears.

4. Configure the new module. a. Type the module Name. b. Select an Ethernet Address option. In this example, the Private Network address is selected. c. Enter the address of your iTRAK power supply. In this example, the last octet of the address is 1.
5. Click the Power category.

IMPORTANT The Logix Designer application enforces shared-bus configuration rules for Kinetix 5700 drives.

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6. From the pull-down menus, choose the power options appropriate for your hardware configuration.

Attribute Bus Configuration

Menu Shared DC/DC (1)

Description Applies to iTRAK power supply modules.

Primary Bus-sharing Group (2) Secondary Bus-sharing Group

· Group1 · Group2 · Group3...

Selects the Bus Sharing Group shared with the AC/DC converter suppling DC voltage to the iTRAK power supply.
Selects the Bus Sharing Group shared with the iTRAK Small Frame modules connected to the iTRAK power supply output.

Bus Regulator Action

Disabled Shunt Regulator

Disables the internal shunt resistor and external shunt option. Enables the internal and external shunt options.

Shunt Regulator Resistor Type External Shunt

Internal External None (3)

Enables the internal shunt (external shunt option is disabled). Enables the external shunt (internal shunt option is disabled). Selects external shunt option.

(1) Shared DC/DC bus configuration is the default selection for iTRAK power supplies. (2) For more information on bus-sharing groups, refer to Understand Bus-sharing Group Configuration on page 265. For more information on primary and secondary bus-
sharing groups, see iTRAK 5730 System User Manual, publication 2198T-UM003. (3) The iTRAK power supply does not support external shunts.

ATTENTION: To avoid damage to equipment all modules physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application.
7. Click OK to close the New Module dialog box.
8. Your iTRAK power supply appears in the Controller Organizer under the Ethernet network in the I/O Configuration folder.

9. Click Close to close the Select Module Type dialog box.
10. Right-click the iTRAK power supply you just created in the Controller Organizer and choose Properties.
The Module Properties dialog box appears.
TIP To configure the remaining iTRAK power supply properties, you must close the New Module dialog box and reopen it as the Module Properties dialog box.

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11. Click the Digital Input category.
12. From the Digital Input pull-down menu choose Enable (default) to monitor an external enable input signal or choose Unassigned depending on your application. In this example, Enable is chosen.
13. Click the Associated Axes category.
14. Click New Axis.

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The New Tag dialog box appears.

15. Type the axis Name.
AXIS_CIP_DRIVE is the default Data Type.
16. Click Create.
The axis (Axis_1 in this example) appears in the Controller Organizer under Motion Groups> Ungrouped Axes and is assigned as Axis 1.

17. Click Apply.
18. Repeat step 1 through step 17 if you have more than one iTRAK power supply.

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Configure the Inverter Drives
This procedure applies to single-axis and dual-axis inverters with hardwired or integrated safety connections. In this example, a 2198-D006-ERS4 dual-axis inverter is configured. Follow these steps to configure Kinetix 5700 inverter drives.
1. Above the DC-bus power supply (converter) you just created, right-click Ethernet and choose New Module. The Select Module Type dialog box appears.
This example shows the 2198-Sxxx-ERSx single-axis inverters you can choose from.

This example shows the 2198-Dxxx-ERSx dual-axis inverters you can choose from.

2. Enter 2198 to narrow your choices and select your 2198-xxxx-ERS3 or 2198-xxxx-ERS4 inverter as appropriate for your hardware configuration.
3. Click Create.

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The New Module dialog box appears.

4. Configure the new drive.
a. Type the drive Name. b. Select an Ethernet Address option.
In this example, the Private Network address is selected.
c. Enter the address of your 2198-xxxx-ERSx inverter. In this example, the last octet of the address is 6.
d. Click Advanced if using network address translation with safety connection to add drive module configured IP address.

The fields to configure in the Module Definition dialog box are dependent on your drive, Logix Designer version, and drive firmware revision. Use the following table to navigate to the series of steps intended for your drive system.

Table 115 - How to Navigate Module Definition

For Drive Cat. No.

Logix Designer Version

2198-xxxx-ERS3 (series A) 30 or earlier

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

31 or later

Drive Firmware Revision 7 or earlier
9 or later

Go to:
Configure Module Definition for 2198-xxxx-ERS3 (series A) Drives on page 214
Configure Module Definition for 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Drives on page 215

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Configure Module Definition for 2198-xxxx-ERS3 (series A) Drives
1. Under Module Definition click Change. The Module Definition dialog box appears.

Depending on the Module Definition revision selection, alternate product features and feedback types can be selected.
2. From the Connection pull-down menu, choose the Connection mode for your motion application.
TIP When `Safety'appears in the Connection mode, integrated safety is implied.

IMPORTANT If the STO bypass jumper wires were applied during machine commissioning or maintenance, they must be removed before the drive will operate in Integrated (Networked) safety mode.

Connection Mode Motion and Safety Motion Only
Safety Only

Table 116 - Module Connection Definitions

Safety Options

Description

Integrated mode

Motion connections and integrated STO are managed by this controller.

· Hardwired STO mode

· Motion connections are managed by this controller.

· Integrated mode if there is a · Hardwired STO is controlled by the hardwired safety inputs or Integrated is

secondary safety controller managed by another controller that has a Safety-only connection to the drive.

Integrated mode

· Integrated STO is managed by this controller. · Motion connections are managed by another controller that has a Motion-
only connection to the drive.

The Safety Network Number (SNN) field populates automatically when the Connection mode includes an integrated Motion and Safety or Safety-only connection. For a detailed explanation of the safety network number, refer to the appropriate GuardLogix controller publication as defined in Additional Resources on page 13.
3. Click OK to close the Module Definition dialog box.
4. Click Apply.
5. Go to Configure the Power and Safety Categories on page 217.

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Configure Module Definition for 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Drives

1. Under Module Definition click Change.

The Module Definition dialog box appears.

Module Definition for 2198-xxxx-ERS3 (series B) inverters
(no feedback configuration).

Module Definition for 2198-xxxx-ERS4 inverters (includes feedback configuration).

Depending on the Module Definition revision selection, alternate product features and feedback types can be selected.
· 2198-xxxx-ERS4 drives appear in only drive firmware revision 9.001 or later
· With drive firmware revision 9.001 or later, 2198-xxxx-ERS3 (series B) drives support Timed SS1 function and STO function with configurable delay
· 2198-xxxx-ERS3 drives do not support feedback monitoring
2. If you are replacing a 2198-xxxx-ERS3 (series A) drive with a 2198-xxxx-ERS3, series B drive, determine your Electronic Keying option from the pull-down menu (Compatible Module is the default setting). See Replacing 2198-xxxx-ERS3 (series A) Drives with Series B Drives on page 300 for more information.

Drive Cat. No.

Studio 5000 Logix Designer Electronic Keying

2198-xxxx-ERS3

Version 30 or earlier

(replacing series A with series B) Version 31 or later

Compatible Module Exact Match (recommended) (1)

(1) See the Logix 5000 Controllers I/O and Tag Data Programming Manual, publication 1756-PM004, for more information on Electronic Keying settings.

3. From the Safety Application pull-down menu, choose between Hardwired for Hardwired STO mode or Networked for an integrated safety application (see Table 117 on page 216 for definitions).

IMPORTANT If the STO bypass jumper wires were applied during machine commissioning or maintenance, they must be removed before the drive will operate in Integrated (Networked) safety mode.

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Table 117 - Safety Application Definitions

Safety Application Mode (1) Safety Functions

Minimum Drive Module (3) Required

Drive Module Connection Options

Minimum Controller Required (4)

Hardwired

Safe Torque-off (STO)

2198-xxxx-ERS3 (series A) Motion Only

· ControlLogix 5570 · CompactLogix 5370

Safe Torque-off (STO)

2198-xxxx-ERS3 (series A)

· Motion and Safety · Safety Only

GuardLogix 5570

Networked (integrated)

Timed SS1

2198-xxxx-ERS3 (series B)

· Timed SS1

· Monitored SS1

2198-xxxx-ERS4

· Controller-based safety functions (2)

· Motion and Safety · Safety Only
· Motion and Safety · Safety Only

· GuardLogix 5580 · Compact GuardLogix 5380

(1) For 2198-Dxxx-ERS4 (dual-axis) inverters, you must configure axes 1 and 3 as either Networked or Hardwired, they cannot be mixed. (2) See the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001, for more information on these Drive Safety instructions. (3) Where a 2198-xxxx-ERS3 drive is specified, a 2198-xxxx-ERS4 drive is backwards compatible.
Where a 2198-xxxx-ERS3 (series A) drive is specified, a 2198-xxxx-ERS3 (series B) drive is backwards compatible. (4) 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.

4. From the Connection pull-down menu, choose the Connection mode for your motion application (see Table 118 for definitions).

TIP When `Safety'appears in the Connection mode, integrated safety is implied.

Table 118 - Module Connection Definitions

Connection Mode Motion and Safety Motion Only
Safety Only

Safety Options

Description

Integrated mode

Motion connections and integrated STO are managed by this controller.

· Hardwired STO mode · Integrated mode if there is a
secondary safety controller

· Motion connections are managed by this controller. · Hardwired STO is controlled by the hardwired safety inputs or
Integrated is managed by another controller that has a Safety-only connection to the drive.

Integrated mode

· Integrated STO is managed by this controller. · Motion connections are managed by another controller that has a
Motion-only connection to the drive.

5. From the Motion Safety x pull-down menu, choose the integrated safety type (see Table 119 on page 217 for definitions).
`Motion Safety' applies to 2198-Sxxx-ERS4 (single-axis) inverters. `Motion Safety 1' and `Motion Safety 2' applies to 2198-Dxxx-ERS4 (dual-axis) inverters.
Motion Safety and Motion Safety 1 align with Axis 1 configured in Associated Axes. Motion Safety 2 aligns with Axis 3 configured in Associated Axes.

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Table 119 - Motion Safety Definitions

Motion Safety Mode

Safety Application Mode

STO Only

Safe Stop Only No Feedback

Single Feedback Monitoring

Networked

Dual Feedback Monitoring

Module Connection Options

Description

2198-xxxx-ERS3 (series A and B): STO function only.

· 2198-xxxx-ERS4: STO function and Timed SS1 Safe Stop functions are available. · 2198-xxxx-ERS3 (series B): STO function and Timed SS1 Safe Stop functions are available.

· Motion and Safety · Safety Only

Primary feedback is used in the safety object for safe monitoring. The feedback can be a SIL rated Hiperface DSL encoder, for example, a VPL-B1003P-Q or W motor used in the DSL Feedback port. This can also be a Sine/Cosine or EnDat device, for example, an MPL-B310P-M motor used in the Universal Feedback port. See the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001, to evaluate SIL levels possible with a single feedback device.

In addition to primary feedback, an external feedback device is used to improve SIL levels. For example, the Bulletin 842HR type encoder can be used in the Universal Feedback port as a Sine/ Cosine device. See the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001, to evaluate SIL levels possible with two feedback devices.

The Safety Network Number (SNN) field populates automatically when the Connection mode includes an integrated Motion and Safety or Safety-only connection. For a detailed explanation of the safety network number, refer to the appropriate GuardLogix controller publication as defined in Additional Resources on page 13.
6. Click OK to close the Module Definition dialog box.
7. Click Apply.

Configure the Power and Safety Categories

1. Click the Power category.

IMPORTANT The Logix Designer application enforces shared-bus configuration rules for Kinetix 5700 drives.

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2. From the pull-down menus, choose the power options appropriate for your hardware configuration.

Attribute

Description

Bus Configuration

Shared DC (2)

Applies to 2198-Sxxx-ERSx and 2198-Dxxx-ERSx inverter drives.

Shared DC - Non-CIP MotionTM Converter (3)

Applies to the designated inverter in drive systems powered by the 8720MC-RPS regenerative power supply.

Bus Sharing Group (1) (3)

· Group1 · Group2 · Group3...

Applies to any bus-sharing configuration.

(1) For more information on bus-sharing groups, refer to Understand Bus-sharing Group Configuration on page 265. (2) Shared DC bus configuration is the default selection for single-axis and dual-axis inverters. (3) Because the 8720MC-RPS unit is not an EtherNet/IP network device the Logix 5000 controller does not communicate with it. The designated inverter,
configured as the Shared DC - Non-CIP Motion Converter, monitors the 8720MC-RPS unit status through a digital input (Regen OK) and communicates with the other inverters to signal when the DC-bus voltage is present.

ATTENTION: To avoid damage to equipment all modules physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application.
3. Click OK to close the Module Properties dialog box.
4. Click Close to close the Select Module Type dialog box.
Your 2198-xxxx-ERS4 inverter appears in the Controller Organizer under the Ethernet network in the I/O Configuration folder.

5. Right-click the drive you just created in the Controller Organizer and choose Properties.
The Module Properties dialog box appears.
TIP To configure the remaining inverter properties, you must close the New Module dialog box and reopen it as the Module Properties dialog box.

Then

Your application includes integrated safety

Go to step 6 on page 219.

Your application includes hardwired safety or has no safety connections

Go to Continue Inverter Configuration on page 220.

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6. Click the Safety category.
7. The connection between the owner and the 2198-xxxx-ERSx inverter is based on the following: · Servo drive safety network number · GuardLogix slot number · GuardLogix safety network number · Path from the GuardLogix controller to the 2198-xxxx-ERSx drive · Configuration signature If any differences are detected, the connection between the GuardLogix controller and the 2198-xxxx-ERSx inverter is lost, and the yellow yield icon appears in the controller project tree after you download the program.
8. Click Advanced. The Advanced Connection Reaction Time Limit Configuration dialog box appears.

Analyze each safety channel to determine the appropriate settings. The smallest Input RPI allowed is 6 ms. Selecting small RPI values consumes network bandwidth and can cause nuisance trips because other devices cannot get access to the network.

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For more information about the Advanced Connection Reaction Time Limit Configuration, refer to Additional Resources on page 13 for the appropriate user manual for your GuardLogix or Compact GuardLogix controller. 9. Click OK to close the Advanced dialog box. 10. Click Apply to save the Safety category parameters.

Continue Inverter Configuration

After you've established your Kinetix 5700 inverters in the Logix Designer application, the feedback options need to be defined for each axis. Each physical axis supports motor and auxiliary feedback.

Table 120 - Kinetix 5700 Feedback Axis Summary

Kinetix 5700 Inverter Single-axis Inverters Dual-axis Inverters

Inverter Cat. No.
2198-Sxxx-ERS3 or 2198-Sxxx-ERS4
2198-Dxxx-ERS3 or 2198-Dxxx-ERS4

Motor Feedback 1 (axis 1) 2 (axis 1 and 3)

Auxiliary Feedback 1 (axis 2) 2 (axis 2 and 4)

Follow these steps to configure the axes for your Kinetix 5700 drive system.

1. Right-click the 2198-xxxx-ERS4 inverter you just created and choose Properties.
The Module Properties dialog box appears. 2. Select the Associated Axes category.

In this 2198-D006-ERS4 (dual-axis inverter) example, four axes are possible. Single-axis inverters support only two axes.

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· Axis 1 and Axis 2 apply to Motor (DSL) Feedback Connector A (Port 1) and Universal Feedback Connector A (Port 1).
· Axis 3 and Axis 4 apply to Motor (DSL) Feedback Connector B (Port 2) and Universal Feedback Connector B (Port 2).

Figure 120 - Dual-axis Inverter Feedback

Kinetix 5700

MOD NET

Dual-axis Inverter

I/O-A

I/O-B

10 5

UFB-A

UFB-B

See Detail A

D+

D-

MF-A

MF-B

Detail A

UFB-A

UFB-B

Motion Safety 1 Associated Axes - Axis 1

D+

D-

MF-A

MF-B

Motion Safety 2 Associated Axes - Axis 3

UFB-A UFB-B MF-A MF-B
Universal and DSL Hiperface Feedback Connectors

The Feedback Devices are configured for either the DSL Feedback Port or the Universal Feedback Port.

Motor Feedback Options Description

DSL Feedback Port

Applies to motors and actuators compatible with the 2198-KITCON-DSL connector kit and 2198-H2DCK converter kit (series B or later). These kits plug into the 2-pin motor feedback (MF) connector.

Universal Feedback Port

Applies to motors and actuators compatible with the 2198-K57CK-D15M universal connector kit. These kits plug into the 15-pin universal feedback (UFB) connector.

3. From the Axis x pull-down menu, choose an axis to assign to that motor feedback or auxiliary feedback device.
4. From the Feedback Device pull-down menu, choose either DSL Feedback x Port or Universal Feedback x Port to associate with each axis.
5. Click New Axis.

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The New Tag dialog box appears.

6. Type the axis Name.
AXIS_CIP_DRIVE is the default Data Type.
7. Click Create.
The axis (Axis_1 in this example) appears in the Controller Organizer under Motion Groups> Ungrouped Axes and is assigned as Axis 1.

TIP You can configure an axis as Feedback Only. Refer to Configure Feedbackonly Axis Properties on page 231 for more information. Refer to Configure Module Properties on page 258 for configuring motor feedback, load feedback, and master feedback devices.
8. Click Apply.

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9. Click the Digital Input category.
10. From the Digital Input pull-down menus choose the functions appropriate for your application. In this example, Digital Input 2 is assigned Bus Capacitor OK to monitor your 2198-CAPMOD-2240 capacitor module. For 8720MC-RPS power supplies: · When a 2198-Sxxx-ERSx single-axis inverter is the first drive module (adjacent to the 2198-CAPMOD-2240 capacitor module) you must configure the Digital Input category as Regeneration OK and wire the IOD connector. · When a 2198-Dxxx-ERSx dual-axis inverter is the first drive module (adjacent to the 2198-CAPMOD-2240 capacitor module) and Axis 1 and 3 are used, you must configure the Digital Input category as Regeneration OK and wire the IOD connector for each axis.
11. Click OK. 12. Repeat step 1 through step 11 for each 2198-xxxx-ERSx servo drive.

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Configure the Motion Group

Follow these steps to configure the motion group.
1. In the Controller Organizer, right-click Motion Groups and choose New Motion Group. The New Tag dialog box appears.

2. Type the new motion group Name. 3. Click Create.
Your new motion group appears in the Controller Organizer under the Motion Groups folder. 4. Right-click the new motion group and choose Properties.
The Motion Group Properties dialog box appears.

5. Click the Axis Assignment tab and move your axes (created earlier) from Unassigned to Assigned.
6. Click the Attribute tab and edit the default values as appropriate for your application.
7. Click OK.
Your axes moves to the new motion group.

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Configure Regenerative Bus Supply Axis Properties

Follow these steps to configure Axis Properties for your 2198-RPxxx regenerative bus supply.
1. In the Controller Organizer, right-click the regenerative-bus supply axis and choose Properties.
2. Select the General category. The General dialog box appears.

3. From the Loop Response pull-down menu choose Medium (default).
Loop Response is for BusVoltageSetPoint dynamic changes during operation, not voltage regulation stiffness or stability. The default setting is appropriate for most applications.

Table 121 - Loop Response Settings

Setting High Medium Low

Impact Under-damped voltage set-point step response (Z = 0.8) Critically-damped voltage set-point step response (Z = 1.0) Over-damped voltage set-point step response (Z = 1.5)

4. From the Converter Startup Method pull-down menu choose:
Automatic (default) for active DC-bus voltage regulation Enable Request for passive AC rectification like the 2198-Pxxx
DC-bus (converter) power supply
For more information on the Converter Startup Method, see DC-bus Voltage Regulation on page 40.
5. Click Apply.

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6. Click the AC Line category.

Source Power is the kVA rating of the transformer feeding the regenerative power supply. The default Source Power setting is 10 times the power rating of the regenerative power supply.
When the transformer rating is less than the regenerative power supply rating, enter the kVA rating of the transformer.
The Source Power attribute applies detuning and current limiting only when Source Power is set lower than the rating of the regenerative power supply (1/10 of default).
7. Click the DC Bus category.

External bus capacitance is the sum of all drive and accessory module capacitance.
IMPORTANT An accurate bus capacitance value is required for proper operation.
8. Manually calculate the sum of the drive and accessory module capacitance values and enter the External Bus Capacitance value. See Calculate System and External-bus Capacitance on page 398 to calculate external bus capacitance.

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9. Click the Bus Voltage Loop category.

We do not recommend changing the default bandwidth values. The default Gains are set to support peak load current. See Detuned Gain Setting Examples table on page 229 for an example of a detuned gain set. Detuned gains increase system stability and can improve THD, but voltage regulation will be less stiff.
IMPORTANT Reduced voltage regulation stiffness can result in overvoltage or undervoltage faults during peak load.
10. Click Parameters.

With the default BusVoltageRateLimit, if the BusVoltageSetPoint value changes (while running) the power supply will draw peak current to change the bus voltage as fast as possible. You can reduce the rate limit to limit the current during changes to the BusVoltageSetPoint attribute without any effect to stability or load response.

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11. From the BusVoltageReferenceSource pull-down menu, choose: In the Automatic (default) setting, the converter optimizes the Bus Voltage Reference for the best converter performance In the Manual setting, you configure the desired Bus Voltage Set Point value for the Bus Voltage Reference signal For more information on these Bus Voltage parameter settings, see DC-bus Voltage Regulation on page 40.
12. Enter a value for the BusVoltageSetPoint. We recommend a maximum value of 715V DC. Over 715V DC can result in higher motor-insulation stress, higher THD, and higher likelihood of over temperature fault in the regenerative bus supply.
13. Click Apply. 14. Click the Bus Observer category.

The Bus Observer setting is used for bus stiffness. If Bus Observer is disabled, you significantly increase the likelihood of getting an overvoltage fault during regeneration.
We do not recommend changing the default Bus Observer setting.

Table 122 - Bus Observer Configurations

Configuration Observer Operation

Impact

Disabled
Voltage Estimate Only

· Load Estimate Decoupling Disabled · Voltage Feedback Filtering Disabled
· Load Estimate Decoupling Disabled · Voltage Feedback Filtering Enabled

· Increased DC-bus voltage ripple · Reduced current THD · Reduced voltage regulation stiffness

Bus Observer Only
Bus Observer with Voltage Estimate (Default)

· Load Estimate Decoupling Enabled · Voltage Feedback Filtering Disabled
· Load Estimate Decoupling Enabled · Voltage Feedback Filtering Enabled

· Decreased DC-bus voltage ripple · Increased current THD · Increased voltage regulation stiffness

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15. Click the Current Reference category.

Low Pass Filter Bandwidth adjusts the filtering of the reference to the current regulator. To minimize the effect on bus voltage regulator stability, this value should be no lower than five times the Bus Voltage Loop bandwidth.
Notch Filter Frequency can be used to address DC-bus resonances in the case of some long cable distributed DC-bus systems. Notch Filter Frequency cannot be used to address line side resonances. A value of 0.0 Hz disables the notch filter.
16. Click the Current Loop category.

We do not recommend changing the default bandwidth values.

Table 123 - Detuned Gain Setting Examples

Gain Setting With Reduced Performance

Value

Bus Voltage Loop Bandwidth

Bus Voltage Loop Integrator Bandwidth

Current Loop Bandwidth

160

Current Loop Integrator Bandwidth

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Detuning to a desired level, while maintaining stability, can be achieved by setting a current loop bandwidth and maintaining proportional spacing of 10x between the voltage and current loop, and 4x spacing from the loop bandwidth to integral loop bandwidth. 17. Click OK.

Configure Vertical Load Control Axis Properties

The 2198-xxxx-ERS4 servo drives (firmware 9.001 or later) support the Vertical Load Control feature. A vertical load is an axis that can move due to stored potential energy. Some examples include a robot arm, lift, or compressed spring. When set to Enabled, rather than applying Stop Category 0 stopping actions in response to most Major fault conditions, the drive brings the motor to a controlled stop and engages the holding brake prior to disabling the power structure.
When Vertical Load Control is enabled and the drive supports Torque Proving and Brake Proving functionality, the controller sets the associated Proving Configuration attribute default value to enable.

IMPORTANT

Brake proving functionality is applicable only to drive control modes that are capable of generating holding torque based on a feedback device. Therefore, Brake Proving is not applicable to Frequency Control mode with Sensorless Vector control method.

For more information on controlling vertical loads, see the Vertical Load and Holding Brake Management Application Technique, publication MOTION-AT003.
Figure 121 - Configure Vertical Load Control

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Configure and Start the Kinetix 5700 Drive System Chapter 6
Follow these steps to configure stopping-action axis properties. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category. The General dialog box appears.

3. From the Axis Configuration pull-down menu, choose Feedback Only.
4. From the Feedback Configuration pull-down menu, choose Master Feedback.
5. From the Module pull-down menu, choose the drive to associate with your Feedback Only axis.
The Module Type and Power Structure fields populate with the chosen drive catalog number.
6. Click Apply.
7. Configure module properties for your Kinetix 5700 servo drive for Master Feedback.
See Configure Module Properties on page 258 for configuration examples.
8. Select the Master Feedback Category.

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The Master Feedback Device Specification appears.
9. From the Type pull-down menu, choose a feedback device type. See Configure Axis Properties beginning on page 260 for configuration examples.
10. Review other categories in the Controller Organizer and make changes as needed for your application.
11. Click OK. See Auxiliary Feedback Specifications on page 115 for more information on auxiliary feedback signals and Allen-Bradley auxiliary feedback encoders available for use.

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Configure Induction-motor Frequency-control Axis Properties

Follow these steps to configure induction-motor axis properties for various frequency control methods.
General and Motor Categories
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category.
The General dialog box appears.

3. From the Axis Configuration pull-down menu, choose Frequency Control.
4. From the Feedback Configuration pull-down menu, choose No Feedback.
5. From the Module pull-down menu, choose the drive to associate with your Frequency Control (induction motor) axis.
The Module Type and Power Structure fields populate with the chosen drive catalog number.
6. Click Apply.

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7. Select the Motor category.
8. From the Data Source pull-down menu, choose Nameplate Datasheet. This is the default setting.
9. From the Motor Type pull-down menu, choose Rotary Induction. 10. From the motor nameplate or datasheet, enter the phase-to-phase values
for your motor. See Motor Category on page 434 for a motor performance datasheet example. Also, see Motor Nameplate Datasheet Entry for Custom Motor Applications, publication 2198-AT002. 11. Click Apply.

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Basic Volts/Hertz Method
1. Configure the General category and Motor category as shown in General and Motor Categories on page 233.
2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Basic
Volts/Hertz.
4. Enter the Basic Volts/Hertz attribute values appropriate for your application. Default values are shown.
5. Click Apply. 6. Select the Parameter List category.

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The Motion Axis Parameters dialog box appears.
7. From the Parameter Group pull-down menu, choose Frequency Control.
8. Set the FluxUp, SkipSpeed, VelocityDroop, and CurrentVectorLimit attributes appropriate for your application. See the corresponding section in Appendix F, beginning on page 419, for information and configuration examples regarding all of these topics.
9. Click OK.

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Sensorless Vector Method
1. Configure the General category and Motor category as shown in General and Motor Categories on page 233.
2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, choose
Sensorless Vector.
4. Enter the Basic Volts/Hertz attribute values appropriate for your application. Default values are shown.
5. Click Apply. 6. Select the Parameter List category.

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7. The Motion Axis Parameters dialog box appears.

8. From the Parameter Group pull-down menu, choose Frequency Control.
9. Set the FluxUp, SkipSpeed, VelocityDroop, MaximumFrequency, MaximumVoltage, and CurrentVectorLimit attributes appropriate for your application.
See the corresponding section in Appendix F, beginning on page 419, for information and configuration examples regarding all of these topics.
10. Click Apply.
11. Select the Motor>Model category.
Motor model attributes are automatically estimated from the Nameplate/Datasheet parameters. For improved performance, motor tests can be run.
12. Select the Motor>Analyzer category.

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13. The Analyze Motor to Determine Motor Model dialog box opens.

14. Click one of the motor test tabs.
In this example, Calculate Model is chosen. See Motor Tests and Autotune Procedure on page 436 for information about each of the tests.
15. Click Start.
16. Click Accept Test Results.
17. Click OK.

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Fan/Pump Volts/Hertz Method
1. Configure the General category and Motor category as shown in General and Motor Categories on page 233.
2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Fan/
Pump Volts/Hertz.
4. Enter the Basic Volts/Hertz attribute values appropriate for your application. Default values are shown.
5. Click Apply. 6. Select the Parameter List category.

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The Motion Axis Parameters dialog box appears.

7. From the Parameter Group pull-down menu, choose Frequency Control.
8. Set the FluxUp, SkipSpeed, VelocityDroop, RunBoost, MaximumFrequency, MaximumVoltage and CurrentVectorLimit attributes appropriate for your application.
See the corresponding section in Appendix F, beginning on page 419, for information and configuration examples regarding all of these topics.
9. Click OK.

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Configure IPM Motor Closedloop Control Axis Properties

Follow these steps to configure interior permanent-magnet (IPM) motor closed-loop axis properties.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category.
The General and Associated Module dialog box appears.

3. From the General pull-down menus, change configuration settings as needed for your application.
IMPORTANT Frequency Control is not supported for interior permanent magnet (IPM) motors.
4. From the Associated Module>Module pull-down menu, choose your Kinetix 5700 drive. The drive catalog number populates the Module Type and Power Structure fields.
5. Click Apply. 6. Select the Motor category.

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The Motor Device Specification dialog box appears.

7. From the Data Source pull-down menu, choose Catalog Number.

IMPORTANT

Motor NV is not a supported data source in the Logix Designer application for axes configured as interior permanent-magnet (IPM) motor closed-loop. In addition, third-party IPM motors are not supported.

8. Click Change Catalog. The Change Catalog Number dialog box appears.

9. Select the motor catalog number appropriate for your application. To verify the motor catalog number, refer to the motor name plate.
10. Click OK to close the Change Catalog Number dialog box. 11. Click Apply.
Motor data specific to your motor appears in the Nameplate / Datasheet - Phase to Phase parameters field.

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12. For Extended Speed operation, check Extended Speed permissive in the Extended Speed field. See Phase Loss Detection on page 454, for more information.
13. Select the Scaling category and edit the default values as appropriate for your application.

14. Click Apply, if you make changes.
15. Select the Load category and edit the default values as appropriate for your application.

16. Click Apply, if you make changes.

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17. Select the Actions category.

From this dialog box, you can program actions and change the action for exceptions (faults). Refer to Logix 5000 Controller and Drive Module Behavior on page 281 for more information.
18. Select the Parameter List category.

From this dialog box you can set brake engage and release delay times for servo motors. For recommended motor brake delay times, refer to the Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001.
19. Click OK.
20. Repeat step 1 through step 19 for each servo motor axis.

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Configure SPM Motor Closed- Follow these steps to configure surface permanent-magnet (SPM) motor loop Control Axis Properties closed-loop axis properties.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category.
The General and Associated Module dialog box appears.

3. From the General pull-down menus, change configuration settings as needed for your application.
IMPORTANT Frequency Control is not supported for permanent magnet motors.
4. From the Associated Module>Module pull-down menu, choose your Kinetix 5700 drive. The drive catalog number populates the Module Type and Power Structure fields.
5. Click Apply. 6. Select the Motor category.

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The Motor Device Specification dialog box appears.

7. From the Data Source pull-down menu, choose Catalog Number. 8. Click Change Catalog.
The Change Catalog Number dialog box appears.

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12. Select the Scaling category and edit the default values as appropriate for your application.

13. Click Apply, if you make changes.
14. Select the Load category and edit the default values as appropriate for your application.

15. Click Apply, if you make changes. 16. Select the Actions category.

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The Actions to Take Upon Conditions dialog box appears.
From this dialog box you can program actions for the drive module to take. Refer to Logix 5000 Controller and Drive Module Behavior on page 281 for more information. 17. Select the Exceptions category. The Action to Take Upon Exception Condition dialog box appears.

From this dialog box you can change the action for exceptions (faults). Refer to Logix 5000 Controller and Drive Module Behavior on page 281 for more information.
TIP In the Logix Designer application, version 32 and later, Disable replaced StopDrive as the default Action.

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18. Select the Parameter List category. The Motion Axis Parameters dialog box appears.
From this dialog box you can set brake engage and release delay times for servo motors. For recommended motor brake delay times, refer to the Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001. 19. Click OK. 20. Repeat step 1 through step 19 for each servo motor axis.

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Configure Induction-motor Closed-loop Control Axis Properties

Follow these steps to configure induction-motor closed-loop control axis properties.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category.
The General and Associated Module dialog box appears.

3. From the General pull-down menus, change configuration settings as needed for your application.
4. From the Associated Module>Module pull-down menu, choose your Kinetix 5700 drive.
The drive catalog number populates the Module Type and Power Structure fields.
5. Click Apply.
6. Select the Motor category.

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The Motor Device Specification dialog box appears.

7. From the Data Source pull-down menu, choose Nameplate Datasheet.
This is the default setting. If you have a Kinetix HPK asynchronous rotary motor, refer to page 247 to see how to populate the Nameplate / Datasheet parameters by selecting the motor catalog number.

IMPORTANT

When you configure Kinetix HPK motor parameters by selecting the motor catalog number, you must also configure the Polarity category. This requirement applies to only Kinetix HPK asynchronous motors. See Knowledgebase document 732760 for more information.

IMPORTANT Motor NV is not a supported data source in the Logix Designer application for axes configured as Induction-motor closed-loop.
a. Select the Polarity category.

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b. For Motor Polarity, click Inverted (default is Normal).

c. Click Apply and return to the Motor category.
8. From the Motor Type pull-down menu, choose Rotary Induction.
9. From the motor nameplate or datasheet, enter the phase-to-phase values for your motor.
See Motor Category on page 434 for a motor performance datasheet example. Also see Motor Nameplate Datasheet Entry for Custom Motor Applications, publication 2198-AT002.
10. Click Apply.
11. Select the Motor Feedback category.
The Motor Feedback Device Specification dialog box appears.

12. From the Type pull-down menu, choose the feedback type appropriate for your application.
See Configure Feedback Properties on page 258 for feedback configuration examples.
13. Click Apply.

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14. Select the Scaling category and edit the default values as appropriate for your application.

15. Click Apply, if you make changes. 16. Select the Actions category.
The Actions to Take Upon Conditions dialog box appears.

From this dialog box you can program actions for the drive module to take. Refer to Logix 5000 Controller and Drive Module Behavior on page 281 for more information.
17. Select the Exceptions category.

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The Action to Take Upon Exception Condition dialog box appears.
From this dialog box you can change the action for exceptions (faults). Refer to Logix 5000 Controller and Drive Module Behavior on page 281 for more information.
TIP In the Logix Designer application, version 32 and later, Disable replaced StopDrive as the default Action.
18. Select the Parameter List category. The Motion Axis Parameters dialog box appears.

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19. From the Parameter Group pull-down menu, choose Torque/Current Loop.
20. Set the FluxUp attributes appropriate for your application. See the corresponding section in Appendix F, beginning on page 419, for information and configuration examples regarding this topic.
IMPORTANT The Automatic FluxUpControl setting is recommended for best autotune results.
21. Click Apply. 22. Select the Load category and edit the default values as appropriate for
your application.

23. Click Apply, if you make changes.
24. Click OK.
25. Select the Motor>Model category.
Motor model attributes are automatically estimated from the Nameplate/Datasheet parameters. For improved performance, motor tests can be run.

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26. The Analyze Motor to Determine Motor Model dialog box opens.

IMPORTANT The Dynamic motor test cannot be run without a non-zero motor inertia.
27. Click the tab corresponding to the Motor Test you want to run. See Motor Tests and Autotune Procedure on page 436 for information about each of the tests.
28. Click Start. 29. Click Accept Test Results. 30. Click Apply. 31. Select the Autotune category. 32. Repeat step 1 through step 32 for each induction motor axis.

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Configure Feedback Properties

This section provides more configuration detail for module properties and axis properties when incremental feedback types are used in your application.
Configure Module Properties
Configure the module properties of your Kinetix 5700 servo drive depending on how you intend to use the feedback connectors.
1. Right-click a drive in the Controller Organizer to configure and choose Properties. The Module Properties dialog box appears.

2. Under Module Definition click Change.
The Module Definition dialog box appears.
Depending on the Module Definition revision selection, alternate feedback types can be selected. However, 2198-xxxx-ERS4 drives only appear in firmware revision 9.001 or later.
3. Click the Associated Axes category.

4. Configure each axis for Motor feedback, Load feedback, and Master feedback devices appropriate for your application.

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See Continue Inverter Configuration on page 220 for more information on configuring module properties for dual-axis and single-axis inverters.

IMPORTANT

The Logix Designer application prevents making feedback port assignments with incompatible feedback types. For example, you cannot assign the same port for multiple devices. The same port cannot be used for Motor Feedback Device, Load Feedback Device, and Master Feedback Device.

Table 124 - Motor Feedback Compatibility

Motor Feedback Device Option Universal Feedback 1 Port
DSL Feedback 1 Port

Feedback Type · Digital AqB · Digital AqB with UVW · Sine/Cosine · Sine/Cosine with UVW · EnDat Sine/Cosine · EnDat Digital
Hiperface
Hiperface DSL

Description

Feedback Connector

Incremental

Applies to Allen-Bradley Kinetix MPL (-H) rotary motors, Kinetix MPAS (direct-drive) linear actuators, LDAT-Series (-xBx) linear thrusters, and LDC-SeriesTM linear motors wired to the 2198-K57CK-D15M universal connector kit.

High-resolution single-turn and multi-turn, absolute

Applies to Allen-Bradley Kinetix RDB and VPC-Bxxxxx-Y motors wired to the 2198-K57CK-D15M universal connector kit.
Applies to Allen-Bradley Kinetix MPL, MPM, MPF, MPS (-M/S or -V/E), and VPC-Bxxxxx-S and VPC-B3004x-M rotary motors; Kinetix MPAS (ballscrew), MPAR, MPAI, linear actuators; Kinetix HPK rotary motors; and LDAT-Series (-xDx) linear thrusters wired to the 2198-K57CK-D15M universal connector kit.
Applies to Allen-Bradley Kinetix MPL, MPM, MPF, MPS (-M/S or -V/E) and VPC-Bxxxxx-Q rotary motors; Kinetix MPAS (ballscrew), MPAR, MPAI linear actuators; Kinetix HPK rotary motors; and LDAT-Series (-xDx) linear thrusters wired to the 2198-H2DCK converter kit.
Applies to Allen-Bradley Kinetix VPL, VPF, VPH, VPS and VPC-Bxxxxx-Q rotary motors and Kinetix VPAR electric cylinders wired to the 2198-KITCON-DSL connector kit.

15-pin universal feedback (UFB)
2-pin motor feedback (MF)

IMPORTANT

Unprogrammed Smart feedback devices (Hiperface Sin/Cos, Hiperface DSL, EnDat Digital, and EnDat Sin/Cos) are not supported. Unprogrammed as load or feedback-only feedback types are supported, except unprogrammed Hiperface DSL encoders. Contact your local distributor or Rockwell Automation representative for support options.

This example shows acceptable feedback port assignments.

5. Click OK.

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Feedback Type Hiperface DSL Hiperface Digital AqB Digital AqB with UVW Sine/Cosine Sine/Cosine with UVW EnDat Sine/Cosine EnDat Digital

Configure Axis Properties

In this section you configure the axis properties of your Kinetix 5700 servo drive for the type of feedback you intend use in your application.

Table 125 defines valid feedback assignments for each feedback type.

Table 125 - Valid Feedback Assignments

Permanent Magnet Motors

Induction Motors

High-resolution single-turn and multi-turn, absolute

Motor feedback

Incremental

N/A Motor feedback N/A Motor feedback

Load feedback
N/A Load feedback N/A

Motor feedback
N/A Motor feedback N/A

Load feedback
N/A Load feedback N/A

Master feedback
N/A Master feedback N/A

High-resolution single-turn and multi-turn, absolute

Motor feedback

Load feedback

Motor feedback

Load feedback

Master feedback

Digital AqB (TTL) Feedback
In this example, a motor feedback device is configured for Digital AqB feedback.
IMPORTANT When Motor Mounted Feedback is the Device Function, Digital AqB (without UVW) is not a valid feedback type for permanent magnet motors.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Motor Feedback category.
The Motor Feedback Device Specification dialog box appears.

3. Configure the device function and type.
In this example, Motor Feedback is the device function and Digital AqB is the feedback type.

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4. Enter values for the Digital AqB specification fields. The only valid value for Cycle Interpolation is 4.
5. From the Startup Method pull-down menu, choose Incremental. 6. Click Apply.
TIP When the Device Function is Load-Side Feedback or Master Feedback, configuration is identical to Motor Mounted Feedback.
Digital AqB with UVW (TTL w/Hall) Feedback
In this example, a motor feedback device is configured for Digital AqB with UVW feedback.
IMPORTANT When Motor Mounted Feedback is the Device Function, Digital AqB with UVW is the only valid feedback type for permanent magnet motors.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Motor Feedback category.
The Motor Feedback Device Specification dialog box appears.

3. Configure the device function and type. In this example, Motor Feedback is the device function and Digital AqB with UVW is the feedback type.
4. Enter values for the Digital AqB with UVW specification fields. The only valid value for Cycle Interpolation is 4.
5. From the Startup Method pull-down menu, choose Incremental. 6. From the Alignment pull-down menu, choose Not Aligned. 7. Click Apply.

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Sine/Cosine Feedback
In this example, a motor feedback device is configured for Sine/Cosine feedback.
IMPORTANT When Motor Mounted Feedback is the Device Function, Sine/Cosine is not a valid feedback type for permanent magnet motors.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Motor Feedback category.
The Motor Feedback Device Specification dialog box appears.

3. Configure the device function and type. In this example, Motor Feedback is the device function and Sine/Cosine is the feedback type.
4. Enter values for the Sine/Cosine specification fields. The only valid values for Cycle Interpolation are powers of 2 from 4 through 65536.
5. From the Startup Method pull-down menu, choose Incremental. 6. Click Apply.
TIP When the Device Function is Load-Side Feedback or Master Feedback, configuration is identical to Motor Mounted Feedback.

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Sine/Cosine with Hall Feedback
In this example, a motor feedback device is configured for Sine/Cosine with UVW feedback.
IMPORTANT When Motor Mounted Feedback is the Device Function, Sine/Cosine with UVW is the only valid feedback type for permanent magnet motors.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Motor Feedback category.
The Motor Feedback Device Specification dialog box appears.

Download the Program

3. Configure the device function and type. In this example, Motor Feedback is the device function and Sine/Cosine with UVW is the feedback type.
4. Enter values for the Sine/Cosine with UVW specification fields. The only valid values for Cycle Interpolation are powers of 2 from 4 through 65536.
5. From the Startup Method pull-down menu, choose Incremental. 6. From the Alignment pull-down menu, choose Not Aligned. 7. Click OK.
After completing the Logix Designer application and saving the file you must download your program to the Logix 5000 processor.

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Apply Power to the Kinetix 5700 Drive System

This procedure assumes that you have wired and configured your Kinetix 5700 system, your Logix 5000 controller, and iTRAK power supply if present.
SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2198 servo drives prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use.

IMPORTANT If multiple iTRAK power supplies are used on a track, they all need to power up within 4 seconds of each other (or at least downstream sections need to power up within 4 seconds of the bankmaster).
Follow these steps to apply power to the Kinetix 5700 system.
1. Disconnect the load to the motor (does not apply to iTRAK PS).
ATTENTION: To avoid personal injury or damage to equipment, disconnect the load to the motor. Make sure each motor is free of all linkages when initially applying power to the system.
2. Apply 24V DC control power. The LCD display begins the startup sequence. Refer to Startup Sequence on page 193. If the startup sequence does not begin, check the 24V control power connections.
3. When the startup sequence completes, verify the following: a. DC-bus and iTRAK power supply NET status indicators are steady green. b. DC-bus and iTRAK power supply MOD status indicators are flashing. c. DC-bus power supply or regenerative bus supply axis-state is PRECHARGE. d. iTRAK power supply axis-state is PRECHARGE. If the DC-bus power supply/regenerative bus supply/iTRAK power supply does not reach the specified axis state and the two status indicators are not as specified, refer to Kinetix 5700 Status Indicators on page 276.
IMPORTANT Apply control power before applying three-phase AC power. This makes sure the shunt is enabled, which can prevent nuisance faults or Bus Overvoltage faults.
4. Apply mains input power and monitor the DC BUS voltage on the LCD display. If the DC BUS does not reach the expected voltage level, check the three-phase input power connections.

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TIP It can take as long as 1.8 seconds after input power is applied before the drive can accept motion commands (does not apply to iTRAK power supply).
a. Verify that all NET and MOD status indicators are steady green. b. Verify that the DC-bus power supply axis-state is RUNNING. c. Verify that the regenerative bus-supply axis-state is RUNNING or
STOPPED depending on the Converter Startup Method used (see DC-bus Voltage Regulation on page 40). d. Verify that the iTRAK power supply axis-state is RUNNING. If the DC-bus power supply/regenerative bus supply/iTRAK power supply does not reach the specified axis state, refer to Fault Code Overview on page 274.
When configuring Module Properties>Power category for each Kinetix 5700 drive, you can breakout drives from one or more servo systems into multiple bus-sharing (power) groups.
A drive that faults in Group 1 does not affect the operation of Group 2, even though all of the drives in Groups 1 and 2 are in the same Motion group in the Logix Designer application. As many as 25 bus-sharing groups are possible.
Figure 122 - Bus-sharing Group Configuration

IMPORTANT

When used with an iTRAK system consisting of L16 motor modules, the iTRAK power supply is not configured as part of a bussharing group in the Logix Designer application. The gateway computer monitors bus status and controls enabling and disabling the iTRAK power supply. See iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002.
When used with the iTRAK 5730 system, both primary and secondary bus-sharing groups must be configured. See iTRAK 5730 System User Manual, publication 2198T-UM003, for more information.

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Bus-sharing Group Example
In Figure 123, twelve axes are needed to support the motion application. All twelve axes are configured in the same Motion group in the Logix Designer application.
However, the twelve axes of motion are also configured as two bus-sharing groups in Module Properties>Power category. By creating two bus-sharing groups, a converter drive that faults in Group 1 only disables Group 1 drives, and has no effect on the drive operation of Group 2 drive.

ATTENTION: To avoid damage to equipment all modules physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application.

Figure 123 - Bus-sharing Group Example

CompactLogix Controller Programming Network

Logix Designer Application

CompactLogix 5370 Controller

Kinetix 5700 Servo Drive System

24V Input Power

Group 1

1585J-M8CBJM-x Ethernet (shielded) Cable

MOD NET

2
1 1 4
I/O

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

Logix Designer Application Module Properties>Power Category

Controller Organizer

Bus Sharing Group 1
Axis_01 Axis_02 Axis_03 Axis_04 Axis_05 Axis_06 Axis_07

Three-phase Input Power

2198-Pxxx DC-bus (converter) Power Supply

2198-D006-ERS3 Dual-axis Inverters

Kinetix 5700 Servo Drive System

24V Input Power

Group 2

MOD NET

1
4 I/O

I/O

2198-D006-ERS3 I/O-A

I/O-B

10 5

UFB

Dual-axis Inverter UFB-A

UFB-B

D+

D-

MF-A

MF-B

MBRK
+

Bus Sharing Group 2
Axis_08 Axis_09 Axis_10 Axis_11 Axis_12

Three-phase Input Power 2198-P208
DC-bus (converter) Power Supply
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Configure Bus-sharing Groups
In both groups, the Bus Configuration for the converter drive is Shared AC/ DC and the Bus Configuration for the inverter drives is Shared DC.
Figure 124 - Group 1 DC-bus Power Supply (converter) Configuration
Figure 125 - Group 1 Dual-axis Inverter Configuration
Figure 126 - Group 2 DC-bus Power Supply (converter) Configuration

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Figure 128 - Group 2 Dual-axis Inverter Configuration

Test and Tune the Axes

This procedure assumes that you have configured your Kinetix 5700 drive, your Logix 5000 controller, and applied power to the system.
IMPORTANT Before proceeding with testing and tuning your axes, verify that the MOD and NET status indicators are operating as described in Kinetix 5700 Status Indicators on page 276.
For help using the Logix Designer application as it applies to testing and tuning your axes with ControlLogix EtherNet/IP modules or CompactLogix 5370 controllers, refer to Additional Resources on page 13.
Also, see Motor Nameplate Datasheet Entry for Custom Motor Applications, publication 2198-AT002, for detailed information on testing and tuning custom motors.
For testing and tuning iTRAK movers see iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, or iTRAK 5730 systems, see the iTRAK 5730 System User Manual, publication 2198T-UM003.

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Test the Axes
Follow these steps to test the axes. 1. Verify the load was removed from each axis.
ATTENTION: To avoid personal injury or damage to equipment, you must remove the load from each axis as uncontrolled motion can occur when an axis with an integral motor brake is released during the test.
2. In your Motion Group folder, right-click an axis and choose Properties. The Axis Properties dialog box appears.

3. Select the Hookup Tests category. 4. In the Test Distance field, enter the desired test distance.

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The Position Units are defined in Axis Properties>Scaling category.

Hookup Test

Definitions

Marker

Verifies marker detection capability as you manually rotate the motor shaft. The test completes when the drive either detects the marker or when the motor moves the distance specified in the Test Distance field. If the marker remains undetected and the test completes successfully, it means the motor moved the full test distance. If the marker remains undetected and the test fails, the motor did not move the full test distance. Run this test after running the Motor Feedback and Motor and Feedback tests.

Commutation

Verifies the commutation offset and commutation polarity of the motor. This test applies to third-party or custom permanent-magnet motors equipped with (TTL with Hall and Sine/Cosine with Hall) incremental encoders that are not available as a catalog number in the Motion Database. See Commutation Test on page page 460.

Motor Feedback

Verifies feedback connections are wired correctly as you manually rotate the motor shaft. The test completes when the drive determines that the motor moved the full distance specified in the Test Distance field. Run this test before the Motor and Feedback Test to verify that the feedback can be read properly.

Verifies motor power and feedback connections are wired correctly as the drive

Motor and Feedback

commands the motor to rotate. Because the drive is rotating the motor, this test requires full bus power to run. Run the Motor Feedback test before running this

test to verify that the feedback is being read correctly.

5. Click the desired test to verify connections. 6. Click Start.
The Logix Designer - Motor and Feedback Test dialog box appears. The Test State is Executing. TESTING appears on the drive LCD display.

Drive LCD Display
TESTING 192.168.1.1 DC BUS: 680.0V

When the test completes successfully, the Test State changes from Executing to Passed.

7. Click OK.
This dialog box appears asking if the axis moved in the forward direction.
8. Click Yes if you agree.
9. Click Accept Test Results.

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10. If the test fails, this dialog box appears. a. Click OK. b. Verify the DC bus voltage. c. Verify unit values entered in the Scaling category. d. Verify the motor power and feedback wiring. e. Return to step 5 and run the test again.

Tune the Axes

With Studio 5000 Logix Designer application, version 33 and later, the load observer and adaptive tuning (tuningless) features are enabled by default for the following servo drives and drive firmware, so drive configuration is not required for tuningless operation.

Table 126 - For Applications with Tuningless Capability

Drive Cat. No. 2198-xxxx-ERS3 (series B) 2198-xxxx-ERS4

Drive Firmware Revision 13.001

Logix Designer Version 33.00

For any other combination of servo drives, drive firmware, or Logix Designer version, see Tuningless Feature Configuration Quick Start, publication MOTION-QS001.

If additional tuning is required, see the Motion System Tuning Application Technique, publication MOTION-AT005, for more information.

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Notes:

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7 Chapter
Troubleshoot the Kinetix 5700 Drive System

This chapter provides troubleshooting tables and related information for your Kinetix® 5700 drive system.

Topic

Page

Safety Precautions

273

Interpret Status Indicators

274

Axis Troubleshooting

278

Regenerative Bus Supply Troubleshooting

279

Logix 5000 Controller and Drive Module Behavior

281

Observe the following safety precautions when troubleshooting your Kinetix 5700 drive system.
ATTENTION: Capacitors on the DC bus can retain hazardous voltages after input power has been removed. Before working on the drive module, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the front of the module. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: Do not attempt to defeat or override the module fault circuits. You must determine the cause of a fault and correct it before you attempt to operate the system. Failure to correct the fault could result in personal injury and/or damage to equipment as a result of uncontrolled machine operation.
ATTENTION: Provide an earth ground for test equipment (oscilloscope) used in troubleshooting. Failure to ground the test equipment could result in personal injury.

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Interpret Status Indicators

Refer to these troubleshooting tables to identify faults, potential causes, and the appropriate actions to resolve the fault. If the fault persists after attempting to troubleshoot the system, please contact your Rockwell Automation sales representative for further assistance.

Display Interface

The LCD display provides fault messages and troubleshooting information by using the soft menu items and navigation buttons.

MAIN MENU DIAGNOSTICS FAULT LOG

Under the Main Menu, select FAULT LOG by using the up/down arrows.

Press to display the list of active fault codes.

Press again to display the fault details (the problem in troubleshooting tables).

Press to display the fault help (possible solutions in troubleshooting tables).

Refer to Understand the Kinetix 5700 Display on page 184 for more information on navigating the LCD display menu.

Fault Code Overview
The fault code tables are designed to help you determine the source of the fault or exception. When a fault condition is detected, the drive module performs the appropriate fault action, the fault is displayed, and the fault is added to a persistent fault log (along with diagnostics data). The earlier faults have priority to be displayed.
The drive module removes the fault text from the display when a Fault Reset service is sent from the controller and the fault is no longer active. If a fault condition is still active following a Fault Reset service, the fault is again posted to the display and written to the fault log.
However, there can be a delay before the fault is posted again. In a Studio 5000 Logix Designer® application, this delay results as the AxisFault tag on the drive axis being cleared until the fault is posted again. During this delay, the AxisState tag continues to indicate that the axis is faulted. Use the AxisState tag on the axis object only to determine if an axis is faulted.
Although software overtravel fault codes do not exist, software overtravel detection for the AXIS_CIP_DRIVE axis type is determined in the Logix 5000TM controller. For more information, see Integrated Motion on the EtherNet/IPTM Network Reference Manual, publication MOTION-RM003.
The DC-bus power supply, regenerative bus supply, single-axis inverters, and dual-axis inverters maintain a fault log of the last 128 faults. The fault log includes time stamps and is stored in persistent memory. However, the fault log cannot be cleared on the module.

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Table 127 - Fault Code Summary

Fault Code Type (1) (2) Description

FLT Sxx

Standard runtime axis exceptions. The exception can apply to an individual axis or to all axes.

FLT Mxx

Manufacturer-specific runtime axis exception. The exception can apply to an individual axis or to all axes.

INIT FLT Sxx INIT FLT Mxx

Exceptions that prevent normal operation and occur during the initialization process.

NODE FLTxx

Exceptions that can prevent normal operation of the drive module and apply to the entire module and affect all axes.

NODE ALARM xx

Exceptions that can prevent normal operation of the drive module, but do not result in any action other than reporting the alarm to the controller.

INHIBIT Sxx INHIBIT Mxx

Conditions that prevent normal operation and indicate the drive module is prevented from being enabled.

ALARM Sxx ALARM Mxx SAFE FLTxx (3)

An underlying exception condition that does not result in any action other than reporting the alarm to the controller.
Exception generated by a fault condition detected in the safety function.

(1) Sxx refers to Standard exceptions. (2) Mxx refers to Manufacturer-specific exceptions. (3) For troubleshooting 2198-xxxx-ERS3 inverter SAFE FLT fault codes, refer to Troubleshoot the Safe Torque-off Function on
page 314 (hardwired safety) or page 328 (integrated safety). For troubleshooting 2198-xxxx-ERS4 inverter SAFE FLT fault codes, refer to the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001.

TIP Fault codes triggered by conditions that fall outside factory set limits are identified by FL at the end of the display message. For example, FLT S07 MTR OVERLOAD FL.
Fault codes triggered by conditions that fall outside user set limits are identified by UL at the end of the display message. For example, FLT S08 MTR OVERLOAD UL.

Fault Codes
For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes. You can download the spreadsheet from this public article. You will be asked to log in to your Rockwell Automation web account or create an account if you do not have one. You do not need a support contract to access this article.

SAFE FLT Fault Codes
For troubleshooting 2198-xxxx-ERS4 inverter SAFE FLT fault codes, refer to the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001.

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Kinetix 5700 Modules

Module Status Network Status

Ethernet RJ45 Connectors
Link Speed Status Indicators
Link/Activity Status Indicators

Kinetix 5700 Status Indicators
These status indicators apply to the Kinetix 5700 DC-bus power supply, the regenerative bus supply, the inverters, and the iTRAK® power supply. The module status and network status indicators are just above the LCD status display.

IMPORTANT Status indicators are not reliable for safety functions. Use them only for general diagnostics during commissioning or troubleshooting. Do not attempt to use status indicators to determine operational status.

Table 128 - Module Status Indicator

Condition Steady Off Steady Green Flashing Green Flashing Red Steady Red
Flashing Green/Red

Status
No power applied to the drive.
Drive is operational. No faults or failures.
Standby (drive not configured) and Precharge (drive is configured).
Major recoverable fault. The drive detected a recoverable fault, for example, an incorrect or inconsistent configuration.
Major fault. The drive detected a non-recoverable fault.
Self-test. The drive performs self-test during powerup. Once self-test is complete, Flashing Green/Red condition continues if drive is waiting for: · Safety configuration when in Integrated STO mode · Safety inputs when in Hardwired STO mode

Table 129 - Network Status Indicator

Condition Steady Off Flashing Green Steady Green
Flashing Red Steady Red Flashing Green/Red

Status
No power applied to the drive or IP address is not configured.
No Motion or Safety connection is established, but drive has obtained an IP address.
Motion or Safety connection is established and no timeout has occurred. Normal operation.
Connection timeout. One or more of the connections, for which this drive is the target, has timed out.
Duplicate IP address. IP address specified is already in use.
Self-test. The drive performs self-test during powerup. Once self-test is complete, Flashing Green/Red condition continues if drive is processing a safety device ID proposal.

Table 130 - Ethernet Link Speed Status Indicator

Condition Steady Off Steady On

Status 10 Mbit 100 Mbit

Table 131 - Ethernet Link/Activity Status Indicator

Condition Steady Off Steady On Blinking

Status No link Link established Network activity

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Kinetix 5700 Accessory Module Status Indicators

The Kinetix 5700 accessory modules include the 2198-CAPMOD-2240 capacitor module and 2198-DCBUSCOND-RP312 DC-bus conditioner module.

Capacitor Module

Status indicators and the module status (MS) connector are on the front of the module. The module status connector is an output suitable for wiring to a DC-bus power supply, regenerative bus supply, or inverter digital input assigned as Bus Capacitor OK, or the Logix 5000 controller.

Table 132 - Capacitor Module Status Indicators and Relay Output

Kinetix 5700 Accessory Modules

Status Indicators

Status

Relay (1) Output

Description

Resolution

MOD DC BUS
MODULE STATUS

Module Status Indicator DC-bus Status Indicator
Module status

Module Status (MS) Connector

DC-bus status

Steady off Open Steady green Closed
Steady red Open
Steady off Open Steady green Closed

24V DC is not present.

24V DC is present and internal fuse is closed.

24V DC is present and internal fuse is open.

· Cycle control and bus power · Verify that AC input meets
specifications · Replace the module if fault persists

24V DC is not present or DC-bus measures < 50V DC.

24V DC is present and DC-bus measures > 50V DC.

(1) Wiring the module status relay output is optional.

DC-bus Conditioner Module

Table 133 - DC-bus Conditioner Module Status Indicators and Relay Output

Status Indicators

Status

Relay Output

Description

Steady off

Open

24V DC is not present

Module status

Steady green Steady red (1)

Closed Open

24V DC is present and internal fuse is closed
· 24V DC is present and internal fuse is open · Over temperature event occurred

DC-bus status

Steady off

Steady green

24V DC is not present or DC-bus measures < 50V DC 24V DC is present and DC-bus measures > 50V DC

(1) Remove DC-bus power and cycle control power. If the fault persists, the internal fuse is blown and the module needs to be replaced. If the fault clears, then there was a thermal fault caused by a system issue. If the fault persists and the rest of the system is functioning properly, add more DC-bus conditioners to the system to reduce thermal stress on the module.

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Axis Troubleshooting
Table 134 - Axis Troubleshooting

These conditions do not always result in a fault code, but can require troubleshooting to improve servo drive performance. For general iTRAK troubleshooting, see iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, or iTRAK 5730 System User Manual, publication 2198T-UM003.

Condition

Potential Cause

Possible Resolution

The position feedback device is incorrect or open.

Check wiring.

Unintentionally in Torque mode.

Check to see what primary operation mode was programmed.

Motor tuning limits are set too high.

Run Tune in the Logix Designer application.

Position loop gain or position controller accel/decel rate is improperly set. Run Tune in the Logix Designer application.

Axis or system is unstable.

Improper grounding or shielding techniques are causing noise to be transmitted into the position feedback or velocity command lines, causing erratic axis movement.

Check wiring and ground.

Motor Select limit is incorrectly set (servo motor is not matched to axis module).

· Check setups. · Run Tune in the Logix Designer application.

Mechanical resonance.

· Notch filter or output filter can be required (refer to Axis Properties dialog box, Compliance tab in the Logix Designer application).
· Enable adaptive tuning. See Adaptive Tuning on page 460 for more notch filter information.

Torque Limit limits are set too low.

Verify that torque limits are set properly.

Incorrect motor selected in configuration.

Select the correct motor and run Tune in the Logix Designer application again.

The system inertia is excessive.

· Check motor size versus application need. · Review servo system sizing.

You cannot obtain the motor

The system friction torque is excessive.

acceleration/deceleration that you

want.

Available current is insufficient to supply the correct accel/decel rate.

Check motor size versus application need.
· Check motor size versus application need. · Review servo system sizing.

Acceleration limit is incorrect.

Verify limit settings and correct them, as necessary.

Velocity Limit limits are incorrect.

Verify limit settings and correct them, as necessary.

The motor is operating in the field-weakening range of operation.

Reduce the commanded acceleration or deceleration.

The axis cannot be enabled until stopping time has expired.

Disable the axis, wait the configured stopping time, and enable the axis.

The motor wiring is open.

Check the wiring.

The motor cable shield connection is improper.

· Check feedback connections. · Check cable shield connections.

Motor does not respond to a command.

The motor has malfunctioned.
The coupling between motor and machine has broken (for example, the motor moves, but the load/machine does not).

Repair or replace the motor. Check and correct the mechanics.

Primary operation mode is set incorrectly.

Check to see what primary operation mode was programmed.

Velocity or torque limits are set incorrectly.

Check and properly set the limits.

Brake connector not wired

Check brake wiring

Recommended grounding per installation instructions have not been followed.

· Verify grounding. · Route wire away from noise sources. · Refer to System Design for Control of Electrical Noise, publication
GMC-RM001.

Presence of noise on command or motor feedback signal wires.

Line frequency can be present.

· Verify grounding. · Route wire away from noise sources.

Variable frequency can be velocity feedback ripple or a disturbance caused by gear teeth or ballscrew, and so forth. The frequency can be a multiple of the motor power transmission components or ballscrew speeds resulting in velocity disturbance.

· Decouple the motor for verification. · Check and improve mechanical performance, for example, the gearbox or
ballscrew mechanism.

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Table 134 - Axis Troubleshooting (continued)

Condition No rotation

Potential Cause The motor connections are loose or open. Foreign matter is lodged in the motor. The motor load is excessive. The bearings are worn.

The motor brake is engaged (if supplied).

Motor overheating

The motor is not connect to the load. The duty cycle is excessive. The rotor is partially demagnetized causing excessive motor current. Motor tuning limits are set too high.

Loose parts are present in the motor.

Abnormal noise

Through bolts or coupling is loose. The bearings are worn.

Mechanical resonance.

Erratic operation - Motor locks into position, runs without control or Motor power phases U and V, U and W, or V and W reversed. with reduced torque.

Troubleshoot the Kinetix 5700 Drive System Chapter 7
Possible Resolution Check motor wiring and connections. Remove foreign matter. Verify the servo system sizing. Return the motor for repair. · Check brake wiring and function. · Return the motor for repair. Check coupling. Change the command profile to reduce accel/decel or increase time. Return the motor for repair. Run Tune in the Logix Designer application. · Remove the loose parts. · Return motor for repair. · Replace motor. Tighten bolts. Return motor for repair. Notch filter can be required (refer to Axis Properties dialog box, Compliance tab in the Logix Designer application).
Check and correct motor power wiring.

Regenerative Bus Supply Troubleshooting

These conditions do not always result in a fault code, but can require troubleshooting to improve regenerative bus supply performance.

Table 135 - Regenerative Bus Supply Troubleshooting

Condition

Potential Cause AC voltage distortion.

AC current appears distorted, non-sinusoidal on oscilloscope.
Audible (loud) noise from regenerative bus supply.

Excessive boost voltage.
Current Saturation. Ride through condition. Load current (<50%). Excessive bus stiffness. Excessive boost voltage. Notching on AC line voltage. Current overload. Cooling fans enabled when AC input power is applied. Loop response.

Dynamic load change.

DC-bus voltage fluctuations.

Voltage loop or observer bandwidths. Normal voltage ripple of 1...2% or approximately 7...15V. External bus capacitance not entered correctly.

Possible Resolution
Improve AC voltage waveform with isolation transformer or line reactor on input power. Distortion from the utility cannot be addressed.
Reduce the BusVoltageSetPoint or set to automatic mode. See DC-bus Voltage Regulation on page 40. for definition of boost voltage.
Normal operation, distortion improves closer to rated current.
Normal operation, distortion clears once input voltage disturbance ends.
Normal operation, distortion improves closer to rated current.
Detune the voltage and observer bandwidths.
Reduce the bus voltage set point or set to automatic mode.
Add isolation transformer or line reactor to isolate from notching source.
Normal peak operation, no resolution needed.
Normal operation.
If changed, set loop response to medium (default).
DC-bus voltage transient is normal with a peak-load step change, but adding a capacitor module can help reduce voltage transients and adding an external active shunt module can help prevent nuisance over-voltage faults.
Optimal voltage loop bandwidth setting is 1/10 of the current loop bandwidth or lower. Optimal observer bandwidth is >2x the voltage loop bandwidth.
Normal operation.
Enter the sum of all bus capacitance external to the regenerative bus supply into the Logix Designer application. See Calculate System and External-bus Capacitance on page 398 to calculate external bus capacitance.

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Table 135 - Regenerative Bus Supply Troubleshooting (continued)

Condition

Potential Cause

Possible Resolution

Bus overvoltage on other converters sharing AC input with the regenerative bus supply as soon as DC-bus regulation is enabled.

Common mode current from regenerative bus supply interacting with common-mode filter capacitors in non-Kinetix 5700 drives.

Remove AC line filter or ground jumper from other non-Kinetix 5700 drives sharing the AC input with the regenerative bus supply. Additionally, properly sized input reactors can help reduce DC-bus pump-up on non-Kinetix 5700 drives.

Input overcurrent or ground current fault on non-Kinetix 5700 drives connected to the regenerative bus supply as soon as DC-bus regulation is enabled.

Single-axis inverters (catalog numbers 2198-S086-ERSx, 2198S130-ERSx, 2198-S160-ERSx) firmware 10.3 or later is required.
Motor insulation breakdown.

Update the single-axis inverter firmware (catalog numbers 2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx).
Replace the motor.

DC bus voltage remains low (<50V) after the AC contactor closes and AC is present at the input to the regenerative bus supply.

DC-bus short circuit. Inverter internal short circuit. Inverter ground jumpers installed.

Find and resolve the DC-bus short circuit.
· Test regenerative bus supply with all inverters disconnected · Replace the shorted inverter
Remove inverter ground jumpers.

Actual DC bus voltage is not equal to the DC voltage set point in the Logix Designer application.

DC voltage set point too high. DC voltage set point too low.

Set the DC-bus voltage set point to a value <747V or use automatic mode.
Set the DC-bus voltage to a value > (input AC voltage rms · 1.414 · 1.05) or use automatic mode.

Startup draws excessive current from the AC input on DC-bus voltage regulation enable.

External bus capacitance entered incorrectly in the Logix Designer application.
Voltage rate limit set too high in the Logix Designer application.

Enter the sum of all bus capacitance external to the regenerative bus supply into the Logix Designer application. See Calculate System and External-bus Capacitance on page 398 to calculate external bus capacitance.
Reduce the bus voltage rate limit in the Logix Designer application.

Loop Response

Set the loop response to medium or low.

Current oscillations at no load.

Filter Bandwidth Notch Frequency.

Increase the filter bandwidth (if lower than 4x the voltage regulator bandwidth).
Increase the notch frequency bandwidth (if lower than 4x the voltage regulator bandwidth).

AC current is limited to less than the peak rating of the regenerative bus supply.

Source kVA. Source kVA set too low. Current loop vector limit set too low.

Set the source kVA to the actual kVA rating of the AC input transformer or input reactor.
Set the current loop vector limit back to the default.

AC contactor won't close.

Stuck in configuring. Contactor enable unplugged.

Check for messages on quick view pane of the controller organizer in the Logix Designer application.
Plug in the contactor enable.

AC contactor coil failure.

Replace contactor.

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Logix 5000 Controller and Drive Module Behavior

By using the Logix Designer application, you can configure how the Kinetix 5700 system responds when a module fault/exception occurs.

TIP The INIT FLT xxx faults are always generated after powerup, but before the drive is enabled, so the stopping behavior does not apply.
NODE ALARM xxx faults do not apply because they do not trigger stopping behavior.
For troubleshooting SAFE FLT fault codes, refer to Chapter 9 on page 312 (hardwired safety) or page 322 (integrated safety).
The iTRAK power supply cannot be configured by using the Studio 5000 Logix Designer application, but the pre-configured faults are shown on page 286.

The DC-bus power supplies and servo drives support fault actions for Ignore, Alarm, Minor Fault, and Major Fault as defined in Table 136. The drives also support five configurable stopping actions as defined in Table 147.

Table 136 - Kinetix 5700 Module Exception Action Definitions

Exception Action Definition

Ignore

The drive module completely ignores the exception condition. For some exceptions that are fundamental to the operation of the planner, Ignore is not an available option.

The drive module sets the associated bit in the Motion Alarm Status word, but does not

Alarm

otherwise affect axis behavior. Like Ignore, if the exception is so fundamental to the drive, Alarm is not an available option. When an exception action is set to Alarm, the Alarm goes

away by itself when the exceptional condition has cleared.

Minor Fault

The drive module latches the exception condition, but the drive does not execute any exception action.

Major Fault

The drive module latches the exception condition and executes the configured exception action.

You can configure exception behavior in the Logix Designer application from the Axis Properties dialog box, Actions category. These controller exception actions are mapped to the drive exception actions.

Table 137 - Logix Designer Exception Action Definitions

Exception Action Ignore Alarm
Fault Status Only
Stop Planner StopDrive (v31 and earlier) Disable (v32 and later) Shutdown

Definition
The controller completely ignores the exception condition. For some exceptions that are fundamental to the operation of the planner, Ignore is not an available option.
The controller sets the associated bit in the Motion Alarm Status word, but does not otherwise affect axis behavior. Like Ignore, if the exception is so fundamental to the drive, Alarm is not an available option. When an exception action is set to Alarm, the Alarm goes away by itself when the exceptional condition has cleared.
Like Alarm, Fault Status Only instructs the controller to set the associated bit in the Motion Fault Status word, but does not otherwise affect axis behavior. However, unlike Alarm an explicit Fault Reset is required to clear the fault once the exceptional condition has cleared. Like Ignore and Alarm, if the exception is so fundamental to the drive, Fault Status Only is not an available option.
The controller sets the associated bit in the Motion Fault Status word and instructs the Motion Planner to perform a controlled stop of all planned motion at the configured maximum deceleration rate. An explicit Fault Reset is required to clear the fault once the exceptional condition has cleared. If the exception is so fundamental to the drive, Stop Planner is not an available option.
When the exception occurs, the associated bit in the Fault Status word is set and the axis comes to a stop by using the stopping action defined by the drive for the particular exception that occurred. In the event of a fault, there is no controller-based configuration to specify what the stopping action is. The stopping action is device dependent.
When the exception occurs, the drive brings the motor to a stop by using the stopping action defined by the drive (as in Stop Drive) and the power module is disabled. An explicit Shutdown Reset is required to restore the drive to operation.

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DC-bus Power Supply Behavior
Stopping action for exception fault codes does not apply to the DC-bus power supply. The Disable exception action for a DC-bus power supply means the power supply enters into a Major Fault state that opens the contactor-enable output, removing three-phase power from the Kinetix 5700 drive system. The Shutdown exception action exhibits the same behavior as Disable, except the power supply enters into Shutdown as the final state and requires a Shutdown Reset to recover.
Fault actions are shown in Table 138 and Table 139.
TIP In the Logix Designer application, version 32 and later, Disable replaced StopDrive as the default Action.
Figure 129 - Logix Designer Axis Properties - Exceptions Category

Table 138 - DC-bus Power Supply Behavior, FLT Sxx Fault Codes

Exception Fault Code

Exception Text

Fault Action

FLT S15 CONV OVERCURRENT

Converter Overcurrent Fault

FLT S16 GROUND CURRENT

Ground Current Factory Limit Fault

FLT S18 CONV OVERTEMP FL

Converter OverTemp Factory Limit Fault

FLT S20 CONV OVERLOAD FL

Converter Thermal OverLoad Factory Limit Fault

FLT S21 CONV OVERLOAD UL

Converter Thermal Overload User Limit Fault

FLT S23 AC PHASE LOSS

AC Single Phase Loss Fault

FLT S25 PRECHARGE FAILURE

Precharge Failure Fault

FLT S27 BUS REG OVERTEMP FL (1)

Bus Regulator Overtemperature Factory Limit Fault

FLT S29 BUS REG OVERLOAD FL

Bus Regulator Thermal OverLoad Factory Limit Fault

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Ignore Alarm Minor Fault Major Fault

Best Available Stopping Action (applies to major faults)
DC-bus power supply does not perform stopping actions.

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Table 138 - DC-bus Power Supply Behavior, FLT Sxx Fault Codes (continued)

Exception Fault Code

Exception Text

Fault Action

FLT S30 BUS REG OVERLOAD UL

Bus Regulator Thermal Overload User Limit Fault X

FLT S31 BUS REG FAILURE

Bus Regulator Failure

FLT S32 BUS CAPACITOR MODULE FAILURE

Bus Capacitor Module Failure

FLT S35 BUS OVERVOLT FL

Bus Overvoltage Factory Limit Fault

FLT S40 BUS POWER SHARING FAULT Bus Power Sharing Fault

FLT S61 ENABLE INPUT

Enable Input Deactivated

(1) Supported when shunt thermal switch is connected to the power supply digital input and configured in the Logix Designer application.

Table 139 - DC-bus Power Supply Behavior, FLT Mxx Fault Codes

Exception Fault Code

Exception Text

Fault Action

FLT M12 POWER CYCLE FL (1)

Converter Precharge Overload Factory Limit Fault

FLT M26 RUNTIME ERROR

Runtime Error

(1) Single-axis and dual-axis drives assert Bus Power Sharing Exception.

Table 140 - DC-bus Power Supply Behavior, NODE FLT Fault Codes

Exception Fault Code

Exception Text

Fault Action

NODE FLT 01 LATE CTRL UPDATE NODE FLT 02 PROC WATCHDOG NODE FLT 03 HARDWARE NODE FLT 05 CLOCK SKEW FLT NODE FLT 06 LOST CTRL CONN NODE FLT 07 CLOCK SYNC NODE FLT 09 DUPLICATE IP ADDRESS

Control Connection Update Fault Processor Watchdog Fault Hardware Fault Clock Skew Fault Lost Controller Connection Fault Clock Sync Fault Duplicate IP Address Fault

Ignore Alarm Minor Fault Major Fault

Best Available Stopping Action (applies to major faults)
DC-bus power supply does not perform stopping actions.
Best Available Stopping Action (applies to major faults) DC-bus power supply does not perform stopping actions.
Best Available Stopping Action (applies to major faults)
DC-bus power supply does not perform stopping actions.

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Regenerative Bus Supply Behavior
Stopping action for exception fault codes does not apply to the regenerative bus supply. The Disable exception action for a regenerative bus supply means the power supply enters into a Major Fault state that opens the contactor-enable output, removing three-phase power from the Kinetix 5700 drive system. The Shutdown exception action exhibits the same behavior as Disable, except the power supply enters into Shutdown as the final state and requires a Shutdown Reset to recover.
Fault actions are shown in Table 141 and Table 142.
Figure 130 - Logix Designer Axis Properties - Exceptions Category

Table 141 - Regenerative Bus Supply Behavior, FLT Sxx Fault Codes

Exception Fault Code

Exception Text

Fault Action

FLT S15 CONV OVERCURRENT

Converter Overcurrent Fault

FLT S16 GROUND CURRENT FLT S17 GROUND CURRENT UL (1)

Ground Current Factory Limit Fault Ground Current User Limit Fault

FLT S18 CONV OVERTEMP FL

Converter OverTemp Factory Limit Fault

FLT S20 CONV OVERLOAD FL

Converter Thermal OverLoad Factory Limit Fault

FLT S21 CONV OVERLOAD UL

Converter Thermal Overload User Limit Fault

FLT S22 AC POWER LOSS

Converter AC Power Loss Fault

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Ignore Alarm Minor Fault Major Fault

Best Available Stopping Action (applies to major faults)
Regenerative bus supply does not perform stopping actions.

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Table 141 - Regenerative Bus Supply Behavior, FLT Sxx Fault Codes (continued)

Exception Fault Code

Exception Text

Fault Action

FLT S23 AC PHASE LOSS

AC Single Phase Loss Fault

FLT S25 PRECHARGE FAILURE

Precharge Failure Fault

FLT S27 BUS REG OVERTEMP FL (1)

Bus Regulator Overtemperature Factory Limit Fault

FLT S32 BUS MODULE FAILURE

Bus Module Failure

FLT S35 BUS OVERVOLT FL

Bus Overvoltage Factory Limit Fault

FLT S58 EXCESSIVE BUS VOLTAGE ERROR Excessive Bus Voltage Error

FLT S61 ENABLE INPUT

Enable Input Deactivated

FLT S64 AC LINE OVERVOLTAGE FL

AC Line Overvoltage FL

FLT S66 AC LINE UNDER VOLTAGE FL (2) AC Line Undervoltage FL

FLT S68 AC LINE HIGH FREQUENCY FL AC Line High Frequency FL

FLT S70 AC LINE LOW FREQUENCY FL AC Line Low Frequency FL

FLT S72 AC LINE VOLTAGE UNBALANCE AC Line Voltage Unbalance

FLT S73 AC LINE CURRENT UNBALANCE AC Line Current Unbalance

FLT S74 AC LINE VOLTAGE SAG (2)

AC Line Voltage Sag

FLT S75 AC LINE FREQUENCY CHANGE AC Line Frequency Change

FLT S76 AC LINE SYNCHRONIZATION LOSS (2)

AC Line Synchronization Loss

FLT S76 AC LINE SYNCHRONIZATION FAILURE

AC Line Synchronization Failure

(1) Supported when shunt thermal switch is connected to the power supply digital input and configured in the Logix Designer application. (2) A single or three-phase open circuit can result in a number of different faults depending on the converter loading.

Table 142 - Regenerative Bus Supply Behavior, FLT Mxx Fault Codes

Exception Fault Code

Exception Text

Fault Action

FLT M12 POWER CYCLE FL (1)

Converter Precharge Overload Factory Limit Fault

FLT M26 RUNTIME ERROR

Runtime Error

FLT M29 AC LINE CONTACTOR

AC Line Contactor

FLT M30 AC LINE RESONANCE FL

AC Line Resonance FL

(1) Single-axis and dual-axis inverters assert Bus Power Sharing Exception.

Ignore Alarm Minor Fault Major Fault

Best Available Stopping Action (applies to major faults)
Regenerative bus supply does not perform stopping actions.
Best Available Stopping Action (applies to major faults) Regenerative bus supply does not perform stopping actions.

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iTRAK Power Supply Behavior

The iTRAK power supply exceptions behavior, as defined in Table 143, is shown in the following tables.

Table 143 - iTRAK Power Supply Exception Action Definitions

Exception Action Definition

Hold

Continue regulating the iTRAK DC buses.

Disable

Actively discharge the iTRAK DC buses then disable the regulators.

Shutdown

Disable the regulators, iTRAK DC buses passively discharge.

Table 144 - iTRAK Power Supply Behavior, FLT Sxx Fault Codes

Exception Fault Code

Exception Text

FLT S10 INV OVERCURRENT FLT S15 CONV OVERCURRENT (1)

Inverter Overcurrent Fault Converter Overcurrent Fault

FLT S16 - GROUND CURRENT FL

Ground Current Factory Limit Fault

FLT S18 - CONV OVERTEMP FL

Converter OverTemp Factory Limit Fault

FLT S20 - CONV OVERLOAD FL

Converter Thermal Overload Factory Limit Fault

FLT S21 CONV OVERLOAD UL

Converter Thermal Overload User Limit Fault

FLT S25 - PRECHARGE FAILURE

Precharge Failure Fault

FLT S31 - BUS REG FAILURE

Bus Regulator Failure

FLT S35 - BUS OVERVOLT FL

Bus Overvoltage Factory Limit Fault

FLT S38 - FUSE BLOWN

Bus Power Fuse Blown Fault

FLT S58 -BUS VOLTAGE ERROR

Bus Voltage Error Fault

FLT S61 - ENABLE INPUT

Enable Input Deactivated

(1) All modules in the same bus group assert a Bus Power Sharing Exception if they are enabled.

Table 145 - iTRAK Power Supply Behavior, FLT Mxx Fault Codes

Exception Fault Code FLT M26 - RUNTIME ERROR

Exception Text Runtime Error

Fault Action

Stopping Action

Ignore Alarm Minor Fault Major Fault

Shutdown

Hold

Shutdown

Disable

Fault Action

Stopping Action

Ignore Alarm Minor Fault Major Fault

Shutdown

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Table 146 - iTRAK Power Supply Behavior, NODE FLT Fault Codes

Exception Fault Code
NODE FLT 01 - LATE CTRL UPDATE NODE FLT 02 - PROC NODE FLT 03 - HARDWARE NODE FLT 05 - CLOCK SKEW FLT NODE FLT 06 - LOST CTRL CONN NODE FLT 07 - CLOCK SYNC NODE FLT 09 - DUPLICATE IP ADDRESS

Exception Text
Control Connection Update Fault Processor Watchdog Fault Hardware Fault Clock Skew Fault Lost Controller Connection Fault Clock Sync Fault Duplicate IP address Fault

Fault Action

Stopping Action

Ignore Alarm Minor Fault Major Fault

Shutdown

Inverter Behavior

For the single-axis inverters and dual-axis inverters, only selected exceptions are configurable. In the drive behavior tables, the controlling attribute is given for programmable fault actions.

Table 147 - Configurable Stopping Actions

Stopping Action Ramped Decel & Hold (1)

Description Most control

Current Decel & Hold Ramped Decel & Disable (1) Current Decel & Disable Disable & Coast (2)

Most control Less control Less control Least control

The best available stopping action is the one that maintains the most control over the motor. However, not all faults support every stopping action.

(1) Ramped Decel is available only when General>Axis Configuration is set to Velocity Loop or Frequency Control. (2) When configured for Frequency Control (induction motors only), select Decel & Disable only when the Current Limiting feature is
enabled. For more information on this feature, see Current Limiting for Frequency Control on page 424.

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Actions define the drive behavior in response to specific conditions. The Actions category includes Standard Actions and Safety Actions.

Table 148 - Actions Definitions

Action Category Action Name

Action Trigger Condition

Disable (MSF) Stopping Action

Execution of an MSF motion instruction.

Standard

Connection Loss Stopping Action

Loss of the motion connection (for example, inhibiting the module or a network cable disconnect).

Motor Overload Action

Receiving MTR OVERLOAD fault.

Inverter Overload Action

Receiving INV OVERLOAD fault.

Safe Torque Off Action Safety
Safe Stopping Action

Transition from logic 0 to 1 of the SafeTorqueOffActiveStatus axis tag, which indicates a safe torque-off action was commanded (STO). (1) Transition from logic 0 to 1 of the SS1ActiveStatus or SS2ActiveStatus axis tag which indicates a safe stopping action was commanded (SS1, SS2). (2)

(1) This action is executed only if the axis tag transitions due to a requested STO, not if it was triggered by another safe-stop function (SS1, for example). (2) See Knowledgebase document 1086747 for more information. (3) Applies to only Velocity Control mode.

Available Actions
· Ramped Decel & Hold · Current Decel & Hold · Ramped Decel & Disable · Current Decel & Disable · Disable & Coast
· Ramped Decel & Disable · Current Decel & Disable · Disable & Coast
· Current Foldback · None
· Current Foldback · None
· Ramped Decel & Disable · Current Decel & Disable · Disable & Coast
· Ramped Decel (3) · Current Decel

Standard Actions

When a control connection update fault (NODE FLT 01) occurs or a controller connection loss fault (NODE FLT 06) occurs, it is possible with firmware revision 11.001 and later, that other node faults can occur first, which triggers a fault action of Current Decel & Disable. Without knowing if NODE FLT 01 or NODE FLT 06 will occur first on a connection loss fault, we recommend that you do not change the default connection loss setting of Current Decel & Disable.

TIP Use DLR ring topology (see Ring Topology on page 30) for applications where the possibility of connection loss must be minimized.

Safety Actions

The Action Source pull-down menus include Connected Drive mode and Running Controller mode.
When configured for Connected Drive (default), the drive initiates the stopping sequence according to the selected stopping action. However, the drive must have an open connection to the motion controller for the configured stopping action to occur.

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When configured for Running Controller and the controller is in Run mode, the stopping sequence is controlled by your application program in the motion controller. This provides flexibility based on your application and requires that your program provide the desired action in response to the safety function active status. If no logic is created, no stopping action will occur. If the motion controller is in Program mode (not actively running the application program), the drive ignores the Action Source and initiates the configured stopping sequence according to the corresponding Action selected in the pull-down menu.
Figure 131 - Logix Designer Axis Properties - Actions Category

Table 149 - Drive Behavior, FLT Sxx Fault Codes

Exception Fault Code

Exception Text

Inverter Modules
2198-xxxx

Permanent Magnet Motor

Induction Motor

Fault Action

Best Available Stopping Action (applies to major faults)

Ignore Alarm Minor Fault Major Fault

FLT S02 MTR COMMUTATION FLT S03 MTR OVERSPEED FL FLT S04 MTR OVERSPEED UL
FLT S05 MTR OVERTEMP FL

Motor Commutation Fault Motor Overspeed Factory Limit Fault
Motor Overspeed User Limit Fault
Motor Overtemperature Factory Limit Fault Motor Overtemperature Factory Limit Fault (If #589 vertical load control) Motor Overtemperature Factory Limit Fault (If not #589 vertical load control)

-ERSx

-ERS3 (series A)

-ERS4

-ERS3 (series B)

-ERS3 (series A)

-ERS4

-ERS3 (series B)

X Disable/Coast

Decel/Hold

X X X X Ramped Decel(5)/Hold

Disable/Coast

Current Decel/Disable X
Disable/Coast

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Table 149 - Drive Behavior, FLT Sxx Fault Codes (continued)

Exception Fault Code

Exception Text

Inverter Modules
2198-xxxx

Permanent Magnet Motor

Induction Motor

Fault Action

Best Available Stopping Action (applies to major faults)

Ignore Alarm Minor Fault Major Fault

FLT S07 MTR OVERLOAD FL

Motor Thermal Overload Factory Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S08 MTR OVERLOAD UL

Motor Thermal OverLoad User Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S09 MTR PHASE LOSS

Motor Phase Loss

-ERSx

FLT S10 INV OVERCURRENT

Inverter Overcurrent Fault

-ERSx

Inverter Overtemperature Factory Limit Fault -ERS3 (series A)

FLT S11 INV OVERTEMP FL

Inverter Overtemperature Factory Limit Fault

(If #589 vertical load control)

-ERS4

Inverter Overtemperature Factory Limit Fault -ERS3 (series B)

(If not #589 vertical load control)

FLT S13 INV OVERLOAD FL

Inverter Thermal Overload Factory Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S14 INV OVERLOAD UL

Inverter Thermal Overload User Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S16 GROUND CURRENT

Ground Current Factory Limit Fault

-ERSx Single-axis X inverters

FLT S22 AC POWER LOSS

Converter AC Power Loss Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S27 BUS REG OVERTEMP FL (1)

Bus Regulator Overtemperature Factory Limit Fault

-ERSx

FLT S32 BUS CAPACITOR MODULE FAILURE

Bus Capacitor Module Failure

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S33 BUS UNDERVOLT FL

Bus Undervoltage Factory Limit Fault

-ERS3 (series A) X

-ERS4 -ERS3 (series B)

FLT S34 BUS UNDERVOLT UL

Bus Undervoltage User Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S35 BUS OVERVOLT FL

Bus Overvoltage Factory Limit Fault

-ERSx

FLT S37 BUS POWER LOSS

Bus Power Loss

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S38 FUSE BLOWN

Bus Power Fuse Blown Fault

-ERSx

FLT S40 BUS POWER SHARING FAULT Bus Power Sharing Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

FLT S41 MTR AQB STATE FL FLT S43 FDBK LOSS FL (2) (4)

Feedback Signal Noise FL Feedback Signal Loss FL

-ERSx

FLT S44 FDBK LOSS UL (2) (4)

Feedback Signal Loss UL

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Decel/Disable

X Ramped Decel(5)/Disable

Decel/Hold

X X X X Ramped Decel(5)/Hold

X X X X Disable/Coast

X Disable/Coast

Disable/Coast

X Current Decel/Disable

Disable/Coast

Current Decel/Disable

Decel/Hold

X X X X Ramped Decel(5)/Hold

X Disable/Coast

Decel/Disable

X X X X Ramped Decel(5)/Disable

X Disable/Coast

Decel/Hold

X X X X Ramped Decel(5)/Hold

X Disable/Coast

X Disable/Coast (6)

Decel/Hold

X X X X Ramped Decel(5)/Hold

X Disable/Coast

Decel/Disable

X X X X Ramped Decel(5)/Disable

X Disable/Coast

Decel/Disable

X X X X Ramped Decel(5)/Disable

X Disable/Coast

Decel/Hold

X X X X Ramped Decel(5)/Hold

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Table 149 - Drive Behavior, FLT Sxx Fault Codes (continued)

Exception Fault Code

Exception Text

Inverter Modules
2198-xxxx

Permanent Magnet Motor

Induction Motor

Fault Action

Best Available Stopping Action (applies to major faults)

Ignore Alarm Minor Fault Major Fault

FLT S45 FDBK COMM FL (3) (4) FLT S46 FDBK COMM UL (2) (4) FLT S47 FDBK DEVICE FAILURE FLT S49 BRAKE SLIP FLT FLT S50 POS HW OTRAVEL FLT S51 NEG HW OTRAVEL
FLT S54 POSN ERROR (4)
FLT S55 VEL ERROR (4)
FLT S56 OVERTORQUE LIMIT (4) FLT S57 UNDERTORQUE LIMIT (4) FLT S61 ENABLE INPUT

Motor Feedback Data Loss Factory Limit Fault -ERSx

Motor Feedback Data Loss User Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Feedback Device Failure

-ERSx

Brake Slip Exception

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Hardware Overtravel - Positive

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Hardware Overtravel - Negative

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Excessive Position Error Fault

-ERS3 (series A)

Excessive Position Error Fault (If #589 vertical load control)
Excessive Position Error Fault (If not #589 vertical load control)

-ERS4

-ERS3 (series B)

Excessive Velocity Error Fault

-ERS3 (series A)

Excessive Velocity Error Fault (If #589 vertical load control)
Excessive Velocity Error Fault (If not #589 vertical load control)

-ERS4

-ERS3 (series B)

Overtorque Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Undertorque Limit Fault

-ERS3 (series A)

-ERS4

-ERS3 (series B)

Enable Input Deactivated

-ERS3 (series A)

-ERS4

-ERS3 (series B)

X Disable/Coast

Decel/Hold

X X X X Ramped Decel(5)/Hold

X Disable/Coast

Decel/Hold

X X X X Ramped Decel(5)/Hold

Decel/Hold

X X X X Ramped Decel(5)/Hold

Decel/Hold

X X X X Ramped Decel(5)/Hold

Disable/Coast

X X X X Current Decel/Disable

Disable/Coast

X X X X Current Decel/Disable

Disable/Coast

Decel/Hold

XXXX

Ramped Decel(5)/Hold

Decel/Hold

X X X X Ramped Decel(5)/Hold

Disable/Coast

X X X X Ramped Decel(5)/Disable

(1) Supported when shunt thermal switch is connected to the inverter digital input and configured in the Logix Designer application. (2) Applies to all compatible feedback devices, except DSL encoder feedback. (3) Applies to DSL and Hiperface feedback devices. (4) Does not apply to induction motors in frequency control mode. (5) Available only in Velocity Control mode. Available stopping action is Current Decel in Position Control mode. (6) Drives running firmware revision 11.003 or earlier use Stopping Time Limit attribute instead of the Coasting Time Limit attribute to determine when the brake will engage.

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Table 150 - Drive Behavior, FLT Mxx Fault Codes

Exception Fault Code

Exception Text

Inverter Modules
2198-xxxx

Permanent Magnet Motor

Induction Motor

Fault Action

Best Available Stopping Action (applies to major faults)

Ignore Alarm Minor Fault Major Fault

FLT M02 MOTOR VOLTAGE (1)

Motor Voltage Mismatch Fault

-ERSx

FLT M05 FDBK BATTERY LOSS FLT M06 FDBK BATTERY LOW

Feedback Battery Loss Fault Feedback Battery Low Fault

-ERS4

-ERS3 (series B) X

FLT M07 FEEDBACK INCREMENTAL Feedback Incremental Count Error

COUNT ERROR FAULT

Fault

-ERSx

FLT M26 RUNTIME ERROR

Runtime Error

-ERSx

FLT M28 SAFETY COMM (2)

Safety Module Communication Error -ERSx

(1) Does not apply to induction motors in frequency control mode. (2) Applies to drives in Integrated STO mode.

X X X X Disable/Coast

X Disable/Coast

X X X X Disable/Coast

X Disable/Coast

Table 151 - Drive Behavior, NODE FLT Fault Codes

Exception Fault Code

Exception Text

Inverter Modules
2198-xxxx

Permanent

Induction

Magnet Motor Motor

Fault Action

Best Available Stopping Action (applies to major faults)

Ignore Alarm Minor Fault Major Fault

-ERS3 (series A)

NODE FLT 01 LATE CTRL UPDATE

Control Connection Update Fault -ERS4

-ERS3 (series B)

NODE FLT 02 PROC WATCHDOG

Processor Watchdog Fault

-ERSx

NODE FLT 03 HARDWARE

Hardware Fault

-ERSx

-ERS3 (series A)

NODE FLT 05 CLOCK SKEW FLT

Clock Skew Fault

-ERS4

-ERS3 (series B)

-ERS3 (series A)

NODE FLT 06 LOST CTRL CONN

Lost Controller Connection Fault -ERS4

-ERS3 (series B)

-ERS3 (series A)

NODE FLT 07 CLOCK SYNC

Clock Sync Fault

-ERS4

-ERS3 (series B)

NODE FLT 09 DUPLICATE IP ADDRESS Duplicate IP Address Fault

-ERSx

(1) Available only in Velocity Control mode. Available stopping action is Current Decel in Position Control mode. (2) With firmware revision 9.xxx. Do not change the default stopping action.

Decel/Disable

Ramped Decel(1)/Disable

X Disable/Coast

Decel/Disable

Ramped Decel(1)/Disable

Decel/Disable

Programmable per (2) Connection Loss Stopping Action (see Table 148 on

page 288).

Decel/Disable

Ramped Decel(1)/Disable

X Disable/Coast

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Before You Begin

8 Chapter
Remove and Replace Drive Modules

This chapter provides remove and replace procedures for Kinetix® 5700 drive modules.

Topic

Page

Before You Begin

293

Remove and Replace Kinetix 5700 Drive Modules

294

Start and Configure the Drive Module

300

ATTENTION: This drive contains electrostatic discharge (ESD) sensitive parts and assemblies. You are required to follow static-control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD awareness handbook.

When each drive module is installed, network settings are configured from the setup screens. Before removing the module, revisit the Network menu and make note of the static IP or DHCP settings. Refer to Configure the Drive on page 194 to access those settings.
IMPORTANT If you intend to use the same Logix Designer application after replacing your drive module, the new module must be the same catalog number as the old module.
You also need these tools available before you begin removal and replacement procedures:
· Screwdrivers (to loosen/remove screws) · Voltmeter (to make sure that no voltage exists on drive connectors)

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Remove and Replace Kinetix 5700 Drive Modules

Follow these steps to remove and replace DC-bus power supplies, regenerative bus supplies, dual-axis inverters, single-axis inverters, iTRAK® power supplies, or accessory modules from the system panel.

Remove Power and All Connections
1. Verify that all control and input power has been removed from the system.
ATTENTION: To avoid shock hazard or personal injury, make sure that all power has been removed before proceeding. This system can have multiple sources of power. More than one disconnect switch can be required to de-energize the system.
2. Wait 5 minutes for the DC bus to discharge completely before proceeding.
SHOCK HAZARD: This product contains stored energy devices. To avoid the hazard of electrical shock, verify that voltage on capacitors has been discharged before attempting to service, repair, or remove this unit. Do not attempt the procedures in this document unless you are qualified to do so and are familiar with solid-state control equipment and the safety procedures in publication NFPA 70E.
3. Using a voltmeter, verify that the DC-bus voltage has discharged, and for iTRAK power supply, verify that the output bus (ICP and IDC connectors) has discharged.
4. Label and remove all wiring connectors from the module that you are removing. To identify each connector, refer to Kinetix 5700 Connector Data on page 92.
TIP For 2198-Pxxx DC-bus power supplies, you do not need to remove the shunt (RC) connector, unless there is an external shunt wired to it.
5. Unplug the DC-bus links and end caps from on top of the power supply, inverters, and accessory modules you are removing.
6. Unplug the shared-bus 24V input wiring connector, T-connectors, and bus-bars from on top of the drive module that you are removing (if applicable).

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7. For 2198-Dxxx-ERSx dual-axis inverters, unplug the motor feedback, motor power, and motor brake connectors and loosen the shield clamp until you can remove the cable from the clamp.

Motor Feedback Connectors

Motor Power and Brake Connectors

2198-Dxxx-ERSx Dual-axis Inverters

Loosen Motor Cable Shield Clamp
8. Single-axis inverters differ by catalog number in how the motor cable bracket attaches to the drive, when the bracket is used.
a. For 2198-S086-ERSx, 2198-S130-ERSx, and 2198-S160-ERSx single-axis inverters, unplug the motor feedback and brake connectors, remove the tie wrap, and remove the motor power bracket.

Motor Feedback Connector
Tie Wrap

2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx, Single-axis Inverters
Motor Brake Connectors

Bracket Screws

W V U
Motor Power Connector (bottom view
Motor Cable Bracket

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b. For 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters, unplug the motor feedback and brake connectors, and remove the tie wrap holding the feedback cable.

Motor Feedback Connector

2198-S263-ERSx, 2198-S312-ERSx, Single-axis Inverters

Tie Wrap M8 Hex Nut
Ground Conductor Termination

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Motor Brake Connectors
Motor Power Connector Screws
Motor Cable Bracket

Shield Clamp

If your axis uses 2090-CPBM7DF power/brake (2 or 4 AWG) cable, remove the motor power cable and bracket from the drive (do not loosen the shield clamp). Refer to the steps and illustrations on page 165 to see how the bracket is attached.
If your axis uses customer-supplied cable (larger than 2 or 4 AWG), the motor cable bracket does not apply.

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9. For 2198T-W25K-ER iTRAK power supplies, unplug the iPS ready connector, 24V control power output connectors, and DC-bus output connectors.
10. Loosen the shield clamp until you can remove the cable from the clamp.

iTRAK PS Ready Connector

2198T-W25K-ER iTRAK Power Supply

DC-bus and 24V Output Connectors
Loosen Motor Cable Shield Clamp
11. Remove the ground screw or lug nut and braided ground strap.
Kinetix 5700 Drive Module Ground Screw or Lug Nut Braided Ground Strap

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Remove the Drive Module

You can remove DC-bus power supplies, regenerative bus supplies, dual-axis inverters, single-axis inverters, iTRAK power supplies, or accessory modules from the panel in any configuration by using the same procedure.

IMPORTANT This procedure applies to any Kinetix 5700 drive module in any configuration.

Follow these steps to remove Kinetix 5700 drive modules from the panel.

1. Loosen the top and bottom screws of the module you are removing.
Modules with 55 mm width have one top and bottom screw. Two or more top and bottom screws are present on modules of greater width.
2. Handling and positioning of the 2198-RPxxx regenerative bus supply and all other Kinetix 5700 drive modules, varies by catalog number. Follow these steps to lift and remove the modules.
a. For the 2198-RP088 regenerative bus supply and all other Kinetix 5700 drive modules, grasp the top and bottom of the module with both hands and pull the module straight out and away from the panel, clearing the zero-stack mounting tabs and cutouts.

Top Screws (bottom screws not shown)

Kinetix 5700 Drive System

(DC bus supply and dual-axis

inverter are shown)

Zero-stack Tab and Cutout Engaged

b. For the 2198-RP200, 2198-RP263, and 2198-RP312, modules, a hoist, straps, and J-hooks with a lockable clasp capable of supporting the maximum module weight is required to lift the module off the mounting screws and away from the panel.
For lifting instructions, see the Kinetix 5700 Regenerative Bus Supply Installation Instructions, publication 2198-IN014.

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Replace the Drive Module

To replace the drive module, reverse the steps that are shown above or refer to Mount Your Kinetix 5700 Drive Modules on page 88.

Table 152 - Drive Module Torque Values Kinetix 5700 Drive Module Cat. No. All Kinetix 5700 Bulletin 2198-drive modules 2198-Pxxx, 2198-RP088, 2198-RP200
2198-RP263, 2198-RP312
2198-Sxxx-ERSx 2198-Dxxx-ERSx, 2198-Sxxx-ERSx 2198-S086-ERSx, 2198-S130-ERSx, 2198-S160-ERSx
2198-S263-ERSx, 2198-S312-ERSx

Fasteners Module mounting screws Module ground lug
Input power connector screws
Input power ground screw Shield clamp screw Feedback connector kit screws Motor power bracket screws Motor power connector screws Motor power ground screw

Torque Value N·m (lb·in)
4.0 (35.4)
0.8 (7.1) 15...20 (132...177) 5.6 (50.0) 5.6 (50.0) 0.4 (3.5) 0.8 (7.1) 15...20 (132...177) 5.6 (50.0)

If replacing a drive module that was configured for Integrated STO mode, refer to Understand Integrated Safety Drive Replacement on page 329.

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Start and Configure the Drive Module

Follow these steps to configure the replacement module.
IMPORTANT If you intend to use the same Logix Designer application after replacing your drive module, the new module must be the same catalog number as the old module.

IMPORTANT If a servo drive was previously configured by a safety controller, reset the drive to the Out of Box state. Refer to Out of Box State on page 306.
1. Reapply power to the drive system.
Refer to Apply Power to the Kinetix 5700 Drive System on page 264 for the procedure. 2. Configure the network settings for the drive module.
For example, if your old module was configured as Static IP, you must set the IP address, gateway, and subnet mask in the new module identical to the old module.
Refer to Configure the Drive on page 194 to access those settings. 3. If you are replacing a 2198-xxxx-ERS3 (series A) drive with a
2198-xxxx-ERS3 (series B) drive, see Replacing 2198-xxxx-ERS3 (series A) Drives with Series B Drives for more information. 4. Download the Logix Designer application to the controller. 5. Verify that the drive system is working properly.

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

When replacing a 2198-xxxx-ERS3 (series A) drive with a 2198-xxxx-ERS3 (series B) drive, the procedure depends on how Electronic Keying is configured in the Module Definition.

IMPORTANT

If Electronic Keying in the Module Definition is configured for Exact Match, the following guidelines apply:
· The Module Definition Revision level must match the 2198-xxxx-ERS3 (series B) drive firmware (revision 9 or later)
· For backwards compatibility with series A drives, Motion Safety in the Module Definition of the 2198-xxxx-ERS3 (series B) drive must be configured for STO Only

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Figure 132 - Module Definition for 2198-xxxx-ERS3 (series B) drives Module Definition With Compatible Module Electronic Keying

Module Definition With Exact Match Electronic Keying

In this flowchart, a 2198-xxxx-ERS3 series A drive (with drive firmware revision 7 or earlier) was programmed by using Studio 5000 Logix Designer®, version 30 or earlier, and is replaced by a 2198-xxxx-ERS3 series B drive (with drive firmware revision 9 or later).
Figure 133 - 2198-xxxx-ERS3 (series B) Replacement Drive Flowchart
Start

How is Electronic Keying
configured?

Compatible Module

No Program Changes (select Revision 7or earlier
in Module Definition)

Download Program

Exact Match

Must use Logix Designer Version 31 or later.

Is the Connection configured No
for Motion and Safety
or Safety Only?

· Motion Only Connection · Must select Drive Revision
9 or later

Download Program

Yes
Must select Revision 9 or later in Module Definition
(selection must match firmware revision in drive)

Must configure Motion Safety (1) and Motion Safety 2 as STO Only to avoid any change in the application program.

Download Program

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Notes:

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Overview

9 Chapter
Kinetix 5700 Safe Torque-off Function

Use this chapter to become familiar with the safe torque-off functionality built into Kinetix® 5700 dual-axis and single-axis inverters.

Topic

Page

Overview

303

Hardwired Safe Torque-off

312

Integrated Safe Torque-off

322

The Kinetix 5700 dual-axis and single-axis inverters are equipped for hardwired safe torque-off (STO). Hardwired STO mode, as described in this chapter, applies to 2198-xxxx-ERS3 and 2198-xxxx-ERS4 dual-axis and single-axis inverters.

The Kinetix 5700 dual-axis and single-axis inverters are also equipped for integrated safe torque-off (STO) over the EtherNet/IPTM network. Integrated STO mode, as described in this chapter, applies to 2198-xxxx-ERS3 and 2198-xxxx-ERS4 dual-axis and single-axis inverters.

The integrated Monitored SS1 and Timed SS1 stopping functions are supported by the 2198-Dxxx-ERS4 dual-axis and 2198-Sxxx-ERS4 single-axis inverters. For integrated Monitored SS1 and Timed SS1 stopping function operations, see the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001.

Table 153 - Kinetix 5700 Functional Safety Mode Support

Safety Mode Hardwired STO mode
Integrated STO mode Monitored SS1 stopping function Timed SS1 stopping function

Dual-axis Inverters Cat. No. 2198-Dxxx-ERS3 2198-Dxxx-ERS4 2198-Dxxx-ERS3 2198-Dxxx-ERS4 2198-Dxxx-ERS4 2198-Dxxx-ERS4 2198-Dxxx-ERS3 (series B)

Single-axis Inverters Cat. No. 2198-Sxxx-ERS3 2198-Sxxx-ERS4 2198-Sxxx-ERS3 2198-Sxxx-ERS4 2198-Sxxx-ERS4 2198-Dxxx-ERS4 2198-Sxxx-ERS3 (series B)

The hardwired and integrated STO modes and SS1 stopping functions meet the requirements of Performance Level e (PL e) per ISO 13849-1 and SIL CL 3 per IEC 61508, IEC 61800-5-2 and IEC 62061.

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Certification
The TÜV Rheinland group has approved 2198-Dxxx-ERSx and 2198-Sxxx-ERSx inverters with hardwired and integrated safe torque-off for use in safety-related applications up to ISO 13849-1 Performance Level e (PL e), SIL CL 3 per IEC 61508, IEC 61800-5-2, and IEC 62061, in which removing the motion producing power is considered to be the safe state.
For product certifications currently available from Rockwell Automation, go to rok.auto/certifications.
Important Safety Considerations
The system user is responsible for the following: · Validation of any sensors or actuators connected to the system · Completing a machine-level risk assessment · Certification of the machine to the desired ISO 13849 performance level or IEC 62061 SIL level · Project management and proof testing in accordance with ISO 13849
Stop Category Definition
Stop Category 0 as defined in IEC 60204 or safe torque-off as defined by IEC 61800-5-2 is achieved with immediate removal of motion producing power to the actuator.

IMPORTANT

In the event of a malfunction, the most likely stop category is Stop Category 0. When designing the machine application, timing and distance must be considered for a coast to stop. For more information regarding stop categories, refer to IEC 60204-1.

Performance Level (PL) and Safety Integrity Level (SIL)
For safety-related control systems, Performance Level (PL), according to ISO 13849-1, and SIL levels, according to IEC 61508 and IEC 62061, include a rating of the systems ability to perform its safety functions. All of the safetyrelated components of the control system must be included in both a risk assessment and the determination of the achieved levels.
Refer to the ISO 13849-1, IEC 61508, and IEC 62061 standards for complete information on requirements for PL and SIL determination.

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Average Frequency of a Dangerous Failure

Safety-related systems are classified as operating in a High-demand/continuous mode. The SIL value for a High-demand/continuous mode safety-related system is directly related to the probability of a dangerous failure per hour (PFH).
PFH calculation is based on the equations from IEC 61508 and show worstcase values. Table 154 provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the data.

IMPORTANT Determination of safety parameters is based on the assumptions that the system operates in High-demand mode and that the safety function is requested at least once every three months.

Table 154 - PFH for 20-year Proof Test Interval (STO function)

Attribute

2198-Sxxx-ERS3 Single-axis Inverters

2198-Dxxx-ERS3 Dual-axis Inverters

PFH (1e-9)

1.57

1.64

HFT (hardware fault tolerance) (1) 1

Proof test (years)

(1) Hardware fault tolerance is the minimum number of faults that can cause a loss of the safety function as defined by IEC 61508-2.

Safe Torque-off Feature
The safe torque-off (STO) circuit, when used with suitable safety components, provides protection according to ISO 13849-1 (PL e), according to IEC 61508, IEC 61800-5-2, and IEC 62061 (SIL CL 3). All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding.
The 2198-xxxx-ERS3 and 2198-xxxx-ERS4 STO circuit is designed to turn off all of the output-power transistors when the STO function is requested. You can use the 2198-xxxx-ERSx STO circuit in combination with other safety devices to achieve a Stop Category 0 stop as described in Stop Category Definition on page 304, and protection-against-restart as specified in IEC 60204-1.
ATTENTION: The safe torque-off (STO) feature is suitable only for performing mechanical work on the drive system or affected area of a machine. It does not provide electrical safety.

SHOCK HAZARD: In Safe Torque-off mode, hazardous voltages can still be present at the drive. To avoid an electric shock hazard, disconnect power to the system and verify that the voltage is zero before performing any work on the drive.

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ATTENTION: Personnel responsible for the application of safety-related programmable electronic systems (PES) shall be aware of the safety requirements in the application of the system and shall be trained in using the system.

Out of Box State
Kinetix 5700 servo drives are capable of safe torque-off (STO) functionality in Hardwired STO mode or Integrated STO mode. Out of the box, the Kinetix 5700 servo drives are in Hardwired STO mode, which means they are ready for hardwired connections to the safety (STO) connector. To bypass the hardwired safety function, jumper wires must be installed in the STO connector.
IMPORTANT Out of the box, Kinetix 5700 servo drives are in Hardwired STO mode.

IMPORTANT To bypass the STO feature while commissioning or testing the drive, the drive must be configured for Hardwired STO mode. Refer to Safe Torqueoff Feature Bypass on page 320 for a wiring example.

Out of the box, you can use Kinetix 5700 servo drives in Integrated STO mode only after a Motion and Safety or Safety-only connection has been established at least once in the Logix Designer application.

How to Recognize Hardwired STO Mode

You can read the safety control state from the axis tag AxisSafetyState, or by using an MSG command in the Logix Designer application to read the Safety Supervisor status.

In Hardwired STO mode, if STO inputs are OFF then Safety Supervisor state is Not Configured (8) and if STO inputs are ON then Safety Supervisor state is Not Configured, torque permitted (51).

Table 155 - Safety Supervisor States

Value Safety Supervisor State

Definition

Configured (no safety connection) No active connections

Running

Normal running state

Configuring

Transition state

Not Configured

Hardwired STO mode with torque disabled

Not Configured (torque permitted)

Hardwired STO mode with torque permitted

Running (torque permitted)

STO bypass state

Safety Mode Integrated Integrated Integrated Hardwired (out of the box)
Hardwired (out of the box) Integrated

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Restore the Hardwired STO Mode by Using the Logix Designer Application

IMPORTANT

This section applies to 2198-xxxx-ERS3 (series A) drives. The 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) drives are configured for Hardwired or Networked mode in the Module Definition dialog box under Module Properties>General category.

After the integrated safety connection configuration is applied to the Kinetix 5700 servo drive at least once, you can restore the drive to the Hardwired STO mode by using the Logix Designer application.

IMPORTANT

Only authorized personnel should attempt Reset Ownership.
The safety connection must be inhibited before the reset is attempted. If any active connection is detected, the safety reset is rejected and Reset Failed appears on the display.

Follow these steps to restore your Kinetix 5700 servo drive to the Hardwired STO mode.
1. Right-click the Kinetix 5700 servo drive you just created and choose Properties.

2. Select the Connection category. The Connection category appears.

3. Check Inhibit Module. 4. Click Apply.

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5. Click the Safety category.

6. In the Configuration Ownership field, click Reset Ownership. The drive reverts back to Hardwired STO mode.
7. Click OK.
Restore Hardwired STO mode by Using the Drive Display
After the integrated safety connection configuration is applied to the Kinetix 5700 servo drive at least once, you can restore the drive to Hardwired STO mode by using the drive display and navigation buttons.

IMPORTANT

Follow these steps to restore your Kinetix 5700 drive to the Hardwired STO mode.

1. Disable any Motion and Safety connections configured in the Logix Designer application.
You can do this in Module Properties or by unplugging the Ethernet cable.

2. From the Home screen on the drive display, press the settings button.

3. From the SETTINGS menu, scroll down by using the and select SAFETY.

arrows

4. Press to request a Reset Ownership. Are You Sure? appears on the display.

5. Press to acknowledge and begin the reset ownership.
If a reset ownership is requested, but not acknowledged within 30 seconds, the display automatically reverts back to the Home screen and the drive does not complete the reset ownership.
If a reset ownership is requested and acknowledged within 30 seconds, the drive reverts back to Hardwired STO mode.

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Safe Torque-off Status

This section describes the safety related status data that is available to the motion controller.

IMPORTANT The status data described in this section is STANDARD data (not SAFETY data) and cannot be used as part of a safety function.

Table 156 - Safety Related Axis Tags
Logix Designer Tag Name AxisFaults
GuardFaultStatus SafetyFaultStatus ModuleFaults GuardStatus GuardOKStatus GuardGateDriveOutputStatus GuardStopInputStatus GuardStopRequestStatus GuardFault GuardStopInputFault GuardGateDriveFault CIPAxisFaultsRA SafetyModuleCommunicationErrorFault CIPAxisAlarmsRA SafetyModuleCommunicationErrorAlarm CIPInitializationFaultsRA InvalidSafetyFirmwareFault CIPStartInhibits SafeTorqueOffActiveInhibit CIPStartInhibitsRA SafeTorqueOffInhibit AxisSafetyState AxisSafetyStatus (1) SafetyFaultStatus SafetyResetRequestStatus SafetyResetRequiredStatus SafeTorqueOffActiveStatus

When a Kinetix 5700 add on profile (AOP) is added to a Logix Designer application I/O tree, axis tags are added to the controller tags.
This table lists the safety related STANDARD tags that are added when a new AXIS_CIP_DRIVE axis is defined.

Attribute [bit]

Type

DINT

[5]

BOOL

[8]

BOOL

163

DINT

980

DINT

[0]

BOOL

[2]

BOOL

[3]

BOOL

[4]

BOOL

981

DINT

[9]

BOOL

[2]

BOOL

903

DINT

[28]

BOOL

904

DINT

[28]

BOOL

910

DINT

[14]

BOOL

676

DINT

[5]

BOOL

912

DINT

[5]

BOOL

760

DINT

761

DINT

[0]

BOOL

[1]

BOOL

[2]

BOOL

[3]

BOOL

Description
STO fault - Hardwired STO fault - Integrated
Not STO fault - Hardwired Torque allowed - Hardwired Safety inputs active - Hardwired Safety input requesting STO - Hardwired
STO fault - Hardwired Internal STO circuit fault - Hardwired
Loss of communication to safety control
Loss of communication to safety control
Invalid safety control firmware
Torque disabled - Integrated
Torque disabled - Hardwired Safety supervisor state
Status of SI.SafetyFault Status of SO.Reset or SO.ResetRequest Status of SI.ResetRequired Status of SO.SafeTorqueOff or SO.STOOutput

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Table 156 - Safety Related Axis Tags (continued)

Logix Designer Tag Name

Attribute [bit]

Type

SafeTorqueOffDisableStatus

[4]

BOOL

SafetyOutputConnectionClosed

[30]

BOOL

SafetyOutputConnectionIdleStatus

[31]

BOOL

AxisSafetyFaults

763

DINT

SafetyCoreFault

[1]

BOOL

SafetyTorqueOffFault

[3]

BOOL

(1) Bits not shown are always zero.

Description Status of SI.TorqueDisabled 1 if all output connections are closed 1 if safety controller is in program mode
Loss of communications to safety control Status of SI.SafetyFault

Explicit Messages

You can use explicit messages to obtain additional diagnostic information from the safety controller by using an MSG instruction.

Safety Supervisor State

The safety supervisor state provides information on the state of the integrated safety connection and the mode of operation. There is only one safety supervisor object per drive module. Therefore, for dual-axis inverters, the safety supervisor is the same on both axes.

Table 157 - Safety Supervisor State: MSG

Parameter

Value

Service Code

0x0E

Class

0x39

Instance

Attribute

0x0B

Data Type

SINT

Description Get attribute single Safety supervisor
Device status Short integer

Table 158 - Safety Supervisor States

Value Safety Supervisor State

Definition

Configured (no safety connection) No active connections

Running

Normal running state

Configuring

Transition state

Not Configured

Hardwired STO mode with torque disabled

Not Configured (torque permitted)

Hardwired STO mode with torque permitted

Running (torque permitted)

STO bypass state

Safety Mode Integrated Integrated Integrated Hardwired (out of the box)
Hardwired (out of the box) Integrated

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Safe Torque-off Mode

You can use the attribute STO Mode to check if the Kinetix 5700 inverter is in STO Bypass mode.

Table 159 - Safe Torque-off Mode: MSG

Parameter

Value

Service Code

0x0E

Class

0x5A

Instance

1 or 2

Attribute

0x104

Data Type

SINT

Description Get attribute single Safety stop functions Inverter axis number STO mode Short integer

Table 160 - Safe Torque-off Mode: Values

Value

Definition

Normal operation

STO bypass mode

Safe Torque-off Faults

When a safety fault is indicated in any of the following tags: · SI.SafetyFault · Axis.SafetyFaultStatus · Axis.SafetyTorqueOffFault

The cause of the fault can be read using an explicit message.

Table 161 - Safe Torque-off Fault Type: MSG

Parameter

Value

Service Code

0x0E

Class

0x5A

Instance

1 or 2

Attribute

0x108

Data Type

SINT

Description Get attribute single Safety stop functions Inverter axis number STO fault type Short integer

Table 162 - Safe Torque-off Fault Type: Values

Value

Definition

No Fault

Circuit Error

104

Hardwired input in Network mode

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Hardwired Safe Torque-off

This section introduces you to the Kinetix 5700 hardwired safe torque-off (STO) feature that meets the requirements of Performance Level e (PL e) per ISO 13849-1 and SIL CL 3 per IEC 61508, IEC 61800-5-2 and IEC 62061.
The 2198-xxxx-ERS3 and 2198-xxxx-ERS4 inverters use the STO connector for wiring external safety devices and cascading hardwired safety connections from drive-to-drive.

Compatible Controllers

A ControlLogix® 5570, ControlLogix 5580, CompactLogixTM 5370 or CompactLogix 5380 controller is required for drive control.

The Studio 5000 Logix Designer® application provides support for programming, commissioning, and maintaining these CompactLogix and ControlLogix controllers with Kinetix 5700 drive systems.

Table 163 - Studio 5000 Logix Designer Requirements

Studio 5000 Logix Designer Application Version 26 or later
Version 31 or later

Kinetix Dual-axis Inverters Cat. No.
2198-Dxxx-ERS3 (series A)
2198-Dxxx-ERS4 2198-Dxxx-ERS3 (series B)

Kinetix Single-axis Inverters Cat. No.
2198-Sxxx-ERS3 (series A)
2198-Sxxx-ERS4 2198-Sxxx-ERS3 (series B)

Description of Operation
The safe torque-off feature provides a method, with sufficiently low probability of failure, to force the power-transistor control signals to a disabled state. When disabled, or any time power is removed from the safety enable inputs, all of the drive output-power transistors are released from the ON-state. This results in a condition where the drive performs a Category 0 Stop (refer to Stop Category Definition on page 304). Disabling the power transistor output does not provide physical isolation of the electrical output that is required for some applications.
For hardwired control of the safe torque-off (STO) function: · The STO function needs to be in Hardwired STO mode · The appropriate wiring must be connected to the Safety (STO) connector plug
Refer to Hardwired Safe Torque-off Electrical Specifications on page 322 for more information on the safety inputs.
Under normal operation, the safe torque-off inputs are energized. If either of the safety enable inputs are de-energized, then all of the output power transistors turn off. The safe torque-off response time is less than 12 ms.

ATTENTION: Permanent magnet motors can, in the event of two simultaneous faults in the IGBT circuit, result in a rotation of up to 180 electrical degrees.

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ATTENTION: If any of the safety enable inputs de-energize, the Start Inhibit field indicates the SafeTorqueOffInhibit and GuardStopRequestStatus bits of the AxisGuardStatus tag are set to 1.

Figure 134 - Normal System Operation SS_IN_CH0 24V DC 0V DC

SS_IN_CH1 24V DC 0V DC
GuardFault 1 0
SafeTorqueOffInhibit 1 0
GuardOkStatus 1 0
GuardGateDriveOutputStatus 1 0
GuardStopInputStatus 1 0
GuardStopRequestStatus 1 0
GuardStopInputFault 1 0
Event 1

1 Second Discrepancy Limit No Fault

1 Second Debounce Time

Start Inhibit

Start Permit

Torque Disabled

Torque Permitted

Disable Torque

Torque Disabled

No Fault
2

3 4 56

Permit Torque Torque Permitted

Table 164 - Normal System Operation Legend

Event Description

At least one input is switched-off. The GuardStopRequestStatus bit is set to 1.

Second input is switched off. If both STO inputs are not in the OFF state simultaneously within 100 ms or after 1 second, then GuardStopInputFault is posted.

First input is switched-on.

Second input is switched-on within 1 second of event 3.

Both inputs are in the ON state simultaneously within 1 second. As a result, GuardStopInputFault is not posted.

The GuardStopRequestStatus bit sets back to 0 if event 4 occurs within a 100 ms interval after event 3. If

event 4 is outside of the 100 ms interval, but within the a 1 second interval after event 3, then the GuardStop RequestStatus bit sets back to 0 after the 1 second interval following event 3 (not

immediately following event 4).

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Troubleshoot the Safe Torque-off Function
For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes. You can download the spreadsheet from this public article. You will be asked to log in to your Rockwell Automation web account or create an account if you do not have one. You do not need a support contract to access this article.

IMPORTANT If both STO inputs are not in the OFF state simultaneously within 100 ms or after 1 second, then GuardStopInputFault is posted.

Figure 135 illustrates when the safe torque-off mismatch is detected and GuardStopInputFault is posted.

Figure 135 - System Operation in the Event of STO Inputs Discrepancy (fault case 1) 24V DC
SS_IN_CH0 0V DC

24V DC SS_IN_CH1
0V DC
1 GuardFault
0
1 SafeTorqueOffInhibit
0
GuardOkStatus 1 0
GuardGateDriveOutputStatus 1 0

No Fault OK

1 Second Discrepancy Limit Faulted
Start Inhibited Not OK
Torque Disabled

GuardStopInputStatus 1 0
GuardStopRequestStatus 1 0
GuardStopInputFault 1 0

No Fault

Stop Requested Faulted

When one safety input is turned off, the second input must also be turned off, otherwise a fault is asserted (see Figure 136). The fault is asserted even if the first safety input is turned on again, without the second input transitioning to the ON state.

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Figure 136 - System Operation in the Event of STO Inputs Discrepancy (fault case 2) SS_IN_CH0 24V DC 0V DC

SS_IN_CH1 24V DC 0V DC
GuardFault 1 0

No Fault

1 Second Discrepancy Limit Faulted

SafeTorqueOffInhibit 1 0

Start Inhibited

GuardOkStatus 1

GuardGateDriveOutputStatus 1 0

Not OK Torque Disabled

GuardStopInputStatus 1 0
GuardStopRequestStatus 1 0
GuardStopInputFault 1 0

No Fault

Stop Requested Faulted

Figure 137 - System Operation in the Event of STO Inputs Discrepancy (fault case 3)

24V DC SS_IN_CH0
0V DC
24V DC SS_IN_CH1
0V DC
1 GuardFault
0

100 ms
No Fault

1 Second Discrepancy Limit Faulted

SafeTorqueOffInhibit 1 0

Start Inhibited

GuardOkStatus 1

GuardGateDriveOutputStatus 1 0

Not OK Torque Disabled

GuardStopInputStatus 1 0
GuardStopRequestStatus 1 0
GuardStopInputFault 1 0

No Fault

Stop Requested Faulted

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ATTENTION: The safe torque-off fault is detected upon demand of the safe torque-off function. After troubleshooting the STO function or performing maintenance that might affect the STO function, the STO function must be executed to verify correct operation.

IMPORTANT

The GuardStopInputFault can be reset only if both inputs are in the OFFstate for more than 1 second. After the fault reset requirement is satisfied, an MAFR command in the Logix Designer application must be issued to reset the GuardStopInputFault.

Safe Torque-off Connector Data

Two rows of eight pins are provided for making drive-to-drive connections. The dual-axis inverters have pins designated for axis A and axis B. The singleaxis inverters do not use STO-6, -7, -8 and STO-14, -15, -16.

Figure 138 - Pin Orientation for 16-pin Safe Torque-off (STO) Connector

2198-Dxxx-ERSx Dual-axis Inverter Safety (STO) Connector Plug

2198-Sxxx-ERSx Single-axis Inverter Safety (STO) Connector Plug

9 SB+/NC

10 S1A

11 SCA

12 S2A

13 SB-

14 S1B

15 SCB

16 S2B

9 SB+/NC

10 S1A

11 SCA

12 S2A

13 SB-

14 N/C

15 N/C

16 N/C

Table 165 - Safe Torque-off Connector Pinouts

STO Pin

Description 2198-Dxxx-ERSx

Description 2198-Sxxx-ERSx

Signal

Safety bypass plus signal. Connect to both safety inputs to disable safe torque-off function. SB+

2 10 Safe stop input channel 1, axis A.

S1A

3 11 Safe stop input common, axis A.

SCA

4 12 Safe stop input channel 2, axis A.

S2A

5 13 Safety bypass minus signal. Connect to safety common to disable safe torque-off function. SB-

6 14 Safe stop input channel 1, axis B.

N/C

S1B

7 15 Safe stop input common, axis B.

N/C

SCB

8 16 Safe stop input channel 2, axis B.

N/C

S2B

N/C

IMPORTANT STO-3 and STO-7 is common for the digital inputs, the safety inputs, and the encoder power supply (optional).

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Wire the Safe Torque-off Circuit
This section provides guidelines for wiring safe torque-off connections to your Kinetix 5700 drive.

IMPORTANT

When replacing 2198-xxxx-ERS3 (series A) single-axis and dual-axis inverters with 2198-xxxx-ERSx (series B) inverters, you must use the series B (safety) connector plugs that are included with your series B inverter.

Install 2198-xxxx-ERS3 (series A) Safety (STO) Connector Plugs
The right side of the safety connector plug requires an off-center push when inserting it into the STO connector. This applies to 2198-xxxx-ERS3 (series A) single-axis and dual-axis inverters.

IMPORTANT

An off-center push is required to engage the locking features on the bottom of the safety connector plugs and seat properly with the drive STO connector. Failure to do this can result in the connector plug pulling out of the drive connector during normal operation.

Kinetix 5700 Inverter Drive (2198-xxxx-ERS3, series A,
inverter is shown)

Figure 139 - Insert the 2198-xxxx-ERS3 (series A) Safety Connector Plug Off-center Push

Locking Features

Push the Right-hand Side

Safety (STO) Connector Plug
MOD NET

Safety Plug

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Kinetix 5700 Inverter Drive (2198-xxxx-ERS4 inverter is shown)
Safety (STO) Connector Plug

Install 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Safety Connector Plugs
The safety connector plugs have two locking leavers that you push in a clockwise direction as you insert the plugs into the drive connector. This is the locked position. Rotate the leavers counter-clockwise to the open position to release the connector plugs. This applies to 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) single-axis and dual-axis inverters.

IMPORTANT Push the locking leavers clockwise into the locked position as you insert the STO connector plugs. Failure to do this can result in the connector plugs pulling out of the drive connector during normal operation.

Figure 140 - Insert the 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) Safety Connector Plugs Push to Lock

Push to Lock Push to Unlock

Locking Leavers in Locked Position

Open Position (rotated counter-clockwise)
MOD NET

Locked Position (rotated clockwise)

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

IMPORTANT To improve system performance, run wires and cables in the wireways as established in Establish Noise Zones beginning on page 68.

IMPORTANT

Pins ST0-1 and ST0-5 (SB+ and SB-) are used to disable the safe torque-off function. When wiring to the STO connector, use an external 24V supply for the external safety device that triggers the safe torque-off request. To avoid jeopardizing system performance, do not use pin ST0-1 as a power supply for the external safety device.

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Safe Torque-off Wiring Requirements
The safe torque-off (STO) connector uses spring tension to secure the wire. Depress the numbered tab along side each pin to insert or release each wire. Two rows of pins are provided for drive-to-drive connections. Wire must be copper with 75 °C (167 °F) minimum rating.
IMPORTANT The National Electrical Code and local electrical codes take precedence over the values and methods provided.

IMPORTANT Stranded wires must terminate with ferrules to prevent short circuits, per table D7 of ISO 13849.
Figure 141 - Safe Torque-off (STO) Terminal Plug

2198-Sxxx-ERSx Single-axis Inverter Safety (STO) Connector Plug

SB+/NC

9 S1

10 SC

11 12 13
14 15

S2SBN-CNCNC

2198-Dxxx-ERSx Dual-axis Inverter Safety (STO) Connector Plug

1 2 3 4 5 69101112S1B3S1+14S1A/C5SNA2SCABS-1SBCSB2B

Kinetix 5700 Inverter, Top View (2198-D057-ERS4 dual-axis inverter is shown)

Table 166 - Safe Torque-off (STO) Connector Plug Wiring

Safe Torque-off (STO) Connector

Signal

STO Pin

2198-Dxxx-ERSx

2198-Sxxx-ERSx

Recommended Wire Size mm2 (AWG)

Strip Length mm (in.)

SB+

10 S1A

11 SCA

12 S2A

13 SB-

14 S1B

S2 SBNC

0.14...1.5 (26...16)

15 SCB

16 S2B

10 (0.39)

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

Torque Value N·m (lb·in)
N/A (1)

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Safe Torque-off Feature Bypass

The Kinetix 5700 inverters do not operate without a safety circuit or safety bypass wiring. For applications that do not require the safe torque-off feature you must install jumper wires to bypass the safe torque-off circuitry.

Kinetix 5700 inverters ship with a 16-pin wiring plug for wiring to safety devices. To bypass the safety function, wire these signals as shown in Figure 142. With the jumper wires installed, the safe-off feature is not used.

Figure 142 - Safe Torque-off Bypass Wiring
2198-Dxxx-ERSx Dual-axis Inverter Safety (STO) Connector Plug

2198-Sxxx-ERSx Single-axis Inverter Safety (STO) Connector Plug

SB+/NC S1A SCA S2A SBS1B SCB S2B

SB+/NC S1A SCA S2A SBN/C N/C N/C

IMPORTANT If the safe torque-off function is not required, the drive safety configuration must be returned to Hardwired STO mode and the bypass jumper wires applied to the safety (STO) connector plugs.

Cascade the Safe Torque-off Signal
The total number of drives in a single cascaded safety circuit is limited by the current carrying capacity of the cascaded safety wiring. Refer to Table 167 for current rating per channel, per drive.
In this example, the cascaded safe torque-off (STO) wiring is for an application with three single-axis inverters and a single safety device.
Figure 143 - Cascaded STO Wiring - Single-axis Inverters

Dual-channel Equivalent Safety Device
24V DC

First Drive

SB+/NC 1

S1A

SCA

S2A

SB-

N/C

Middle Drive

SB+/NC 1

S1A

SCA

S2A

SB-

N/C

Last Drive

SB+/NC 1

S1A

SCA

S2A

SB-

N/C

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In this example, the cascaded safe torque-off (STO) wiring is for an application with three dual-axis inverters and two separate safety devices.
Figure 144 - Cascaded STO Wiring - Dual-axis Inverters with Two Safety Devices

Dual-channel Equivalent Safety Device
24V DC
Dual-channel Equivalent Safety Device

First Drive

SB+/NC 1

S1A

SCA

S2A

SB-

S1B

SCB

S2B

Middle Drive

SB+/NC 1

S1A

SCA

S2A

SB-

S1B

SCB

S2B

Last Drive

SB+/NC 1

S1A

SCA

S2A

SB-

S1B

SCB

S2B

Dual-channel Equivalent Safety Device
24V DC

In this example, the cascaded STO wiring is for an application with three dualaxis inverters and a single safety device for all axes.
Figure 145 - Cascaded STO Wiring - Dual-axis Inverter with Single Safety Device

First Drive

SB+/NC 1

S1A

SCA

S2A

SB-

S1B

SCB

S2B

Middle Drive

SB+/NC 1

S1A

SCA

S2A

SB-

S1B

SCB

S2B

Last Drive

SB+/NC 1

S1A

SCA

S2A

SB-

S1B

SCB

S2B

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Hardwired Safe Torque-off Electrical Specifications

IMPORTANT

To maintain their safety rating, Kinetix 5700 inverters must be installed inside protected control panels or cabinets appropriate for the environmental conditions of the industrial location. The protection class of the panel or cabinet must be IP54 or higher.

Table 167 - Hardwired STO Electrical Specifications

Attribute

Value

Input current

< 10 mA

Input ON voltage range

18...26.4V DC

Safety inputs (per channel)

Input OFF voltage, max
Input ON current, per input, max
Input OFF current, max (@ V in < 5V DC)

5V DC 10 mA, each drive (2)
2 mA

Pulse rejection width External power supply (1)

700 s SELV/PELV

Input type

Optically isolated and reverse voltage protected

(1) SELV or PELV rated power supplies must be used to energize external safety devices connected to the Kinetix 5700 safety inputs. (2) The maximum number of drives cascaded with safe torque-off wiring is 50.

For additional information regarding Allen-Bradley® safety products, including safety relays, light curtain, and gate interlock applications, refer to https://ab.rockwellautomation.com/Safety.

Integrated Safe Torque-off

This section introduces you to the Kinetix 5700 safe torque-off (STO) feature over the EtherNet/IP network that meets the requirements of Performance Level e (PL e) per ISO 13849-1 and SIL 3 per IEC 61508, IEC 61800-5-2, and IEC 62061. Integrated STO applies to 2198-xxxx-ERS3 and 2198-xxxx-ERS4 dual-axis and single-axis inverters.
In Integrated STO mode, the GuardLogix® safety controller issues the STO command over the EtherNet/IP network and the 2198-xxxx-ERS3 and 2198-xxxx-ERS4 dual-axis and single-axis inverters execute the STO command.

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Compatible Safety Controllers

A GuardLogix 5570 or Compact GuardLogix 5370 safety controller is required for integrated safety control of the Kinetix 5700 safe torque-off function.

The Studio 5000 Logix Designer application, version 26.00 or later, provides support for programming, commissioning, and maintaining Logix 5000TM safety controllers with Kinetix 5700 drive systems.

The safety connection can originate from either of these controller configurations:
· Single safety controller that provides both safety and motion control
· Safety controller that controls only the safety, while a separate ControlLogix 5570, ControlLogix 5580, CompactLogix 5370, or CompactLogix 5380 controller that controls motion

Table 168 - Studio 5000 Logix Designer Requirements

Studio 5000 Logix Designer Application

Kinetix Dual-axis Inverters Cat. No.

Kinetix Single-axis Inverters Cat. No.

Version 26 or later

2198-Dxxx-ERS3 (series A)

2198-Sxxx-ERS3 (series A)

Version 31 or later

2198-Dxxx-ERS4 2198-Dxxx-ERS3 (series B) (1)

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

(1) When 2198 -xxxx-ERS3 (series B) drives are used in Timed SS1 safety applications, Studio 5000 Logix Designer application, version 31, must be used.

Safety Application Requirements
Safety application requirements include evaluating probability of failure rates (PFH), system reaction time settings, and functional verification tests that fulfill SIL 3 criteria. Refer to Average Frequency of a Dangerous Failure on page 305 for more PFH information.
Creating, recording, and verifying the safety signature is also a required part of the safety application development process. Safety signatures are created by the safety controller. The safety signature consists of an identification number, date, and time that uniquely identifies the safety portion of a project. This includes all safety logic, data, and safety I/O configuration.
For safety system requirements, including information on the safety network number (SNN), verifying the safety signature, and functional verification tests refer to the appropriate GuardLogix controller publication as defined in Additional Resources on page 13.
IMPORTANT You must read, understand, and fulfill the requirements detailed in the GuardLogix controller systems safety reference manual prior to operating a safety system that uses a GuardLogix controller and Kinetix 5700 drive.

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Description of Operation

The safe torque-off (STO) feature provides a method, with sufficiently low probability of failure, to force the power-transistor control signals to a disabled state. When the command to execute the STO function is received from the GuardLogix controller, all of the drive output-power transistors are released from the ON-state. This results in a condition where the motor is coasting. Disabling the power transistor output does not provide isolation of the electrical output that is required for some applications.
These conditions must be met for integrated control of the STO function:
· The Kinetix 5700 drive module must be added to the GuardLogix 5570 or Compact GuardLogix 5370 controller I/O Configuration.
· The module must be configured for Safety Only or Motion and Safety connections
· The safety bypass jumper wires must be removed.

IMPORTANT If the STO bypass jumper wires were applied during machine commissioning or maintenance, they must be removed before the drive will operate in Integrated STO mode.

The Kinetix 5700 drive STO function reaction time is less than 10 ms. Reaction time for the drive is the delay between the time the drive STO command receives the CIP SafetyTM packet with an STO request and the time when motion producing power is removed from the motor.

Table 169 - Safe Torque-off Network Specifications

Attribute

2198-xxxx-ERS3

2198-xxxx-ERS4

STO function reaction time

10 ms, max

Safety connection RPI, min

6 ms

Input assembly connections (1)

Output assembly connections (1)

Integrated safety open request support Type 1 and Type 2 requests

(1) Motion and Safety and Safety Only connections with the inverter uses 1 input assembly connection and 1 output assembly connection.

Safe Torque-off Assembly Tags
In Integrated safe torque-off (STO) mode, a GuardLogix 5570 or Compact GuardLogix 5370 safety controller commands the Kinetix 5700 safe torque-off function through the appropriate tag in the safety output assembly.
IMPORTANT The tag names listed in Table 170 changed in the Logix Designer application, version 31 and later, depending on how Motion Safety is configured in the Module Definition.

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Table 170 - STO Tag Name Changes in the Logix Designer Application

STO Tag Names

STO Only Tag Names

Safe Stop Only - No Feedback Tag Names

Studio 5000 Logix Designer Studio 5000 Logix Designer Studio 5000 Logix Designer

(version 30 and earlier) (version 31 and later)

(version 31 and later)

SO.SafeTorqueOff

SO.STOOutput

SO.Reset

SO.ResetRequest

The SO.Command tags are sent from the GuardLogix safety output assembly to the Kinetix 5700 safety output assembly to control the safe torque-off function.

The SI.Status tags are sent from the Kinetix 5700 inverter to the GuardLogix safety input assembly and indicate the Kinetix 5700 safety control status.

The SI.ConnectionStatus tags indicate the safety input connection status.

Table 171 and Table 172 list the safety tags added to the controller tags when a Kinetix 5700 servo drive is added to a GuardLogix I/O Configuration and the connection is configured for Motion and Safety or Safety Only.

IMPORTANT The SO.SafeTorqueOff and SO.ResetRequest tag names change when Motion Safety in the Module Definition is configured as Safe Stop Only - No Feedback.

The attribute values listed are the Assembly Object attribute values.

Table 171 - Single-axis Inverter Integrated STO Specifications

Logix Designer Tag Name
SI.ConnectionStatus (1) (2) SI.RunMode SI.ConnectionFault
SI.Status (1) (3)

Safe Stop Only - No Feedback Tag Names Studio 5000 Logix Designer (version 31 and later)

SI.TorqueDisabled

SI.SafetyFault SI.ResetRequired SO.Command (1) (4)

SO.SafeTorqueOff

SO.STOOutput

SO.Reset

SO.ResetRequest

(1) Bits not listed are always zero. (2) ConnectionStatus is determined by the Safety Validator in the GuardLogix controller. (3) Status is sent from the drive to the controller using integrated safety protocol. (4) Commands are sent from the controller to the drive using integrated safety protocol.

Attribute [bit]

Type

Description

DINT

[0]

BOOL

Combinations of the RunMode and

[1]

BOOL

ConnectionFaulted states

SINT

[0]

BOOL

0 = Torque Permitted 1 = Torque Disabled

[6]

BOOL 1 = STO fault present

[7]

BOOL 1 = Reset is required

SINT

[0]

BOOL

0 = Disable Permit 1 = Permit Torque

[7]

BOOL 0 --> 1 = Reset STO fault

IMPORTANT Only the data listed in Table 171 is communicated with SIL 3 integrity.

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Table 172 - Dual-axis Inverter Integrated STO Specifications

Logix Designer Tag Name SI.ConnectionStatus (1) (2)

Safe Stop Only - No Feedback Tag Names Studio 5000 Logix Designer (version 31 and later)

SI.RunMode

SI.ConnectionFaulted SI.Status1 (1) (3)

SI.TorqueDisabled1

SI.SafetyFault1

SI.ResetRequired1 SI.Status2 (1) (3)

SI.TorqueDisabled2

SI.SafetyFault2

SI.ResetRequired2 SO.Command1 (1) (4)

SO.SafeTorqueOff1

SO.STOOutput1

SO.Reset1 SO.Command2 (1) (4)

SO.ResetRequest1

SO.SafeTorqueOff2

SO.STOOutput2

SO.Reset2

SO.ResetRequest2

(1) Bits not listed are always zero. (2) ConnectionStatus is determined by the Safety Validator in the GuardLogix controller. (3) Status is sent from the drive to the controller using integrated safety protocol. (4) The Command is sent from the controller to the drive using integrated safety protocol.

Attribute [bit]

Type

Description

DINT

[0]

BOOL Combinations of the RunMode and

[1]

BOOL ConnectionFaulted states

SINT Motion Safety 1

[0]

BOOL 0 = Torque Permitted; 1 = Torque Disabled

[6]

BOOL 1 = STO Fault present

[7]

BOOL 1 = A reset is required

SINT Motion Safety 2

[0]

BOOL 0 = Torque Permitted; 1 = Torque Disabled

[6]

BOOL 1 = STO Fault present

[7]

BOOL 1 = A reset is required

SINT Motion Safety 1

[0]

BOOL 0 = Disable Permit; 1 = Permit Torque

[7]

BOOL 0-->1 = Reset STO Fault

SINT Motion Safety 2

[0]

BOOL 0 = Disable Permit; 1 = Permit Torque

[7]

BOOL 0-->1 = Reset STO Fault

IMPORTANT Only the data listed in Table 172 is communicated with SIL 3 integrity.
In these examples, the appropriate STO bit permits torque when the bit is high (see Table 170 on page 325 for changes in STO tag names).
Figure 146 - STO Function (Logix Designer, version 30 or earlier)

Figure 147 - STO Function with STO Only (Logix Designer, version 31 or later)

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Figure 148 - STO Function with Safe Stop Only-No Feedback (Logix Designer, version 31 or later)
STO Fault Reset
To clear the STO Fault condition, a transition from logic 0 to 1 of the SO.Reset tag is required after the SO.SafeTorqueOff tag has transitioned from logic 0 to 1 (see Table 170 on page 325 for changes in STO tag names). If the Kinetix 5700 servo drive safety controller detects a fault, the input assembly tag SI.SafetyFault is set to 1. To reset Axis.SafetyFault, an MAFR command must be issued.
IMPORTANT Transition of the SO.SafeTorqueOff tag to logic 1 must always be executed prior to transition of the SO.Reset tag to logic 1.
IMPORTANT All Kinetix 5700 inverter axes enter the faulted state if any STO function fault is detected. Refer to Table on page 329 for integrated safety troubleshooting.
Refer to Figure 149 for an understanding of the Kinetix 5700 STO state restart functionality.

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Figure 149 - Reset Safe Torque-off Fault Diagram

Drv:SO,SafeTorqueOff (1) Drv:SO, Reset (1)

Disable Torque

Safety Fault Occurs Permit Torque

Drv:SI.TorqueDisabled

Torque Permited

Torque Disabled

Drv:SI.SafetyFault Drv:SI.ResetRequired
Axis.SafetyFault Axis.SafeTorqueOffActiveInhibit
Axis.SafetyFaultStatus

No Fault
No Fault Start Permitted
No Fault

Reset Not Required Faulted (cleared by MAFR)
Start Inhibitted Faulted

Axis.SafetyResetRequestStatus

S0.ResetRequest

Axis.SafetyResetRequiredStatus

Reset Not Required

Axis.SafeTorqueOffActiveStatus

Permit Torque

Axis.SafeTorqueDisabledStatus

Torque Permited

Axis.SafeTorqueOffFault

No Fault

(1) See Table 170 on page 325 for STO tag name changes.

Reset Required Disable Torque Torque Disabled

Troubleshoot the Safe Torque-off Function
For Kinetix 5700 fault code descriptions and possible solutions, see the Knowledgebase Technote: Kinetix 5700 Servo Drives Fault Codes. You can download the spreadsheet from this public article.
You will be asked to log in to your Rockwell Automation web account or create an account if you do not have one. You do not need a support contract to access this article.

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Understand Integrated Safety Drive Replacement

GuardLogix controllers retain I/O device configuration on-board and are able to download the configuration to the replacement device.

IMPORTANT

If the Kinetix 5700 replacement drive was used previously, clear the existing configuration before installing it on a safety network by resetting the drive to Hardwired STO mode. To see how this is done, refer to Restore the Hardwired STO Mode by Using the Logix Designer Application on page 307.

Replacing a Kinetix 5700 servo drive that sits on an integrated safety network is more complicated than replacing standard devices because of the safety network number (SNN). The device number and SNN make up the safety device's DeviceID. Safety devices require this more complex identifier to make sure that duplicate device numbers do not compromise communication between the correct safety devices. The SNN is also used to provide integrity on the initial download to the Kinetix 5700 servo drive.
When the Logix Designer application is online, the Safety category of the Module Properties dialog box displays the current configuration ownership. When the opened project owns the configuration, Local is displayed.

A communication error is displayed if the module read fails. Refer to Replace an Integrated Safety Drive in a GuardLogix System on page 330 for integrated safety drive replacement information.

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Replace an Integrated Safety Drive in a GuardLogix System
When you replace an integrated safety drive, the replacement device must be configured properly and the replacement drives operation must be user-verified.
ATTENTION: During drive replacement or functional test, the safety of the system must not rely on any portion of the affected drive.
Two options for safety drive replacement are available on the Safety category of the Controller Properties dialog box in the Logix Designer application:
· Configure Only When No Safety Signature Exists · Configure Always
Figure 150 - Safety Drive Replacement Options

Configure Only When No Safety Signature Exists
This setting instructs the GuardLogix controller to automatically configure a safety drive only when the safety task does not have a safety task signature, and the replacement drive is in an out-of-box condition, meaning that a safety network number does not exist in the safety drive.
If the safety task has a safety task signature, the GuardLogix controller automatically configures the replacement CIP Safety I/O device only if the following is true:
· The device already has the correct safety network number. · The device electronic keying is correct. · The node or IP address is correct.
For detailed information, refer to Additional Resources on page 13 for the appropriate user manual for your GuardLogix or Compact GuardLogix controller.

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Configure Always
When the Configure Always feature is enabled, the controller automatically checks for and connects to a replacement drive that meets all of the following requirements:
· The controller has configuration data for a compatible drive at that network address
· The drive is in Hardwired STO mode or has an SNN that matches the configuration
ATTENTION: Enable the Configure Always feature only if the entire integrated safety control system is not being relied on to maintain SIL 3 behavior during the replacement and functional testing of a Kinetix 5700 drive. Do not place drives that are in Hardwired STO mode on an integrated safety network when the Configure Always feature is enabled. If other parts of the integrated safety control system are being relied upon to maintain SIL 3, make sure that the controller's Configure Always feature is disabled. It is your responsibility to implement a process to make sure proper safety functionality is maintained during device replacement.
ATTENTION: Do not place any devices in the out-of-box condition on any integrated safety network when the Configure Always feature is enabled. For the device replacement procedure, refer to Additional Resources on page 13. ATTENTION: for the appropriate user manual for your GuardLogix or Compact GuardLogix controller.
Motion Direct Commands in Motion Control Systems
You can use the Motion Direct Command (MDC) feature to initiate motion while the controller is in Program mode, independent of application code that is executed in Run mode. These commands let you perform a variety of functions, for example, move an axis, jog an axis, or home an axis.
A typical use might involve a machine integrator testing different parts of the motion system while the machine is being commissioned or a maintenance engineer, under certain restricted scenarios in accordance with safe machine operating procedures, wanting to move an axis (like a conveyor) to clear a jam before resuming normal operation.

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ATTENTION: To avoid personal injury or damage to equipment, follow these rules regarding Run mode and Program mode. · Only authorized, trained personnel with knowledge of safe machine
operation should be allowed to use Motion Direct Commands · Additional supervisory methods, like removing the controller key switch,
should be used to maintain the safety integrity of the system after returning the safety controller to RUN mode
Understand STO Bypass When Using Motion Direct Commands
If a Safety-only connection between the GuardLogix safety controller and the Kinetix 5700 servo drive was established at least once after the drive was received from the factory, the drive does not allow motion while the safety controller is in Program mode by default.
This is because the safety task is not executed while the GuardLogix safety controller is in Program mode. This applies to applications running in a singlesafety controller (with Motion and Safety connections). When an integrated safety drive has a Motion connection to a standard controller and a separate Safety connection to a safety controller, the standard controller can transition to Program mode while the safety controller stays in Run mode and continues to execute the safety task.
However, Kinetix 5700 drive systems are designed with a bypass feature for the STO function in single-safety controller configurations. You can use the MDC feature to allow motion while following all the necessary and prescribed steps per your machine's safety operating procedures.
ATTENTION: Consider the consequences of allowing motion through the use of MDC when the controller is in Program mode. You must acknowledge warning messages in the Logix Designer application that warn of the drive bypassing the STO function and unintended motion can occur. The integrated safety drive does not respond to requests of the STO function if MDC mode is entered. It is your responsibility to maintain machine safety integrity while executing motion direct commands. One alternative is to provide ladder logic for Machine Maintenance mode that leaves the controller in Run mode with safety functions executing.

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Logix Designer Application Warning Messages
When the controller is in Run mode, executing safety functions, the Kinetix 5700 servo drive follows the commands that it receives from the safety controller. The controller reports Safety state = Running and Axis state = Stopped/Running, as shown in Figure 151.
Figure 151 - Safety State Indications When Controller is in Run Mode (safety task executing)
When the controller transitions to Program mode, the integrated safety drive is in the safe state (torque is not permitted). The controller reports Safety state = Not Running and Axis state = Start Inhibited, as shown in Figure 152).
Figure 152 - Safety State Indications After Controller Transitions to Program Mode

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When you issue a motion direct command to an axis to produce torque in Program mode, for example MSO or MDS, with the safety connection present to the drive, a warning message is presented before the motion direct command is executed, as shown in Figure 153.
Figure 153 - STO Bypass Prompt When the Safety Controller is in Program Mode
ATTENTION: Unexpected motion and the possibility of personal injury or equipment damage exists if a motion direct command is issued for one axis of any 2198-Dxxx-ERS3 dual-axis inverter. Both (A and B) inverters associated with the physical drive permit torque after you acknowledge this warning message by clicking Yes. Make sure that preventive measures are in place for both axes to maintain the safety integrity of the machine.
IMPORTANT The warning in Figure 153 is displayed only the first time a motion direct command is issued.
After you acknowledge the warning message by clicking Yes, torque is permitted by the drive and a warning message is indicated in the software as shown in Figure 154. The controller reports Safety state = Not Running (torque permitted), Axis state = Stopped/Running and Persistent Warning = Safe Torque Off Bypassed.
IMPORTANT Switch the controller to Run mode to exit Motion Direct Command mode and end the STO function bypass.

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Figure 154 - Safety State Indications After Controller Transitions to Program Mode (MDC executing)

IMPORTANT

The persistent warning message text Safe Torque Off bypassed appears when a motion direct command is executed.
The warning message persists even after the dialog is closed and reopened as long as the integrated safety drive is in STO Bypass mode.
The persistent warning message is removed only after the integrated safety drive's Safety State is restored to the Running state.

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Torque Permitted in a Multi-workstation Environment
The warning in Figure 155 is displayed to notify a second user working in a multi-workstation environment that the first user has placed the integrated safety drive in the STO state and that the current action is about to bypass the STO state and permit torque.
Figure 155 - STO Bypass Prompt When MDC is Issued in Multi-workstation Environment
Warning Icon and Text in Axis Properties
In addition to the other warnings that require your acknowledgement, the Logix Designer application also provides warning icons and persistent warning messages in other Axis Properties dialog boxes when the integrated safety drive is in STO Bypass mode.
Figure 156 - Axis and Safe State Indications on the Hookup Services Dialog Box
Figure 157 - Axis and Safe State Indications on Motion Direct Commands Dialog Box

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Kinetix 5700 Safe Torque-off Function Chapter 9 Figure 158 - Axis and Safe State Indications on the Motion Console Dialog Box

Functional Safety Considerations
ATTENTION: Before maintenance work can be performed in Program mode, the developer of the application must consider the implications of allowing motion through motion direct commands and should consider developing logic for run-time maintenance operations to meet the requirements of machine safety operating procedures.
ATTENTION: Motion is allowed and the STO function is not available when motion direct commands are used in Program mode. Motion direct commands issued when the controller is in Program mode cause the drive to bypass the STO Active condition. It is your responsibility to implement additional preventive measures to maintain safety integrity of the machinery during execution of motion direct commands in Program mode.
ATTENTION: To avoid personal injury and damage to equipment in the event of unauthorized access or unexpected motion during authorized access, return the controller to Run mode and remove the key before leaving the machine unattended.

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Integrated Safe Torque-off Specifications

IMPORTANT

To maintain safety rating, Kinetix 5700 drives must be installed inside protected control panels or cabinets appropriate for the environmental conditions of the industrial location. The protection class of the panel or cabinet must be IP54 or higher.

Table 173 - Integrated STO Specifications

Attribute Safety connection RPI, min Input assembly connections (2198-xxxx-ERS3 drives) Input assembly connections (2198-xxxx-ERS4 drives) Output assembly connections Integrated safety open request support
Axis safety status
Axis safety faults

Value 6 ms
3
1
1 Type 1 and Type 2 requests Bit 0: Safety fault Bit 1: Safety reset request Bit 2: Safety Reset Required Bit 3: Safe torque-off active Bit 4: Safe torque disabled Bit 5...31: Undefined (0) Bit 1: Safety core fault Bit 3: Safe torque-off fault All others: Undefined (0)

Logix Designer Tag Name N/A
N/A
N/A N/A Axis.SafetyFaultStatus Axis.SafetyResetRequestStatus Axis.SafetyResetRequiredStatus Axis.SafeTorqueOffActiveStatus Axis.SafeTorqueDisabledStatus N/A Axis.SafetyCoreFault Axis.SafeTorqueOffFault N/A

Table 174 - Single-axis Inverter STO Assembly Specifications

Attribute
Safety input assembly
Safety output assembly

Value Bit 0: Torque disabled Bit 6: Safety fault Bit 7: Reset required Bit 0: Safe torque-off output
Bit 7: Reset request

Logix Designer Tag Name
Drv:SI.TorqueDisabled
Drv:SI.SafetyFault
Drv:SI.ResetRequired
Drv:SO.SafeTorqueOff or Drv:SO.STOOutput
Drv:SO.Reset or Drv:SO.ResetRequest

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Table 175 - Dual-axis Inverter STO Assembly Specifications

Attribute

Value

Byte 0 Bit 0: Torque disabled 1

Byte 0 Bit 6: Safety fault 1

Byte 0 Bit 7: Reset required 1
Safety input assembly Byte 1 Bit 0: Torque disabled 2

Byte 1 Bit 6: Safety fault 2

Byte 1 Bit 7: Reset required 2

Byte 0 Bit 0: Safe torque-off output 1

Safety output assembly

Byte 0 Bit 7: Reset request 1 Byte 1 Bit 0: Safe torque-off output 2

Byte 1 Bit 7: Reset request 2

Logix Designer Tag Name
Drv:SI.TorqueDisabled1
Drv:SI.SafetyFault1
Drv:SI.ResetRequired1
Drv:SI.TorqueDisabled2
Drv:SI.SafetyFault2
Drv:SI.ResetRequired2
Drv:SO.SafeTorqueOff1 or Drv:SO.STOOutput1
Drv:SO.Reset1or Drv:SO.ResetRequest1
Drv:SO.SafeTorqueOff2 or Drv:SO.STOOutput2
Drv:SO.Reset2or Drv:SO.ResetRequest2

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Notes:

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Interconnect Diagrams

A Appendix

This appendix provides wiring examples and system block diagrams for your Kinetix® 5700 system components.

Topic

Page

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

Interconnect Diagram Notes
Table 176 - Interconnect Diagram Notes

This appendix provides wiring examples to assist you in wiring the Kinetix 5700 drive system. These notes apply to the wiring examples on the following pages.

Note Information
1 For power wiring specifications, refer to Wiring Requirements on page 136.
2 For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Selection on page 46.
3 For fuse and circuit breaker sizes and other 8720MC-RPS specifications, see the 8720MC Regenerative Power Supply User Manual, publication 8720MC-RM001.
4 The iTRAK® system with TriMax bearings power supply must have three-phase power sourced from grounded-wye power distribution.
5 AC (EMC) line filter is required for CE compliance. Mount the line filter with 50 mm (1.97 in.) minimum clearance between the drive and filter. If routing in wireway is unavoidable, use shielded cable with shields grounded to the drive chassis and filter case. For AC line filter specifications, refer to Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003. 2198-DBRxx-F line filters are preferred.
6 Terminal block is required to make connections.
7 Cable shield clamp must be used to meet CE requirements with Bulletin 2090 power cables 2 AWG and smaller. See Customer-supplied Motor Power Cables on page 173 to meet CE when wiring 2198-S263-ERSx and 2198-S312-ERSx drives with power cables larger than 2 AWG.
8 2198-Dxxx -ERSx dual-axis inverters include separate digital inputs, DSL feedback, universal feedback, motor power, and motor brake wiring plugs for each axis.
9 See Digital Inputs Connector Pinouts beginning on page 101 for digital input configurable functions and default settings.
10 · When a 2198-Sxxx-ERSx single-axis inverter is the first drive module (adjacent to the 2198-CAPMOD-2240 capacitor module) you must configure the Digital Input category in the Logix Designer application as Regeneration OK and wire the IOD connector.
· When a 2198-Dxxx-ERSx dual-axis inverter is the first drive module (adjacent to the 2198-CAPMOD-2240 capacitor module) and Axis 1 and 3 are used, you must configure the Digital Input category in the Logix Designer application as Regeneration OK and wire the IOD connector for each axis.

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Table 176 - Interconnect Diagram Notes (continued)
Note Information
11 PE ground connection bonded to the panel must be used to meet CE requirements. See Ground the Drive System on page 134.
12 Contactor coil (MC) needs integrated surge suppressors for AC coil operation and must have a normally-open auxiliary contact that is terminated at TB3 (24V DC to MC input as shown). See the 8720MC Regenerative Power Supply User Manual, publication 8720MC-RM001 for contactor types and wiring examples.
13 For M1 contactor selection and specifications, refer to Contactor Selection on page 48.
14 Internal shunt wired to the RC connector is default configuration. Remove internal shunt wires to attach external shunt wires.
15 Default configuration for ground screws or jumper is for grounded power at customer site. For impedance-grounded power configurations, remove the screws/jumper. Refer to Input Power Configurations for Kinetix 5700 Power Supplies on page 123 for more information.
16 Leave jumper between PR2 and PR3 as shown to use the internal precharge resistor. Remove jumper when external precharge/circuit is required. For more information, refer to the 8720MC Regenerative Power Supply User Manual, publication 8720MC-RM001.
17 ATTENTION: Implementation of control circuits and risk assessment is the responsibility of the machine builder. Reference international standards IEC 62061 and ISO 13849-1 estimation and safety performance categories.

ATTENTION: An AC three-phase mains contactor must be wired in series between the branch circuit protection and the Kinetix 5700 system power

supply. In addition, the AC three-phase contactor control string must be wired in series with the contactor-enable relay at the CED connector. Refer to

Contactor Enable Relay on page 108, for more information. The recommended minimum wire size for wiring the circuitry to the contactor-enable connector is 1.5 mm2 (16 AWG).

19 For motor cable specifications, refer to Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004.

20 Brake connector pins are labeled plus (+) and minus (-) or F and G respectively. Power connector pins are labeled U, V, W, and (GND) or A, B, C, and (D) respectively.

21 LDAT-Series linear thrusters do not have a brake option, so only the 2090-CPWM7DF-xxAAxx or 2090-CPWM7DF-xxAFxx motor power cables apply.

22 MPAS-Bxxxxx-VxxSxA (ballscrew) linear stages use the 9V supply. MPAS-Bxxxxx-ALMx2C (direct-drive) linear stages use the 5V supply.

23 Mount the 8720MC-RPS unit on the same panel and as close to the Kinetix 5700 drive system as possible. DC-bus cables not to exceed 2.0 m (6.5 ft), maximum length. See the 8720MC Regenerative Power Supply User Manual, publication 8720MC-RM001, for installation and wiring instructions.

24 MPL-A/B15xx-H...MPL-A/B45xx-H, MPL-A15xx-V/E...MPL-A2xx-V/E, MPL-A3xx-S/M...MPL-A45xx-S/M, MPM-A115xx...MPM-A130xx, MPF-A3xx...MPF-A45xx, MPS-Axxx, MPAS-Bxxx (direct drive), and encoders use the +5V DC supply.

25 MPL-B15xx-V/E...MPL-B2xx-V/E, MPL-B3xx-S/M...MPL-B6xx-S/M, MPL-A5xx, MPM-Bxx, MPM-A165xx...MPM-A215xx, MPF-Bxx, MPF-A5xx, MPS-Bxxx, MPAR-Bxxx, and MPAS-Bxxx (ballscrew) encoders use the +9V DC supply.

26 The 2198-CAPMOD-2240 capacitor module is used in applications with up to 104 A maximum external DC-bus current. You can add the 2198-DCBUSCOND-RP312 DC-bus conditioner module to the left or right of the capacitor module when the external DC-bus current exceeds 104 A, up to a maximum of 208 A.

27 The Converter OK relay provides a 24V signal to non-Kinetix 5700 inverters indicating that they can draw power from the regenerative power supply and that the power supply is not faulted. This signal is intended for use with Kinetix 6000, Kinetix 6200, or Kinetix 7000 drives when migrating from the 8720MC-RPS to the 2198-RPxxx regenerative bus supply. Interposing relay can be required if more than one drive is attached.

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Interconnect Diagrams Appendix A

Power Wiring Examples

You must supply input power components. The three-phase line filter is wired downstream of the circuit protection devices. Each drive module includes the appropriate DC-bus link and connector set. The 24V supply can be jumpered from drive-to-drive by using discrete wires or the shared-bus connection system.

In this example, the inverter drives and optional accessory modules are downstream of a single 2198-Pxxx DC-bus power supply.
Figure 159 - DC-bus Power Supply (single converter) Configuration

24V AC/DC 50/60 Hz
Bonded Cabinet Ground Bus *

Refer to table on page 341 for note information.

2198-Pxxx DC-bus Power Supply

DC+ Shunt Power

(RC) Connector

Internal Shunt Note 14

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8
Note 7 Cable Shield
Clamp U4
Motor Power V 3 (MP) Connector W 2
1

Additional Inverters or Accessory Modules
Three-phase Motor Power Connections Notes 8,19

DC+

DC-

Bonded Cabinet Ground Bus *

Chassis

Motor Brake (BC) Connector

MBRK - 2 MBRK + 1

MBRK MBRK +

Motor Brake Connections

DC+ DC Bus

Note 8

DC- (DC) Connectors

Customer Supplied +24V DC
Power Supply *

24V_COM +24V

24V_COM Control Power +24V (CP) Connectors

2198-TCON-24VDCIN36

2198-xxxx-P-T

Digital Input (IOD) Connector
Grounding Screws/Jumpers Note 15

24V Input Power

Wiring Connector

1 IN1

2 3 4

COM IN2 SHLD

Digital Input Connections Note 9

CR1 * CR1 *
M1 *

STOP *

START *

EN+ EN

CONT EN+ CONT EN

Contactor Enable (CED) Connector Note 18

T-connectors

and Bus Bars

IN1 1

COM 2

Digital Input (IOD) Connector

IN2 SHLD

3 4

COM 5

IN3 6

COM 7

IN4 8

COM 9

SHLD 10

Notes 13,18

CR1 *

PE Ground Note 11

Refer to Attention statement (Note 17).

Three-phase Input (IPD) Connector

L3 L2 L1

Digital Input Connections Note 8

195...528V AC rms Three-phase Input
Notes 1, 2

Circuit Protection*
Note 2

M1 Contactor Note 13

2198-DBRxx-F Three-phase AC Line Filter
Note 5

* Indicates User Supplied Component

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24V AC/DC 50/60 Hz

In this example, the inverter drives and optional capacitor modules are downstream of three DC-bus (converter) power supplies. When two or three DC-bus power supplies are used, they must be catalog number 2198-P208. This configuration provides more power (kW) to the drive system.
Figure 160 - DC-bus Power Supply (multiple converters) Configuration

Refer to table on page 341 for note information.

2198-P208

DC-bus Power Supply DC-bus Power Supply DC-bus Power Supply

DC+ Shunt Power

(RC) Connector

DC+ Shunt Power

(RC) Connector

DC+ Shunt Power

(RC) Connector

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

Internal Shunt Note 14

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

Additional Inverters, Capacitor Modules, or DC-bus Conditioner Modules

Bonded Cabinet Ground Bus *
Chassis
Customer Supplied +24V DC
Power Supply *

CR1 * CR1 *

START *

M1 * STOP *

Notes 13,18

CR1 *

Refer to Attention statement (Note 17).

Grounding Screws/Jumpers Note 15

Bonded Cabinet Ground Bus *

DC+

DC-

2 1

24V_COM +24V

When three 2198-P208 DC-bus power supplies are connected in parallel, two additional 2198-BARCON-85DC200 bus-links must be ordered separately.

24V_COM +24V

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

2198-H070-P-T T-connector and Bus Bar

2198-xxxx-P-T T-connector and Bus Bar

DC+ DC Bus DC- (DC) Connectors
24V_COM Control Power +24V (CP) Connectors
2198-xxxx-P-T T-connector and Bus Bar

EN+ CONT EN+ CONT EN
EN
Three-phase Input (IPD) Connectors
1321-3R80-B Line Reactors (required components) Circuit Protection *
Note 2

CONT EN+ CONT EN
PE Ground Note 11
L3 L2 L1

CONT EN+ CONT EN

Contactor Enable (CED) Connectors Note 18

PE Ground Note 11

L3 L2 L1

PE Ground Note 11

PE Ground Note 11
Bonded Cabinet Ground Bus *

195...528V AC rms Three-phase Input
Notes 1, 2

2198-DBR200-F Three-phase AC Line Filter Note 5
Circuit M1 Contactor Protection* Note 13
Note 2

* Indicates User Supplied Component

Appendix A Interconnect Diagrams

Interconnect Diagrams Appendix A

24V AC/DC 50/60 Hz

In this example, the 2198-CAPMOD-2240 capacitor module is included for energy storage and to improve dynamic performance.
Figure 161 - DC-bus Power Supply with Capacitor Module

Refer to table on page 341 for note information.

2198-Pxxx DC-bus Power Supply

DC+ Shunt Power

(RC) Connector

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

2198-CAPMOD-2240 Capacitor Module

Internal Shunt Note 14

Bonded Cabinet Ground Bus *

DC+

DC+ DC Bus

DC-

DC- (DC) Connectors

Chassis

Customer Supplied +24V DC
Power Supply *

CR1 * CR1 *

START *

M1 * STOP *

Notes 13,18

CR1 *

Refer to Attention statement (Note 17).

Grounding Screws/Jumpers Note 15

2 1

24V_COM +24V

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

24V_COM +24V
2198-xxxx-P-T T-connector and Bus Bar

24V_COM Control Power

+24V

(CP) Connectors

2198-H040-P-T T-connector and Bus Bar

Module Status (MS) Connector

MS 2 MS 1

EN+ CONT EN+ EN CONT EN

Contactor Enable (CED) Connectors Note 18
PE Ground Note 11

PE Ground Note 11

Monitor capacitor module status by wiring to digital input Bus Capacitor OK
or Logix 5000TM controller. Refer to Capacitor Module Status Wiring Example
on page 357, for an example.
PE Ground Note 11

Bonded Cabinet Ground Bus *

Three-phase Input (IPD) Connectors

195...528V AC rms Three-phase Input
Notes 1, 2

Circuit Protection*
Note 2

M1 Contactor Note 13

2198-DBRxx-F Three-phase AC Line Filter
Note 5

L3 L2 L1

Bonded Cabinet Ground Bus *
* Indicates User Supplied Component

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24V AC/DC 50/60 Hz
Bonded Cabinet Ground Bus *

Figure 162 - DC-bus Power Supply (single iTRAK power supply) Configuration

Refer to table on page 341 for note information.

2198-P070 Kinetix 5700 DC-bus Power Supply

2198T-W25K-ER Kinetix 5700
iTRAK Power Supply

DC+ Shunt Power SH (RC) Connector
Internal Shunt Note 14

Cable Shield Clamp Note 7
DC-bus Power Output A (IDC) Connector A
and Control Power Output A (ICP) Connector

DC 1 L2 H3
4 24V + 1 24V - 2

DC Power Bus A to iTRAK Motor Modules
Control Power A to iTRAK Motor Modules

Bonded Cabinet Ground Bus *
Chassis Customer Supplied +24V DC Power Supply *
Grounding Screws/Jumpers Note 15

DC+

DC+ DC Bus

DC-

DC- (DC) Connectors

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

DC-bus Power Output B (IDC) Connector
and Control Power Output B B (ICP) Connector

1 2

+24V

24V_COM

+24V Control Power 24V_COM (CP) Connectors

2198T-W25K-P-T

T-connectors and Bus Bars

1 IN1

2 3 4

COM IN2 SHLD

Digital Input (IOD) Connector Note 9

Digital Input (IOD) Connector

DC- 1 L2 H3

24V+ 1 24V 2

ENABLE 1
COM 2
CLEAR 3
FAULT
COM 4
SHLD 5

24V COM
24V COM SHIELD

CR1 * CR1 *
M1 * STOP *
Notes 13,18

START * CR1 *

EN+ EN

CONT EN+ CONT EN

Contactor Enable (CED) Connector

Three-phase Input (IPD) Connector

iTRAK Power Supply Ready (IR) Connector

RDY RDY+ +

Refer to Attention statement (Note 17).

L3 L2 L1

PE Ground Note 11

DC Power Bus B to iTRAK Motor Modules
Control Power B to iTRAK Motor Modules

324...528V AC rms Three-phase Input
Notes 1, 2, 4

Circuit Protection*
Note 2

M1 Contactor Note 13

2198-DBRxx-F Three-phase AC Line Filter
Note 5

* Indicates User Supplied Component

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Interconnect Diagrams Appendix A

In this example, the DC-bus power supply 24V input-wiring connector and the three iTRAK power supply 24V input wiring connectors are wired separately. The 2198T-W25K-P-IN input wiring connector is rated for 41 A. See Appendix C on page 395 to determine 24V current requirements needed for proper distribution for 24V control power.

Figure 163 - DC-bus Power Supply (multiple iTRAK power supply) Configuration

Refer to table on page 341 for note information.

2198-P141

2198T-W25K-ER

Kinetix 5700

DC-bus Power Supply iTRAK Power Supply iTRAK Power Supply iTRAK Power Supply

24V AC/DC 50/60 Hz

Bonded Cabinet Ground Bus * Chassis Customer Supplied +24V DC Power Supply *
Grounding Screws/Jumpers Note 15

CR1 * CR1 *
M1 * STOP *
Notes 13,18

START * CR1 *

Refer to Attention statement (Note 17).

DC+ Shunt Power SH (RC) Connector
Internal Shunt Note 14

DC+

DC-

DC+

DC+ DC Bus

DC-

DC- (DC) Connectors

1 2 +24V
24V_COM
2198-TCON-24VDCIN36 24V Input Power Wiring Connector

+24V 24V_COM
2198T-W25K-P-IN 24V Input Power Wiring Connector

EN+ EN

CONT EN+ CONT EN

Contactor Enable (CED) Connector

+24V 24V_COM
2198T-W25K-P-T T-connectors and Bus Bars

+24V Control Power 24V_COM (CP) Connectors
2198T-W25K-P-T T-connectors and Bus Bars

Three-phase Input (IPD) Connector

PE Ground Note 11
L3 L2 L1

PE Ground Note 11

Bonded Cabinet Ground Bus *
324...528V AC rms Three-phase Input
Notes 1, 2, 4

2198-DBRxx-F Three-phase AC Line Filter
Note 5

Circuit Protection*
Note 2

M1 Contactor Note 13

* Indicates User Supplied Component

Bonded Cabinet Ground Bus *

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24V AC/DC 50/60 Hz
Bonded Cabinet Ground Bus *

In this example, the inverter drives and optional accessory modules are downstream of a 2198-RPxxx regenerative bus supply.

Figure 164 - Regenerative Bus Supply Configuration

Refer to table on page 341 for note information.
Active Shunt (optional component) See External Active-shunt Connections
on page 178 for more information.

2198-RPxxx Regenerative Bus Supply
DC+ Shunt Power DC (RC) Connector

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

Note 7 Cable Shield
Clamp
Motor Power (MP) Connector

U4 V3 W2
1

Additional Inverters or Accessory Modules
Three-phase Motor Power Connections Notes 8,19

Bonded Cabinet Ground Bus *

Chassis
Customer Supplied +24V DC
Power Supply *

See Contactor Wiring for Regenerative Bus Supply on page 358 for M1 auxiliary contact wiring example.
Digital Input Connections

Grounding Screws/Jumpers Note 15

CR1 * CR1 *

START *

M1 *

STOP *

Notes 13,18

CR1 *

Refer to Attention statement (Note 17).

Motor Brake (BC) Connector

MBRK - 2 MBRK MBRK + 1 MBRK +

Motor Brake Connections Note 8

DC+

DC+ DC Bus

DC-

DC- (DC) Connectors

24V_COM +24V

2198-TCON-24VDCIN36 (1)

or 2198T-W25K-P-IN

1 IN1 2 COM

24V Input Power Wiring Connector

3 IN2

4 5 6

SHLD COM IN3

Digital Input (IOD) Connector Note 9

7 COM

8 IN4

9 COM

10 SHLD

24V_COM Control Power +24V (CP) Connectors

2198-xxxx-P-T

T-connectors and Bus Bars

IN1 1

COM 2

IN2 3

Digital Input (IOD) Connector

SHLD COM

4 5

Note 9 IN3 6

COM 7

IN4 8

COM 9

SHLD 10

OK+ OK

CONV OK+ CONV OK

EN+ EN

CONT EN+ CONT EN

Contactor Enable (CED) Connector Note 18

Digital Input Connections Note 8

Three-phase Input (IPD) Connector

PE Ground Note 11
L3 L2 L1

PE Ground Note 11

324...506V AC rms Three-phase Input
Notes 1, 2

Circuit Protection*
Note 2

M1 Contactor Note 13

2198-DBRxx-F Three-phase AC Line Filter
Note 5

* Indicates User Supplied Component

(1) Use 2198-TCON-24VDCIN36 input wiring connector with 2198-RP088 and 2198-RP200 bus supplies. Use 2198T-W25K-P-IN input wiring connector with 2198-RP263 and 2198-RP312 bus supplies. See CP Connector Wiring - Shared Bus on page 141 for wiring specifications.

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In this example, the 2198-DCBUSCOND-RP312 DC-bus conditioner module is included because total motor cable length exceeds 400 m (1312 ft).
Figure 165 - Regenerative Bus Supply with DC-bus Conditioner Module

Refer to table on page 341 for note information.
Active Shunt (optional component) See External Active-shunt Connections
on page 178 for more information.

2198-RPxxx Regenerative Bus Supply
DC+ Shunt Power DC (RC) Connector

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

24V AC/DC 50/60 Hz

Bonded Cabinet Ground Bus *

DC+

DC-

Chassis

DC+

DC+ DC Bus

DC-

DC- (DC) Connectors

Customer Supplied +24V DC
Power Supply *

Kinetix 6000 Drives IOD-3 IOD-2 24VCOM
Enable

Kinetix 6200/6500 Drives IOD-40 IOD-41 24VCOM
Regeneration OK

Kinetix 7000 Drives

GPIO-7 GPIO-8

Regen_OK+ Regen_OK

CR1 * CR1 *

START *

M1 * STOP *

Notes 13,18

CR1 *

Refer to Attention statement (Note 17).

24V_COM +24V

2198-TCON-24VDCIN36 (1) or 2198T-W25K-P-IN 24V Input Power Wiring Connector

24V_COM +24V

24V_COM Control Power

+24V

(CP) Connectors

2198-xxxx-P-T

2198-H040-P-T

T-connector and Bus Bar T-connector and Bus Bar

Module Status (MS) Connector

2 MS 1
MS

Note 27

OK+ OK

CONV OK+ CONV OK

EN+ CONT EN+ EN CONT EN

Contactor Enable (CED) Connectors Note 18
PE Ground Note 11

Three-phase Input (IPD) Connectors

L3 L2 L1

Monitor DC-bus conditioner module status by wiring to digital input Bus Conditioner OK or
Logix 5000 controller. Refer to DC-bus Conditioner Module Status Wiring Example on
page 357, for an example.

PE Ground Note 11

Grounding Screws/Jumpers
Note 15

Bonded Cabinet Ground Bus *

* Indicates User Supplied Component

324...506V AC rms Three-phase Input
Notes 1, 2

Circuit Protection*
Note 2

M1 Contactor Note 13

2198-DBRxx-F Three-phase AC Line Filter
Note 5

IMPORTANT The regenerative bus supply is not compatible with the iTRAK power supply.

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Refer to table on page 341 for note information.

In this example, the 2198-CAPMOD-2240 capacitor module and 2198-CAPMOD-DCBUS-IO extension module are used for energy storage and to extend the DC-bus voltage to another inverter cluster. The capacitor modules are used alone when the external DC-bus current is 104 A. The extension module (or any combination of two accessory modules) is needed when the external DC-bus current is >104 A, up to a maximum 208 A.

Figure 166 - Kinetix 5700 Extended Drive System Example (extension module)

Flexible Bus-bars

User-supplied External DC-bus Wire Lug Connections

Flexible Bus-bars

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

Additional Inverters and/or Kinetix 5700 System Power Supply

2198-CAPMOD-DCBUS-IO Extension Modules

Additional Inverters

DC+

DC-

24V_COM +24V

2198-TCON-24VDCIN36 or 2198T-W25K-P-IN
24V Input Power Wiring Connector

24V_COM +24V
2198-xxxx-P-T T-connectors and Bus Bars

Use 2198T-W25K-P-IN input wiring connector with 2198S263-ERSx and 2198-S312-ERSx
drives. Use 2198-TCON24VDCIN36 input wiring connector with all other drives. See CP Connector Wiring Shared Bus on page 141 for wiring specifications.

DC+ DC-

DC+ DC Bus DC- (DC) Connectors

ATTENTION: Circuit protection can be added after the power supply cluster to help protect converters

DC+ DC-

and inverters from damage due to

a DC-bus cable short-circuit.

24V_COM Control Power +24V (CP) Connectors

2 1

24V_COM +24V

2198-H040-P-T T-connector and Bus Bar

PE Ground Note 11

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

2198-xxxx-P-T T-connectors and Bus Bars

Module Status (MS) Connector

MS MS

2 1 Monitor capacitor module status by wiring to digital input Bus Capacitor
OK or Logix 5000 controller. Refer to Capacitor Module Status Wiring

2 MS 1 MS

Example on page 357, for an example.

Module Status (MS) Connector

2198-CAPMOD-2240 Capacitor Module

DC+ DC Bus DC- (DC) Connectors
24V_COM Control Power +24V (CP) Connectors
2198-xxxx-P-T T-connectors and Bus Bars

PE Ground Note 11

Bonded Cabinet Ground Bus *

* Indicates User Supplied Component

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Refer to table on page 341 for note information.

In this example, the 2198-CAPMOD-2240 capacitor module and 2198-DCBUSCOND-RP312 DC-bus conditioner module are used for energy storage and to extend the DC-bus voltage to another inverter cluster. The capacitor modules are used alone when the external DC-bus current is 104 A. The DC-bus conditioner module (or any combination of two accessory modules) is needed when the external DC-bus current is >104 A, up to a maximum 208 A.

Figure 167 - Kinetix 5700 Extended Drive System Example (DC-bus conditioner module)

Customer-supplied External DC-bus

Flexible Bus-bars

Wire Lug Connections

Flexible Bus-bars

2198-Sxxx -ERSx or 2198-Dxxx -ERSx
Inverter
Note 8

Additional Inverters and/or Kinetix 5700 System Power Supply

2198-DCBUSCOND-RP312 DC-bus Conditioner Modules

Additional Inverters

DC+

DC-

2 1

24V_COM +24V

2198-TCON-24VDCIN36 or 2198T-W25K-P-IN
24V Input Power Wiring Connector

24V_COM +24V
2198-xxxx-P-T T-connectors and Bus Bars

DC+

DC+ DC Bus

ATTENTION: Circuit protection can be added after the power supply DC+

DC+

DC-

DC- (DC) Connectors cluster to help protect converters DC-

DC-

and inverters from damage due to

a DC-bus cable short-circuit.

24V_COM +24V

Control Power (CP) Connectors

2 1

24V_COM +24V

2198-H040-P-T T-connector and Bus Bar

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

2198-H040-P-T T-connector and Bus Bar

2198-xxxx-P-T T-connectors and Bus Bars

Module Status (MS) Connector

Monitor capacitor module status by wiring to digital input Bus Capacitor OK or Logix 5000 controller. Refer to Capacitor Module Status Wiring Example on page 357, for an example.

Monitor DC-bus conditioner module status by wiring to digital input Bus Conditioner OK or Logix 5000 controller. Refer to DC-bus Conditioner Module Status Wiring Example on page 357, for an example.

2 MS 1
MS

MS 2 MS 1

2
MS
1 MS

2
MS
1
MS

Module Status (MS) Connector

PE Ground Note 11

DC+

DC Bus (DC) Connectors

DC-

24V_COM

Control Power (CP) Connectors

+24V

2198-xxxx-P-T T-connectors and Bus Bars

PE Ground Note 11

Interconnect Diagrams Appendix A

Bonded Cabinet Ground Bus *

2198-CAPMOD-2240 Capacitor Modules

Bonded Cabinet Ground Bus *

* Indicates User Supplied Component

351

Appendix A Interconnect Diagrams

In this example, three-phase AC input power is fed to two 8720MC-RPS065 units in a leader/follower configuration. The DC-bus (TB1) terminals connect to the Kinetix 5700 DC-bus via the DC-bus conditioner module because the system current exceeds 104 A.
Figure 168 - 8720MC-RPS065 Leader/Follower Units with Kinetix 5700 Drive System

324...506V AC rms Three-phase Input
Note 3

Refer to table on page 341 for note information.

Circuit

Protection *

Bonded Cabinet

Ground Bus *

Three-phase AC Line Filter

8720MC-RPS065 Regenerative

Note 5

Harmonic Filter E/N
R S T

Power Supply (Follower)

Note 23

TB1

Circuit

R L1
S L2
T L3

Protection * TB1
P DC+ N DC-

Varistor

MC * Note 12

Line Reactors

324...506V AC rms Three-phase Input
Note 3

Aux Contact MC1
Customer Supplied 120V AC

Note 16 MC

TB2 R1 L1 AUX S1 L2 AUX T1 L3 AUX
PR1
PR2
PR3
MC1
MC2

Power Interface CN2
Board

Note 6

Circuit Protection *
Three-phase AC Line Filter
Note 5

Bonded Cabinet Ground Bus *
Harmonic Filter E/N
R S T

Varistor

MC * Note 12

Line Reactors

8720MC-RPS065 Regenerative Power Supply
(Leader)
Note 23

TB1

R L1
S L2
T L3

Power Interface CN3
Board
TB1 DC+ DC-

Circuit Protection * P
N

* Indicates User Supplied Component

Aux Contact MC2

Customer Supplied 120V AC

Note 16 MC

TB3

MC1 MC2

Contactor * MC

TB2

Note 12 0V

R1 L1 AUX

COM

S1 L2 AUX

RDY

T1 L3 AUX

PR1

PR2

Note 6

PR3

MC1

+24V DC

MC2

PWR

DC Bus to Kinetix 5700 Drive System
Regeneration OK to Digital Inputs Aux Contact to Control String

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Interconnect Diagrams Appendix A

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

Refer to table on page 341 for note information.

8720MC-RPS065 Leader/Follower Units with Kinetix 5700 Drive System (continued)
2198-DCBUSCOND-RP312 2198-CAPMOD-2240 DC-bus Conditioner Module Capacitor Module

Circuit Protection *

2198-Sxxx -ERSx Inverter
Note 8

2198-Dxxx -ERSx Inverter
Note 8

Additional Inverters

DC Bus From P Regenerative N Power Supply
Bonded Cabinet Ground Bus *

Note 23
Chassis Customer Supplied
+24V DC Power Supply *
Note 6

DC+

DC-

Note 26

2 24V_COM 1 +24V

24V_COM +24V

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

2198-H040-P-T T-connector and Bus Bar

2198-xxxx-P-T T-connector and Bus Bar

DC+ DC Bus DC- (DC) Connectors
24V_COM Control Power +24V (CP) Connectors
2198-xxxx-P-T T-connector and Bus Bar

Regeneration OK From TB3-RDY

Digital Inputs * Indicates User Supplied Component

Aux Contact to Control String

Start * Stop *
CR1*

Refer to Attention statement

(Note 17).

CR1*

Note 26

2 1

MS MS

Note 6

Module Status (MS) Connector
2 MS 1 MS

I/O
2 COM 1 INx

(IOD) Connector Single-axis Inverter Note 10

Module Status (MS) Connector

I/O - A

I/O - B

COM

INx

(IOD) Connectors Dual-axis Inverter
Note 10

PE Ground Note 11

Grounding Screws/Jumpers Note 15
PE Ground Note 11

PE Ground Note 11

Bonded Cabinet Ground Bus *

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Appendix A Interconnect Diagrams

In this example, three-phase AC input power is fed to the 8720MC-RPS190 unit. The DC-bus (TB1) terminals connect to the Kinetix 5700 DC-bus via the DC-bus conditioner module because the system current exceeds 104 A.

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

324...506V AC rms Three-phase Input
Note 3

8720MC-EF190-VB AC Line Filter

TB1

Circuit

Protection *

TB1

L1 L2 L3

CN2
A1 A2 A3 A4 A5 B1 B2 B3 B4 B5
CN4
R1 1 S1 2 T1 3
CN1
MC1 A1 MC2 A2 +24V2 A3 0V2 A4
NC A5 +24V3 B1
0V3 B2 SENS-out B3
+24V B4 MC B5

Figure 169 - 8720MC-RPS190 Unit with Kinetix 5700 Drive System

Refer to table on page 341 for note information.

L1 8720MC-LR10-100B L4

L2 Line Reactor

Fan 2

8720MC-RPS190BM Regenerative Power Supply
TB1

YLW

BLK

RED

Note 6

RED

L1
L2
L3 Note 6

L1 8720MC-LR10-100B L4

L2 Line Reactor

Fan 3

YLW

BLK

TB2 RED L1 AUX WHT L2 AUX BLU L3 AUX
PR1
PR2
PR3

TB4 +24V3
0V3 SENS +24V2 0V2 MC1 MC2

Circuit

TB1

Protection *

DC+

DC-

DC Bus to Kinetix 5700 Drive System

MC * TB3 Note 12 MC 0V COM RDY

Regeneration OK to Digital Inputs

Note 6
+24V DC PWR

Aux Contact to Control String

* Indicates User Supplied Component

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Refer to table on page 341 for note information.

8720MC-RPS190 Unit with Kinetix 5700 Drive System (continued)
2198-DCBUSCOND-RP312 2198-CAPMOD-2240 DC-bus Conditioner Module Capacitor Module

Circuit Protection *

2198-Sxxx -ERSx Inverter

2198-Dxxx -ERSx Inverter
Note 8
Additional Inverters

DC Bus From P Regenerative N Power Supply
Bonded Cabinet Ground Bus *

Note 23
Chassis Customer Supplied
+24V DC Power Supply *
Note 6

DC+

DC-

Note 26

2 1

24V_COM +24V

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

24V_COM +24V
2198-H040-P-T T-connector and Bus Bar

24V_COM +24V
2198-xxxx-P-T T-connector and Bus Bar

DC+ DC Bus DC- (DC) Connectors
24V_COM Control Power +24V (CP) Connectors
2198-xxxx-P-T T-connector and Bus Bar

Note 26

Regeneration OK From TB3-RDY

Digital Inputs * Indicates User Supplied Component

Aux Contact to Control String

Start * Stop *
CR1*

Refer to Attention statement

(Note 17).

CR1*

2 MS 1 MS
Note 6

Module Status (MS) Connector

2 1

MS MS

I/O
2 COM 1 INx

(IOD) Connector Single-axis Inverter Note 10

Module Status (MS) Connector

I/O - A

I/O - B

COM

INx

(IOD) Connectors Dual-axis Inverter
Note 10

PE Ground Note 11

Grounding Screws/Jumpers Note 15
PE Ground Note 11

PE Ground Note 11

Bonded Cabinet Ground Bus *

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Appendix A Interconnect Diagrams

356

In this example, three-phase AC input power is fed to the Bulletin 8720MC-RPS065 regenerative power supply. The DC-bus voltage supplies the Kinetix 5700 DC-bus via the 2198-CAPMOD-2240 capacitor module. In configurations that exceed 104 A, up to a maximum of 208 A, the DC-bus conditioner module is also required.

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

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Figure 170 - 8720MC-RPS with Kinetix 5700 Drive System

324...506V AC rms Three-phase Input
Note 3

Refer to table on page 341 for note information.

Circuit Protection *
Three-phase AC Line Filter
Note 5

Bonded Cabinet Ground Bus *
Harmonic Filter E/N
R S T

Varistor Motor Fan Fusing *
To Motor Fan

MC * Note 12
Aux Contact

Customer Supplied 120V AC

Line Reactors
Note 16 MC

8720MC-RPS065 8720MC
Regenerative Power Supply

Note 23

TB1

R L1
S L2
T L3

TB1 P
DC+ N
DC-
Bonded Cabinet Ground Bus *

TB3

Contactor * MC

TB2

Note 12 0V

R1 L1 AUX

COM

S1 L2 AUX

RDY

T1 L3 AUX

Aux Contact

PR1

PR2

PR3

MC1

+24V DC

MC2

PWR

2198-DCBUSCOND-RP312 DC-bus Conditioner Module
Circuit Protection *
Note 23

2198-CAPMOD-2240 Capacitor Module
2198-Sxxx -ERSx Inverter

2198-Dxxx -ERSx Inverter
Note 8

Circuit Protection *

Additional Inverters

Chassis

DC+

DC-

DC+ DC Bus DC- (DC) Connectors

Customer Supplied +24V DC
Power Supply * Note 6
Digital Inputs
Note 6

2 1

24V_COM +24V

2198-TCON-24VDCIN36 24V Input Power Wiring Connector

2 1 MS
MS

24V_COM +24V
2198-H040-P-T T-connector and Bus Bar
2 1

24V_COM +24V

24V_COM Control Power +24V (CP) Connectors

2198-xxxx-P-T T-connector and Bus Bar
I/O

2198-xxxx-P-T T-connector and Bus Bar

I/O - A

I/O - B

COM (IOD) Connector COM

COM

INx Single-axis Inverter INx

INx

Module Status (MS) Connectors

(IOD) Connectors Dual-axis Inverter
Note 10

2 1 MS
MS
PE Ground Note 11

PE Ground Note 11

* Indicates User Supplied Component

Stop * CR1*

Start *

Refer to Attention statement (Note 17). CR1*

Grounding Screws/Jumpers Note 15

Bonded Cabinet Ground Bus *

Interconnect Diagrams Appendix A

Capacitor Module Status Wiring Example

You can configure either of the DC-bus power supply digital inputs as Bus Capacitor OK in the Logix Designer application to monitor the Module Status output. Refer to page 201 to see how the DC-bus power supply Digital Inputs category is configured.

Figure 171 - DC-bus Power Supply with Capacitor Module

2198-Pxxx DC-bus Power Supply

2198-CAPMOD-2240 Capacitor Module

Module Status

(MS) Connector

Digital Input INx (1) (IOD) Connector COM

24V DC

(1) Configure either of two digital inputs as Bus Capacitor OK. For DC-bus power supply configurable functions, see the DC-bus Power Supply Configurable Functions table on page 101.
Refer to the Kinetix 5700 Capacitor Modules Installation Instructions, publication 2198-IN008, for additional installation information.

DC-bus Conditioner Module Status Wiring Example

You can configure any of the regenerative bus supply digital inputs as Bus Conditioner OK in the Logix Designer application to monitor the Module Status output. Refer to page 205 to see how the regenerative bus supply Digital Inputs category is configured.

Figure 172 - Regenerative Bus Supply with DC-bus Conditioner Module

2198-RPxxx Regenerative Bus Supply

2198-DCBUSCOND-RP312 DC-bus Conditioner Module

Module Status

(MS) Connector

Digital Input INx (1) (IOD) Connector COM

24V DC

(1) Configure any one of four digital inputs as Bus Conditioner OK. For regenerative bus supply configurable functions, see the Regenerative Bus Supply Configurable Functions table on page 102.
Refer to the Kinetix 5700 DC-bus Conditioner Module Installation Instructions, publication 2198-IN016, for additional installation information.

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Appendix A Interconnect Diagrams

Contactor Wiring Examples

We recommend that you wire an Allen-Bradley® (Bulletin 100) auxiliary contactor to the 2198-RPxxx regenerative-bus supply digital input (IOD connector) and configure AC Line Contactor OK to monitor three-phase input power. Use the Normally Open (N.O.) auxiliary contact, if more than one auxiliary contact is available.

Figure 173 - Contactor Wiring for DC-bus Power Supply

2198-Pxxx DC-bus Power Supply

Allen-Bradley Bulletin 100 Contactor

Contactor Enable

CONT EN+

24V DC

(CED) Connector

CONT EN

CONT EN+ CONT EN

AC Input Power (IPD) Connector

2198-DBRxx-F AC Line Filter

Figure 174 - Contactor Wiring for Regenerative Bus Supply

2198-RPxxx Regenerative Bus Supply

Allen-Bradley Bulletin 100 Contactor

Contactor Enable

CONT EN+

24V DC

(CED) Connector

CONT EN

CONT EN+ CONT EN

AC Input Power (IPD) Connector

21A9C8-LDinBeRxx-F ACFLiilnteerFilter

Digital Input INx (IOD) Connector COM

AUX N.O. AUX N.C.

24V DC
(1) Configure digital input #2 as AC Line Contactor OK (default setting). For regenerative bus supply configurable functions, see the Regenerative Bus Supply Configurable Functions table on page 102.
Refer to IEC Contactor Specifications Technical Data, publication 100-TD013, for additional contactor related information.

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Passive Shunt Wiring Examples

Interconnect Diagrams Appendix A

Wiring from the Bulletin 2198 shunt modules and resistor are made directly to the shunt (RC) connector. You can configure either of the DC-bus power supply digital inputs as Shunt Thermal Switch OK in the Logix Designer application. Refer to page 201 to see how the DC-bus power supply Digital Input category is configured.

IMPORTANT

Passive shunts attach to only 2198-Pxxx DC-bus power supplies. Before wiring the Bulletin 2198 external shunt to the RC connector, remove the wires from the internal servo-drive shunt. Do not connect both internal and external shunt resistors to the DC-bus power supply.

ATTENTION: To avoid damage to the Kinetix 5700 drive system, wire the 2198-R014, 2198-R031, or 2198-R127 shunt thermal switch to a digital input on the DC-bus power supply and configure the Shunt Thermal Switch OK function in the Logix Designer application.

Figure 175 - DC-bus Power Supply with External Passive Shunt Module

2198-Pxxx DC-bus Power Supply
Shunt (RC) DC+ Connector SH

2198-R014, 2198-R031, and 2198-R127 External Passive Shunt Module

Resistor

Internal Shunt Digital Input INx (1) (IOD) Connector COM

Thermal Switch

24V DC

(1) Configure either of two digital inputs as Shunt Thermal Switch OK. For DC-bus power supply configurable functions, see the DC-bus Power Supply Configurable Functions table on page 101.
Figure 176 - DC-bus Power Supply with External Passive Shunt Resistor

2198-Pxxx DC-bus Power Supply

2198-R004 External Passive Shunt Resistor

Shunt (RC) DC+ Connector SH

Internal Shunt

Refer to the Kinetix 5700 Passive Shunt Module Installation Instructions, publication 2198-IN011, for additional installation information.

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Appendix A Interconnect Diagrams

Active Shunt Wiring Examples

Active shunts are available from the Rockwell Automation EncompassTM partner Powerohm Resistors, Inc. (http://www.powerohm.com).
IMPORTANT Powerohm Bulletin PKBxxx active shunt modules use built-in internal brake resistors. Bulletin PWBxxx active shunt modules require appropriately sized external brake resistors.
For compatible Powerohm active shunts paired with 2198-Pxxx DC-bus power supplies and 2198-RPxxx regenerative bus supplies, see External Activeshunt Connections on page 178.
ATTENTION: 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.

Figure 177 - 2198-RPxxx Supply with External Active Shunt (built-in brake resistor)

2198-RPxxx Regenerative Bus Supply

Shunt (RC) Connector

DC+ (1) DC

Powerohm Bulletin PKB-xxx-xxx Active Shunt Module

DC+

Resistor

4.6 m (15 ft) Maximum Cable Length

Digital Input INx (2) (IOD) Connector COM

24V DC

Fault Contact
(3) 9 10 120V AC

(1) The active shunt (RC) connector is rated for wire size up to 6 mm2 (10 AWG). When conductors larger than 6 mm2 (10 AWG) connect to the shunt, the drive connection must be made to the external DC-bus connections on an accessory module.
(2) Configure any available digital input as Shunt Thermal Switch OK. See the Digital Inputs Connector Pinouts on page 101. (3) Powerohm PKB050 and PKB050-800 shunts require 120V AC between pins 9 and 10 to supply power to the cooling fans.

Figure 178 - 2198 Power Supply with External Active Shunt (built-in brake resistor)

2198-Pxxx DC-Bus Power Supply
or

2198-xxxx-ERSx

2198-

Inverter CAPMOD-2240

Capacitor Module 4.6 m (15 ft) Maximum Cable Length

Powerohm Bulletin PKBxxx-xxx Active Shunt Module

2198-RPxxx

DC+

Regenerative Bus Supply

External DC-bus DC

DC+

Resistor

Digital Input (IOD) Connector

INx COM

(1)

3 4
24V DC

Fault Contact

(2) 9 10 120V AC

(1) Configure any available digital input as Shunt Thermal Switch OK. See the Digital Inputs Connector Pinouts on page 101. (2) Powerohm PKB050 and PKB050-800 shunts require 120V AC between pins 9 and 10 to supply power to the cooling fans.

See Knowledgebase document 1082776 for more information on wiring to these Powerohm Bulletin PKBxxx active shunts.

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Interconnect Diagrams Appendix A

IMPORTANT

Due to the 10 A connector current rating, connections to the Active Shunt (RC) connector on the regenerative bus supply are limited to Powerohm PKBxxx-xxx active shunts. PWBxxx-xxx active shunt connections must be made to the 2198-CAPMOD-2240 capacitor module.

Figure 179 - 2198 Power Supply with External Active Shunt (external brake resistor)

2198-Pxxx DC-Bus
Power Supply or
2198-RPxxx Regenerative Bus Supply

2198-xxxx-ERSx

2198-

Inverter CAPMOD-2240

Capacitor Module

DC+

Powerohm Bulletin PWBxxx-xxx Active Shunt Module

Powerohm External Passive Shunt Module

External DC Bus

DC+

4.6 m (15 ft) Maximum Cable Length

3 4

DC+

9.1 m (30 ft) Maximum Cable Length

Resistor

Fault Contact
9 10

(2)
120V AC

Digital Input (IOD) Connector
INx (1) COM

TS TS
24V DC

Thermal Switch

(1) Configure any available digital input as Shunt Thermal Switch OK. See the Digital Inputs Connector Pinouts on page 101. (2) Powerohm PWB050 and PWB050-800 shunts require 120V AC between pins 9 and 10 to supply power to the cooling fans.

See Knowledgebase document 1082777 for more information on wiring to these Powerohm Bulletin PWBxxx active shunts.
For more information on Powerohm products, refer to the documentation included with those products or online at (http://www.powerohm.com).

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Appendix A Interconnect Diagrams

Kinetix 5700 Servo Drive and Rotary Motor Wiring Examples

These Kinetix rotary motors use single cable technology. The motor power, brake, and feedback wires are all packaged in a single cable.
Figure 180 - Kinetix 5700 Drives with Kinetix VPL, VPC-Bxxxxx-Q, VPF, VPH, and VPS Motors

2198-Sxxx -ERSx or 2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8
Note 7
Cable Shield Clamp

Motor Power (MP) Connector

U4 V3 W2
1

Refer to table on page 341 for note information.
Brown Black Blue Green/Yellow

VPL-A/Bxxxx-C/P/Q/W, VPC-Bxxxxx-Q,
VPF-A/Bxxxx-C/P/Q/W, VPH-A/Bxxxx-C/Q/W, or VPS-BxxxD-P Motors with High-resolution
Feedback

A/U

B/V

Three-phase

C/W Motor Power

Black

Motor Brake MBRK +

(BC) Connector MBRK - 2

White

Note 20
F/+ G/

Motor Brake

Motor Feedback D+ 1 (MF) Connector D- 2
2198-KITCON-DSL Connector Kit

Blue White/Blue

Data+/EPWR+ Data-/EPWR-
Shield

2090-CSBM1DE-xxxAxx or 2090-CSBM1DE-xxxFxx
or 2090-CSBM1DG-xxxAxx or 2090-CSBM1DG-xxxFxx
Single Motor Cable
Note 19

E/1

Motor

H/2

Feedback

SpeedTec DIN Single Motor Connector
Power, Brake, and Feedback Connector

2090-CSxM1DE cables include the 2198-KITCON-DSL connector kit preassembled with the feedback conductors. 2090-CSxM1DG cables have flyingleads and the 2198-KITCON-DSL kit is ordered separately.

Figure 181 - Single Motor Cables for Kinetix 5700 Servo Drives

2090-CSBM1DE-xxxAxx 2090-CSBM1DE-xxxFxx

2198-KITCON-DSL Feedback Connector Kit

2090-CSWM1DE-xxxAxx (not shown)

2090-CSBM1DG-xxxAxx 2090-CSBM1DG-xxxFxx

Flying Leads

2090-CSWM1DG-xxxAxx (not shown)

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These Kinetix rotary motors have separate cables for motor power/brake and feedback connections.
Figure 182 - Kinetix 5700 Drives with Kinetix VPC-Y Continuous Duty Motors

2198-Sxxx -ERSx 2198-Dxxx -ERSx Kinetix 5700 Servo Drives

Refer to table on page 341 for note information.

VPC-Bxxxx-Y Continuous Duty Servo Motors with
High Resolution Feedback

Cable Shield

Clamp
Note 7

2 3 4

Motor Power (MP) Connector

V2 W1

7 8 Universal Feedback 9 (UFB) Connector

1 Motor Brake MBRK +

13 14

(BC) Connector MBRK - 2

Shield
Brown Black Blue Green/Yellow
2090-CPxM7DF-xxAAxx (standard) or
2090-CPxM7DF-xxAFxx (continuous-flex) Motor Power Cable Note 19
White
Black

A B C D
Note 20

V Three-phase W Motor Power

3 4

GND

6 Motor 9

Feedback 10

Thermostat

MBRK+

MBRK-

Motor Brake

CLK+ CLK-
DATA+ DATA+5VDC ECOM
TS

2198-K57CK-D15M Feedback
Connector Kit

RED

WHITE/RED

GREEN

WHITE/GREEN

GRAY

WHITE/GRAY

WHITE/ORANGE

COM

Refer to feedback kit illustration (lower left)

for proper grounding technique.

2090-CFBM7DF-CEAAxx (standard) or 2090-CFBM7DF-CEAFxx (continuous-flex)
(flying-lead) Feedback Cable Note 19

Grounding Techniques for Feedback Cable Shield
2198-K57CK-D15M Universal Feedback
Connector Kit

SpeedTec DIN Motor Connectors

Feedback Connector

Power Connector

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Clamp Screws (2)

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

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Appendix A Interconnect Diagrams

These compatible Allen-Bradley rotary motors have separate cables for motor power/brake and feedback connections.

Figure 183 - Kinetix 5700 Drives with Kinetix MPL, MPM, MPF, MPS, and VPC Motors

2198-Sxxx -ERSx or 2198-Dxxx -ERSx

Refer to table on page 341 for note information.

MPL-A/B15xx...MPL-A/B9xx, VPC-Bxxxxx-S and VPC-B3004x-M

2198-H2DCK Feedback

Kinetix 5700 Servo Drives
Note 8

MPM-A/Bxxx, MPF-A/Bxxx, and MPS-A/Bxxx Servo Motors with

Converter Kit or 2198-K57CK-D15M Feedback

Cable Shield

High Resolution Feedback

Connector Kit

Clamp
Note 7

3 4 5

Motor Power (MP) Connector

V2 W1

7 8

Universal Feedback

9 (UFB) Connector

Shield
Brown Black Blue Green/Yellow
2090-CPxM7DF-xxAAxx (standard) or
2090-CPxM7DF-xxAFxx (continuous-flex) Motor Power Cable Note 19

V Three-phase

W Motor Power

Note 20

GND

Motor 9

Feedback 10

Thermostat

SIN+ SIN-
COS+ COS-
DATA+ DATA+5VDC ECOM
+9VDC TS

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

White

MBRK+

Motor Brake MBRK +

14 15

(BC) Connector MBRK - 2

Black

MBRK-

Motor Brake

COM Refer to feedback kit

illustrations (lower left)

for proper grounding technique.

Motor Feedback (MF) Connector

D+ 1 D- 2

SpeedTec DIN

2090-CFBM7DF-CEAAxx (standard) or 2090-CFBM7DF-CEAFxx (continuous-flex)
(flying-lead) Feedback Cable Note 19, 24, 25

Grounding Techniques for

Motor Connectors

Feedback Cable Shield

Feedback Connector

Power Connector

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit
Clamp Screws (2)

14 11 10 7 6 5 4 3 2 1

Exposed shield secured under clamp.

Cable Clamp

Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006, for converter kit specifications.

2198-K57CK-D15M Universal Feedback
Connector Kit

Clamp Screws (2)

MPL-A/B15xx...MPL-A/B45xx Servo Motors with
Incremental Feedback

U Three-phase

V Motor Power

Note 20

Motor Feedback

9 10

13 Thermostat

MBRK+

MBRK

Motor Brake

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

AM+ AM-
BM+ BM-
IM+ IM+5VDC ECOM
TS

2198-K57CK-D15M Feedback
Connector Kit

BLACK

WHITE/BLACK

RED

WHITE/RED

GREEN

WHITE/GREEN

GRAY

WHITE/GRAY

ORANGE

WHITE/ORANGE

WHITE/BLUE

YELLOW

WHITE/YELLOW

COM

Refer to feedback kit illustrations (left) for proper grounding technique.
2090-XXNFMF-Sxx (standard) or 2090-CFBM7DF-CDAFxx (continuous-flex)
(flying-lead) Feedback Cable Notes 19, 25

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Figure 184 - Kinetix 5700 Drives with Kinetix HPK Servo Motors

2198-Sxxx -ERSx Kinetix 5700 Servo Drives
Note 8

Refer to table on page 341 for note information.

Cable Shield Clamp
Note 7

3 4 5

Motor Power (MP) Connector

V2 W1

7 8 Universal Feedback 9 (UFB) Connector

13 14 15

Motor Brake (BC) Connector

MBRK + MBRK -

Motor Feedback (MF) Connector

D+ 1 D- 2

Shield Brown Black Blue Green/Yellow
White Black

Kinetix HPK HPK-Bxxx and HPK-Exxx Asynchronous Servo Motors with High Resolution Feedback

Motor Connector Shell

V Three-phase

W Motor Power

GND

Motor 9

Feedback 10

13 Thermostat

BR+

BR-

Motor Brake

2198-H2DCK Feedback Converter Kit or
2198-K57CK-D15M Feedback Connector Kit

SIN+ SIN-
COS+ COS-
DATA+ DATA-
ECOM
+9VDC TS

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

COM Refer to feedback kit
illustrations (below) for proper grounding technique.
2090-CFBM7DF-CEAAxx (standard) or 2090-CFBM7DF-CEAFxx (continuous-flex)
(flying-lead) Feedback Cable Note 19

Grounding Techniques for Feedback Cable Shield

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit

2198-K57CK-D15M Universal Feedback
Connector Kit

Clamp Screws (2)

SpeedTec DIN Feedback Connector
Clamp Screws (2)

14 11 10 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Exposed shield secured under clamp.

Cable Clamp

Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006, for converter kit specifications.

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

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Appendix A Interconnect Diagrams

Figure 185 - Kinetix 5700 Drives with Kinetix RDB Direct Drive Motors

2198-Sxxx -ERSx or 2198-Dxxx -ERSx Kinetix 5700 Servo Drives

Cable Shield Clamp
Note 7

2 3 4

Motor Power V (MP) Connector W

7 8 Universal Feedback 9 (UFB) Connector

Refer to table on page 341 for note information.

RDB-Bxxxx Direct Drive Servo Motors with
High Resolution Feedback

Shield

Brown

Black

C/W

GND

Blue

B/V

V Three-phase

Green/Yellow

A/U

W Motor Power

2090-CPWM7DF-xxAAxx (standard) or
2090-CPWM7DF-xxAFxx (continuous-flex) Motor Power Cable Notes 19

Note 20

Motor Feedback

7 8 9

Thermistor

SIN+ SIN-
COS+ COS-
DATA+ DATACLK+ CLK+5VDC ECOM
TS

2198-K57CK-D15M Feedback
Connector Kit

BLACK

WHITE/BLACK

RED

WHITE/RED

GREEN

WHITE/GREEN

BROWN

WHITE/BROWN

GRAY

WHITE/GRAY

ORANGE

WHITE/ORANGE

Refer to feedback kit

COM

illustration (lower left)

for proper grounding technique.

2090-XXNFMF-Sxx (standard) or 2090-CFBM7DF-CDAFxx (continuous-flex)
(flying-lead) Feedback Cable Note 19

Grounding Techniques for Feedback Cable Shield
2198-K57CK-D15M Universal Feedback
Connector Kit

SpeedTec DIN Motor Connectors

Feedback Connector

Power Connector

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Clamp Screws (2)

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

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Interconnect Diagrams Appendix A

Kinetix 5700 Servo Drive and These Kinetix linear actuators use single cable technology. The motor power,

Linear Actuator Wiring

brake, and feedback wires are all packaged in a single cable.

Examples

Figure 186 - Kinetix 5700 Drives with Kinetix VPAR Electric Cylinders

2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8

Note 7
Cable Shield Clamp
Motor Power (MP) Connector

U4 V3 W2
1

Refer to table on page 341 for note information.
Brown Black Blue Green/Yellow

VPAR-Bxxxxx-P/Q/W Electric Cylinders with High-resolution
Feedback

A/U

B/V

Three-phase

C/W Motor Power

Black

Motor Brake MBRK +

(BC) Connector MBRK - 2

White

Note 20
F/+ G/

Motor Brake

Motor Feedback D+ 1 (MF) Connector D- 2
2198-KITCON-DSL Connector Kit

Blue White/Blue

Data+/EPWR+ Data-/EPWR-
Shield

2090-CSBM1DE-xxxAxx or 2090-CSBM1DE-xxxFxx
or 2090-CSBM1DG-xxxAxx or 2090-CSBM1DG-xxxFxx
Single Motor Cable
Note 19

E/1

Motor

H/2

Feedback

SpeedTec DIN Single Motor Connector
Power, Brake, and Feedback Connector

2090-CSxM1DE single cables include the 2198-KITCON-DSL connector kit pre-assembled with the feedback conductors. 2090-CSxM1DG cables have flying-leads and the 2198-KITCON-DSL kit is ordered separately. See the single cable examples on page 362.

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Appendix A Interconnect Diagrams

These compatible linear actuators have separate connectors and cables for power/brake and feedback connections.
Figure 187 - Kinetix 5700 Drives with LDAT-Series Linear Thrusters

2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8

Refer to table on page 341 for note information.

LDAT-Sxxxxxx-xDx Linear Thrusters with High Resolution Feedback

Cable Shield

Clamp
Note 7

Shield

2 3 4

Motor Power (MP) Connector

7 8

Universal Feedback

9 (UFB) Connector

4 U3 V2 W1

Brown Black Blue Green/Yellow
2090-CPWM7DF-xxAAxx (standard) or
2090-CPWM7DF-xxAFxx (continuous-flex)

A B C D

V Three-phase 3 W Motor Power 4

GND

Motor 10

Feedback

11 12

Motor Feedback D+ 1

(MF) Connector D- 2

Motor Power Cable Notes 19, 21

13 14 Thermostat 12

Grounding Techniques for Feedback Cable Shield

SpeedTec DIN Motor Connectors

SIN+ SIN-
COS+ COS-
DATA+ DATA-
ECOM
+9VDC TS

2198-H2DCK Feedback Converter Kit or
2198-K57CK-D15M Feedback Connector Kit

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

Refer to feedback kit

COM

illustrations (lower left)

for proper grounding technique.

2090-CFBM7DF-CEAAxx (standard) or 2090-CFBM7DF-CEAFxx (continuous-flex)
(flying-lead) Feedback Cable Note 19

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit
Clamp Screws (2)

Feedback Connector

Power Connector

LDAT-Sxxxxxx-xBx Linear Thrusters with Incremental Feedback

2198-K57CK-D15M Feedback
Connector Kit

14 11 10 7 6 5 4 3 2 1

Exposed shield secured

Cable Clamp

under clamp.

Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, D publication 2198-IN006, for converter kit specifications.

2198-K57CK-D15M Universal Feedback
Connector Kit

V Three-phase 3

W Motor Power 4

GND

Motor 9

Feedback 10

AM+ AM-
BM+ BM-
IM+ IM+5VDC ECOM
TS

BLACK

WHITE/BLACK

RED

WHITE/RED

GREEN

WHITE/GREEN

GRAY

WHITE/GRAY

ORANGE

WHITE/ORANGE

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Clamp Screws (2)

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

Thermostat

WHITE/BLUE

YELLOW

WHITE/YELLOW

COM

Refer to Universal feedback connector kit illustration (left) for proper grounding technique.
2090-XXNFMF-Sxx (standard) or 2090-CFBM7DF-CDAFxx (continuous-flex)
(flying-lead) Feedback Cable Notes 19

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Interconnect Diagrams Appendix A

Figure 188 - Kinetix 5700 Drives with Kinetix MPAS Linear Stages

2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8

Refer to table on page 341 for note information.

MPAS-Bxxxxx-VxxSxA Ballscrew Linear Stages with High Resolution Feedback

Cable Shield

Clamp Note 7

Shield

2 3 4

Motor Power (MP) Connector

V W

2 1

Brown Black Blue Green/Yellow

V Three-phase 3

W Motor Power 4

5
6 7 Universal Feedback 8 (UFB) Connector

2090-CPxM7DF-xxAAxx (standard) or
2090-CPxM7DF-xxAFxx (continuous-flex)

GND

Motor 10

Feedback 11

9 10

Motor Power Cable Note 19

Thermostat

White

MBRK+

Motor Brake MBRK +

13 14

(BC) Connector MBRK - 2

Black

MBRK-

Motor Brake

Motor Feedback D+ 1 (MF) Connector D- 2

SIN+ SIN-
COS+ COS-
DATA+ DATA-
ECOM
+9VDC TS

2198-H2DCK Feedback Converter Kit or
2198-K57CK-D15M Feedback Connector Kit

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

Refer to feedback kit

COM

illustrations (lower left) for proper grounding technique.

2090-CFBM7DF-CEAAxx (standard) or 2090-CFBM7DF-CEAFxx (continuous-flex)
(flying-lead) Feedback Cable Notes 19, 22

Grounding Techniques for Feedback Cable Shield

SpeedTec DIN Motor Connectors

Feedback Connector

Power Connector

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit
Clamp Screws (2)

MPAS-Bxxxxx-ALMx2C Direct Drive Linear Stages with
Incremental Feedback

2198-K57CK-D15M Feedback
Connector Kit

14 11 10 7 6 5 4 3 2 1

Exposed shield secured

Cable Clamp

under clamp.

D Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions,

publication 2198-IN006, for converter kit specifications.

2198-K57CK-D15M Universal Feedback
Connector Kit

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Clamp Screws (2)

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

U Three-phase

V Motor Power 4

Motor 6

Feedback 9

Thermostat

AM+ AM-
BM+ BM-
IM+ IM+5VDC ECOM
TS

BLACK

WHITE/BLACK

RED

WHITE/RED

GREEN

WHITE/GREEN

GRAY

WHITE/GRAY

ORANGE

WHITE/ORANGE

S1
S2 S3 COM

WHITE/BLUE

YELLOW

WHITE/YELLOW

Refer to Universal feedback connector kit illustration (left) for proper grounding technique.
2090-XXNFMF-Sxx (standard) or 2090-CFBM7DF-CDAFxx (continuous-flex)
(flying-lead) Feedback Cable Notes 19, 22

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Appendix A Interconnect Diagrams

Figure 189 - Kinetix 5700 Drives with Kinetix MPAR and MPAI Electric Cylinders

2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8

Refer to table on page 341 for note information.

Cable Shield

Clamp
Note 7

Shield

2 3 4

Motor Power (MP) Connector

V W

2 1

Brown

Black

Blue

Green/Yellow

5 6 Universal Feedback 7 (UFB) Connector

Refer to Table 177 for motor power cable.
Notes 19

9 10 11

1 Motor Brake MBRK + (BC) Connector MBRK - 2

White Black

F G

13 14 15

Motor Feedback D+ 1 (MF) Connector D- 2

MPAR-Bxxxxx and MPAI-Bxxxxx Electric Cylinders with
High Resolution Feedback

V Three-phase

W Motor Power

GND

Motor Feedback

6 9

MBRK+

Thermostat

11 13

MBRK-

Motor Brake

Grounding Techniques for Feedback Cable Shield

2198-H2DCK Feedback Converter Kit or
2198-K57CK-D15M Feedback Connector Kit

SIN+ SIN-
COS+ COS-
DATA+ DATA-
ECOM
+9VDC TS

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

Refer to feedback kit

COM

illustrations (lower left) for proper grounding technique.

Refer to Table 177 for (flying-lead) motor feedback cable.
Note 19

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit

2198-K57CK-D15M Universal Feedback
Connector Kit

SpeedTec DIN Motor Connectors

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

14 11 10 7 6 5 4 3 2 1

Exposed shield secured under clamp.

Clamp Screws (2)
Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006, for converter kit
specifications.
Cable Clamp
Exposed shield secured under clamp.

Feedback Connector

Power Connector

Clamp Screws (2) Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.
Cable Clamp

Table 177 - Kinetix MPAR and MPAI Electric Cylinders Power and Feedback Cables

Frame

Kinetix MPAR and MPAI Electric Cylinders Cat. No.

Power Cable Cat. No.

MPAR-B1xxx (series A and B) MPAR-B2xxx (series A and B) MPAR-B1xxx (series B and C)

32 2090-XXNPMF-16Sxx (standard) or 40 2090-CPxM4DF-16AFxx (continuous-flex)
32

MPAR-B2xxx (series B and C) MPAR-B3xxx MPAI-B2xxxx MPAI-B3xxxx

2090-CPxM7DF-16AAxx (standard) or 2090-CPxM7DF-16AFxx (continuous-flex)

MPAI-B4xxxx

110

MPAI-B5xxxx

144

Feedback Cable Cat. No. 2090-XXNFMF-Sxx (standard) or 2090-CFBM4DF-CDAFxx (continuous-flex)
2090-CFBM7DF-CEAAxx (standard) or 2090-CFBM7DF-CEAFxx (continuous-flex)

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Interconnect Diagrams Appendix A

Figure 190 - Kinetix 5700 Drives with LDC-Series Linear Motors (cable connectors)

2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8

LDC-SeriesTM LDC-Cxxxxxx-xHTx1 Linear Motor Coil with

Cable Shield Clamp Note 7

Sin/Cos or TTL External Encoder and Cable Connectors
Shield

1 2 3 4

Motor Power (MP) Connector

4 U3 V2

Brown Black Blue

A B C

Green/Yellow

6 Universal Feedback

2090-CPWM7DF-xxAAxx

7 (UFB) Connector 8

(standard) or 2090-CPWM7DF-xxAFxx

(continuous-flex) Motor Power Cable

10 11

Motor Feedback D+ 1

Notes 19, 23

12 13

(MF) Connector D- 2

Thermostat 12

W Three-phase

Motor Power

GND

Motor 17

Feedback 10

6 5

4 3

2 1

1 4
2 5
3 6 8 7

Refer to table on page 341 for note information.

2198-H2DCK Feedback Converter Kit or
2198-K57CK-D15M Feedback Connector Kit

WHT/ORANGE

WHT/BLUE

YELLOW

WHT/YELLOW

ECOM +5VDC

WHT/GRAY

GRAY

IM-

WHT/GREEN

IM+

GREEN

COS- (BM-)

WHT/RED

COS+ (BM+)

RED

SIN- (AM-)

WHT/BLACK

SIN+ (AM+)

BLACK

2090-XXNFMF-Sxx (standard) or 2090-CFBM7DF-CDAFxx (continuous-flex)
(flying-lead) Feedback Cable Note 19

Refer to feedback connector kit illustrations (lower left)
for proper grounding technique.

SIN+ (AM+) SIN- (AM-) COS+ (BM+) COS- (BM-) IM+ IMPOWER COM

External Sin/Cos or (TTL)
Encoder

Grounding Techniques for Feedback Cable Shield

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit
Clamp Screws (2)

2198-K57CK-D15M Universal Feedback
Connector Kit

SpeedTec DIN Motor Connectors

Feedback Connector

Power Connector

Clamp Screws (2)

14 11 10 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Exposed shield secured under clamp.

Cable Clamp

Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006, for converter kit
specifications.

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

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Appendix A Interconnect Diagrams

2198-Dxxx -ERSx Kinetix 5700 Servo Drives
Note 8

Cable Shield

Clamp

Note 7

Motor Power (MP) Connector

U4 V3 W2
1

Figure 191 - Kinetix 5700 Drives with LDC-Series Linear Motors (flying-lead cables)

Refer to table on page 341 for note information.

RED

WHITE

BLACK

GREEN/YELLOW

TS+

BLACK

TS-

BLACK

LDC-Cxxxxxx-xHTx0 Linear Motor Coil with Sin/Cos or TTL External Encoder and Flying-lead Cables

Three-phase Motor Power

GND

Thermostat

Motor Feedback D+ 1 (MF) Connector D- 2

11 12 13 8 1 Universal Feedback 2 (UFB) Connector 3 4
5 10
14 6

TS+ S1 S2 S3 SIN+ (AM+) SIN- (AM-) COS+ (BM+) COS- (BM-)
IM+
IM-
POWER
COM

POWER S1 S2 S3 COM

RED WHITE BLUE ORANGE BLACK

Wire as shown using cable type appropriate for
your application.

SIN+ (AM+) SIN- (AM-) COS+ (BM+) COS- (BM-) IM+ IMPOWER COM

Hall Effect Module
External Sin/Cos or (TTL)
Encoder

Grounding Techniques for Feedback Cable Shield

2198-H2DCK Hiperface-to-DSL Feedback Converter Kit
Clamp Screws (2)

2198-K57CK-D15M Universal Feedback
Connector Kit

Clamp Screws (2)

14 11 10 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Exposed shield secured under clamp.

Cable Clamp

Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006, for converter kit
specifications.

Exposed shield secured under clamp.

Cable Clamp

Refer to Universal Feedback Connector Kit Installation Instructions, publication 2198-IN010, for connector kit specifications.

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System Block Diagrams
L1 Three-phase L2 Input Power (IDP) Connector L3

Interconnect Diagrams Appendix A
This section provides block diagrams of the Kinetix 5700 drive modules.
Figure 192 - DC-bus Power Supply Block Diagram
Shunt Resister (RC) Connector
Internal Shunt Resistor
DC+
DC Bus Power (DC) Connector
DC

DC+ SH

Ground Screw (1) Chassis

Contactor Enable CONT EN+ (CED) Connector
CONT EN

24V Control Power 24V+ (CP) Connector 24V

Control

(1) Ground screw in the installed (default) configuration.

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Appendix A Interconnect Diagrams

Figure 193 - Regenerative Bus Supply Block Diagram

Active Shunt (RC) Connector

DC+ DC

L1 Three-phase
Input Power L2 (IDP) Connector
L3

CONV OK+
Contactor Enable CONV OK (CED) Connector
CONT EN+
CONT EN
24V Control Power 24V+ (CP) Connector 24V

Ground Screw (1) Chassis
+ 24V DC
Control

(1) Ground screw in the installed (default) configuration.

DC+ DC Bus Power (DC) Connector
DC

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DC+
DC Bus Power (DC) Connector
DC
BR+ Motor Brake (BC) Connector
BR
24V+ 24V Control Power
(CP) Connector 24V

Figure 194 - Single-axis Inverter Block Diagram

Interconnect Diagrams Appendix A

Ground Jumper (1)

Chassis

U V Motor Power W (MP) Connector

Control
(1) Ground jumper installed on 2198-Sxxx-ERS3 (series A) drives. Ground jumper removed on 2198-Sxxx-ERS4 and 2198-Sxxx-ERS3 (series B) drives.

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Appendix A Interconnect Diagrams DC+

Figure 195 - Dual-axis Inverter Block Diagram

DC Bus Power (DC) Connector

U V Motor Power W (MP) Connector - A
Chassis

DC
BR+ Motor Brake (BC) Connector - A
BR
BR+ Motor Brake (BC) Connector - B
BR
24V+ 24V Control Power
(CP) Connector 24V
376

Ground Jumper (1)

Chassis

U V Motor Power W (MP) Connector - B

Control
(1) Ground jumper installed on 2198-Sxxx-ERS3 (series A) drives. Ground jumper removed on 2198-Sxxx-ERS4 and 2198-Sxxx-ERS3 (series B) drives.
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DC+
DC-bus Power (DC) Connector
DC

Figure 196 - iTRAK Power Supply Block Diagram
2x DC-DC Converters
H
L DC-
Ground Jumper (1) Chassis

24V Control Power 24V+ (CP) Connector 24V

Control

Interconnect Diagrams Appendix A

DCL H

DC-bus Output IDC Connector - A

Chassis 24V+ 24V Control Output 24V ICP Connector - A
Chassis

DCL H

DC-bus Output IDC Connector - B

Chassis 24V+ 24V Control Output 24V ICP Connector - B
Chassis

Chassis Ground Connection (2)
(1) Ground screw in the installed (default) configuration. (2) Connection from 24V- to Chassis is made inside of the iTRAK power supply.

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Appendix A Interconnect Diagrams
DC Bus Output DC+ Lug Connector DC

Figure 197 - Capacitor Module Block Diagram Fuse Detection

Module Status Status Indicator
MS Module Status MS (MS) Connector

DC-bus Detection

DC-bus Status Status Indicator

DC Bus Input DC+ Link Connector
DC

Fuse

DC+

Capacitor Bank

Bleeder Resistor
DC

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DC Bus Output DC+ Lug Connector
DC
DC Bus Input DC+ Link Connector
DC Chassis

Interconnect Diagrams Appendix A Figure 198 - DC-bus Conditioner Module Block Diagram

Fuse Detection and Over Temperature
Protection

Module Status Status Indicator
MS Module Status MS (MS) Connector

DC-bus Detection

DC-bus Status Status Indicator

Conditioning Circuit Fuse

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Appendix A Interconnect Diagrams
Notes:

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Before You Begin

Upgrade the Drive Firmware

B Appendix

This appendix provides procedures for upgrading your Kinetix® 5700 drive firmware.

Topic

Page

Before You Begin

381

Upgrade Your Firmware

383

Verify the Firmware Upgrade

393

You can upgrade your Kinetix 5700 drive firmware by using either of these two methods:
· ControlFLASH PlusTM software · ControlFLASHTM software
To upgrade drive firmware, you must configure a path to your drive, select the drive module to upgrade, and complete the firmware upgrade procedure.
TIP We recommend that you use ControlFLASH Plus software for firmware upgrades. See the ControlFLASH Plus Quick Start Guide, publication CFP-QS001, for more information.

For firmware upgrades, you must use the following software revisions.

Table 178 - Kinetix 5700 System Requirements

Description

Firmware Revision

Logix Designer application RSLinx® software (1) FactoryTalk® Linx software (2) ControlFLASH software kit (3) ControlFLASH Plus software kit (3)

26.00.00 or later 3.60.00 or later 6.20.00 or later 12.01.00 or later 3.01 or later

(1) Required only when using ControlFLASH software. (2) Required only when using ControlFLASH Plus software. (3) Download the ControlFLASH software kit from the Product Compatibility and Download Center at: rok.auto/pcdc. For more
ControlFLASH software information (not Kinetix 5700 specific), refer to the ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-UM105.

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Appendix B Upgrade the Drive Firmware

Gather this information before you begin your firmware upgrade. · Network path to the targeted Kinetix 5700 drives you want to upgrade. · Catalog numbers of the targeted Kinetix 5700 drives you want to upgrade.
IMPORTANT Control power must be present at CP-1 (24V+) and CP-2 (24V-) prior to upgrading your target module.

IMPORTANT For the DC-bus power supply and inverter modules, the axis state on the LCD display must be STANDBY, CONFIGURING, or PRECHARGE before beginning this procedure.

IMPORTANT The axis state on the LCD display must be STANDBY, when Protected mode is enabled. See Table 109 on page 189 for more information.

IMPORTANT

For iTRAK® power supplies configured for normal (non-standalone) operation, the axis state on the LCD display must be in the STANDBY state. If Protected Flash Update is disabled in the Settings Menu, the device can also be in either the CONFIGURING or PRECHARGE state. See Table 112 on page 192 for more information.

IMPORTANT

For iTRAK power supplies configured for standalone operation, the axis state on the LCD display must be in the START INHIBITED state. See iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002, for information on upgrading firmware on iTRAK L16 motor modules.

ATTENTION: To avoid personal injury or damage to equipment during the firmware upgrade due to unpredictable motor activity, do not apply threephase AC or common-bus DC input power to the drive.

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Upgrade the Drive Firmware Appendix B
Inhibit the Module
You must inhibit the Kinetix 5700 drive prior to performing the firmware upgrade. Follow these steps to inhibit a module.
1. Open your Logix Designer application. 2. Right-click the 2198-xxxx-ERSx servo
drive you configured and choose Properties. The Module Properties dialog box appears. 3. Select the Connection category.

Upgrade Your Firmware

4. Check Inhibit Module. 5. Click OK. 6. Save your file and download the program to the controller. 7. Verify that the network (NET) and module (MOD) status indicators
are flashing green.

Use either ControlFLASH Plus software or ControlFLASH software to upgrade your firmware.

Table 179 - Firmware Upgrade Software

Software Upgrade Procedure ControlFLASH Plus ControlFLASH

Go to Page 384 387

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Appendix B Upgrade the Drive Firmware

Use ControlFLASH Plus Software to Upgrade Your Drive Firmware
Follow these steps to select the Kinetix 5700 drive to upgrade. 1. Start ControlFLASH Plus software. TIP You can choose to select and upgrade the firmware for all drive modules in your system. However, in this procedure only one drive is selected for a firmware upgrade.
2. Click the Flash Devices tab. If the device is not already present in Browsing from path:, complete these steps:
a. Click .

b. In the Network Browser dialog box, locate and select the device to upgrade.

c. Click OK.
3. On the Flash Devices tab, verify that the check box to the left of the device is selected.

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Upgrade the Drive Firmware Appendix B
4. From the Flash To pull-down menu, choose one of these methods for choosing the desired firmware revision: · Latest from Download Center · Latest on Computer TIP If you have already downloaded the firmware, choose Latest on Computer and select the desired revision. Otherwise, choose Latest from Download Center and select the desired revision.
In this example, the Latest on Computer method is chosen.
5. Click Next. 6. If a warning dialog box appears, read the warning, complete any
recommendations, and click Close.

7. After acknowledging all warnings and confirming the desired revisions, click Flash.

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Appendix B Upgrade the Drive Firmware

The Status bar appears to show the progress of the firmware update. Also, the status display scrolls `Updating. Do Not Turn Off', which indicates that the upgrade is in progress.

After the upgrade information is sent to the drive, the drive resets and performs diagnostic checking.
After the download, the drive applies the new firmware and reboots. This can take several minutes.
IMPORTANT Do not cycle power to the drive during this process. A power cycle results in an unsuccessful firmware upgrade and an inoperable module.
After the drive reboots, ControlFlash Plus software indicates success or failure of the update.

8. When the upgrade has completed, click Close. 9. To complete the process and close the application, click Done.
IMPORTANT You must return to the drive Module Properties>Connection category to clear the Inhibit Module checkbox before resuming normal operation.

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Upgrade the Drive Firmware Appendix B
Use ControlFLASH Software to Upgrade Your Drive Firmware
Before using ControlFLASH software you need to configure the communication path by using RSLinx software.
Configure Your Communication Path with RSLinx Software
This procedure assumes that your communication method to the target device is the Ethernet network. It also assumes that any Ethernet communication module or Logix 5000TM controller in the communication path has already been configured.
For more controller information, see Additional Resources on page 13.
Follow these steps to configure the communication path to the target device.
1. Open your RSLinx Classic software. 2. From the Communications menu, choose Configure Drivers.
The Configure Drivers dialog box appears.

3. From the Available Driver Types pull-down menu, choose Ethernet devices.
4. Click Add New. 5. The Add New RSLinx Classic Driver dialog box appears. 6. Type the new driver name.
7. Click OK.

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Appendix B Upgrade the Drive Firmware

The Configure driver dialog box appears.

8. Type the IP address of your Ethernet Module or Controller that bridges between the Ethernet network and the EtherNet/IPTM network.
9. Click OK.
The new Ethernet driver appears under Configured Drivers.

10. Click Close. 11. Minimize the RSLinx application dialog box.

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Upgrade the Drive Firmware Appendix B
Start the ControlFLASH Software
Follow these steps to start ControlFLASH software and begin your firmware upgrade.
1. In the Logix Designer application, from the Tools menu, choose ControlFLASH. TIP You can also open ControlFLASH software by choosing Start>Programs>FLASH Programming Tools>ControlFLASH. The Welcome to ControlFLASH dialog box appears.
2. Click Next. The Catalog Number dialog box appears.

TIP If your catalog number does not appear, click Browse, select the monitored folder where the firmware kit (DMK files) is located. Click Add and OK.
3. Select your drive module. In this example, the 2198-D006-ERS3 servo drive is selected.
4. Click Next.

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Appendix B Upgrade the Drive Firmware

The Select Device to Update dialog box appears.

5. Expand your Ethernet node, Logix backplane, and EtherNet/IP network module.
6. Select the servo drive to upgrade. 7. Click OK.
The Firmware Revision dialog box appears.

8. Select the firmware revision to upgrade. 9. Click Next.
The Summary dialog box appears.

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Upgrade the Drive Firmware Appendix B
10. Confirm the drive catalog number and firmware revision. 11. Click Finish.
This ControlFLASH warning dialog box appears.

12. To begin the firmware update, click Yes. This ControlFLASH warning dialog box appears.
13. Acknowledge the warning and click OK. The Progress dialog box appears and updating begins.
After the upgrade information is sent to the drive, the drive resets and performs diagnostic checking. 14. Wait for the Progress dialog box to time out.

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It is normal for this process to take several minutes.
IMPORTANT Do not cycle power to the drive during this process. A power cycle results in an unsuccessful firmware upgrade and an inoperable module.
15. Verify that the Update Status dialog box appears and indicates success or failure as described below.

Upgrading Status Success
Failure

If
Update complete appears in a green Status dialog box, then go to step 16.
Update failure appears in a red Status dialog box, then refer to the ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-UM105 for troubleshooting information.

16. Click OK.
IMPORTANT You must return to the drive Module Properties>Connection category to clear the Inhibit Module checkbox before resuming normal operation.

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Upgrade the Drive Firmware Appendix B
Verify the Firmware Upgrade Follow these steps to verify your firmware upgrade was successful.
TIP Verifying the firmware upgrade is optional. 1. Open your RSLinx software. 2. From the Communications menu, choose RSWho.
3. Expand your Ethernet node, Logix backplane, and EtherNet/IP network module.
4. Right-click the drive module and choose Device Properties. The Device Properties dialog box appears.
5. Verify the new firmware revision level. 6. Click Close.

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Appendix B Upgrade the Drive Firmware
Notes:

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Shared DC-bus Configurations

C Appendix
Size Multi-axis Shared-bus Configurations

This appendix provides information and examples for sizing your Kinetix® 5700 drive system power supplies and inverters in multi-axis sharedbus configurations.

Topic

Page

Shared DC-bus Configurations

395

System Sizing Guidelines

397

System Sizing Example

403

System Sizing Application Example

404

You can supply power to your Kinetix 5700 shared DC-bus system configuration from 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 supply

Shared DC-bus Definitions

Throughout this manual, these terms are used to describe how drive modules are grouped together.

Table 180 - Shared-bus Terminology

Term DC-bus group Cluster
Extended cluster Power supply cluster Extended DC-bus

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Appendix C Size Multi-axis Shared-bus Configurations

In this example, two drive clusters in the same cabinet are connected by the same 276...747V DC-bus voltage. Kinetix 5700 capacitor modules provide connection points for the DC bus. The extension module is needed only when the DC-bus system current exceeds 104 A, and can support up to 208 A maximum external DC-bus current.

Figure 199 - Extended DC-bus Installation

Kinetix 5700 Extended Servo Drives Cluster 2 (front view)

Extension Capacitor Module Module

Dual-axis Inverters

Shared DC-bus and

24V DC Control Power

MOD

DC BUS

NET

DC-bus Extension

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

MODULE STATUS

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+ D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

195...528V AC Three-phase Input Power
Line Disconnect Device
Circuit Protection
Magnetic (M1) Contactor

Bulletin 2198 Shared-bus Connection System
(24V shared-bus connection system is optional)
Magnetic Contactor (M1) Control String

2198-P208 DC-bus Power Supplies

MOD NET

2
1 1 4
I/O

Kinetix 5700 Servo Drives Cluster 1 (front view)

Single-axis Dual-axis Capacitor Extension Inverter Inverters Module Module

DC-bus Extension

MOD NET

MOD DC BUS

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

MODULE STATUS

D+ D-
MF

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

ATTENTION: 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.

2198-DBR200-F AC Line Filter
(required for CE)

1321-3R80-B

Circuit

Line Reactors

Protection (required components)

Bonded Cabinet Ground Bus

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.

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Size Multi-axis Shared-bus Configurations Appendix C
General Sizing Guidelines
These limitations apply to Kinetix 5700 servo drive systems supplied by a single 2198-Pxxx or multiple 2198-P208 DC-bus power supplies, or 2198-RPxxx regenerative bus supplies:
· The sum of the inverter motor-power cable lengths for all inverters on the same DC bus-sharing group must not exceed 1200 m (3937 ft) to comply with CE requirements when used with 2198-DBRxx-F line filters. 2198-DBxx-F line filters have a total motor cable length limit of 400 m (1312 ft). See Drive to Motor Cable Lengths on page 153 for additional motor power cable-length limitations.
· The total system capacitance limit is based on the power supply catalog number. DC-bus groups must not exceed the limits as defined in Table 181.
· No more than three 2198-P208 DC-bus power supplies can be used to increase the converter power.
· 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.
· The Kinetix 5700 system can have multiple drive clusters in a single DC-bus group. See DC Bus Cluster-to-Cluster Cable Lengths on page 150 for more information on extended clusters.
Refer the 8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001, for additional system sizing limitations.

System Sizing Guidelines

You begin the process by selecting the motor for your application and sizing the drive and power supply combinations. Next, calculate whether the motor power cable length, total system capacitance, and 24V current demand are within specifications.
For systems with an iTRAK® power supply, the iTRAK system requirements must be calculated to determine the following:
· Kinetix 5700 DC-bus loading (DC-bus motoring and bus-regulation power requirements)
· 2198-Pxxx power supply for providing DC-bus to the iTRAK power supplies
· 24V current demand · Number of iTRAK power supplies required · Resulting net converter power and bus-regulator capacity
See iTRAK System with TriMax Bearings User Manual, publication 2198TUM002, or iTRAK 5730 System User Manual, publication 2198T-UM003.
For iTRAK hardware and iTRAK power supplies, proceed to the Calculate System and External-bus Capacitance on page 398.

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Appendix C Size Multi-axis Shared-bus Configurations

Select Drive/Motor Combinations
The motor required for a particular application determines the servo drive required for full motor performance.
For best results, use the Motion Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com. Drive/motor performance specifications and torque/speed curves are also available in the Kinetix 5700 Drive Systems Design Guide, publication KNX-RM010.

Select the Power Supply and Define the DC-bus Groups
· Determine the converter DC-bus motoring and bus-regulation power requirements based on the load profile.
· Estimate the net converter and inverter power and bus-regulator capacity, based on the load profiles.
· Determine if 2198-CAPMOD-2240 capacitor modules are required. · Determine if 2198-DCBUSCOND-RP312 DC-bus conditioner
modules are required.
For best results, use the Motion Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com.

Calculate System and External-bus Capacitance

Total system capacitance is the sum of all internal capacitance values from each of the drive modules (single-axis inverters, dual-axis inverters, power supplies, and capacitor modules) in the same DC-bus group.
The total system capacitance must be less than the maximum supported DC-bus capacitance value of the power supply.

IMPORTANT

If your total system capacitance value exceeds the maximum supported capacitance value of the DC-bus power supply, perform one of the following:
· Increase the size of the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply
· Use multiple DC-bus power supplies (1...3 power supplies are possible)
Decrease the total system capacitance by removing inverters or capacitor modules from the DC-bus group.

External bus capacitance is the total system capacitance minus the power supply capacitance. The external bus capacitance must be entered into the Logix Designer application for a regenerative power supply to maintain proper control.

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Power Supply Single DC-bus Power Supply Multiple DC-bus Power Supplies Regenerative Bus Supplies iTRAK Power Supply

Size Multi-axis Shared-bus Configurations Appendix C

Table 181 - Power Supply Capacitance

DC-bus Power Supply Cat. No. 2198-P031 2198-P070 2198-P141 2198-P208 2198-P208 x 2 2198-P208 x 3 2198-RP088 2198-RP200 2198-RP263 2198-RP312 2198T-W25K-ER

Supported Capacitance, max F
8,000
13,000
26,000 39,000 9,000 15,000
25,000
390

Internal Capacitance F 585 780 1640 2050 4100 6150 940 2460 4510 5740 0

Table 182 - Internal Inverter and Accessory Module Capacitance

Drive Module
Dual-axis Inverters
Single-axis Inverters Capacitor Module Extension Module DC-bus Conditioner Module

Drive Module Cat. No. 2198-D006-ERSx 2198-D012-ERSx 2198-D020-ERSx 2198-D032-ERSx 2198-D057-ERSx 2198-S086-ERSx 2198-S130-ERSx 2198-S160-ERSx 2198-S263-ERSx 2198-S312-ERSx 2198-CAPMOD-2240 2198-CAPMOD-DCBUS-IO 2198-DCBUSCOND-RP312

Internal Capacitance F
165
330 390 705 560 840 1120
2050
2240 0 0

Calculate the Total Motor Power Cable Length
To meet CE requirements, the sum of all motor power cable lengths from the same DC-bus group must not exceed 1200 m (3937 ft) when 2198-DBRxx-F line filters are used. See Drive to Motor Cable Lengths on page 153 for additional motor power cable-length limitations.

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Appendix C Size Multi-axis Shared-bus Configurations

Calculate 24V DC Control Power Current Demand

If using the 24V DC shared-bus connection system to distribute control input power to a drive cluster, output current from the 24V power supply must not exceed 40 A.

Table 183 - Control Power Current Specifications

Drive Module DC-bus Power Supplies

Drive Module Cat. No.
2198-P031 2198-P070 2198-P141 2198-P208

24V Current Per Module (non-brake motor)

24V Current, max (with maximum brake current)

24V Inrush Current (5)

ADC

0.8

4.0

1.9

2198-RP088

4.3

2198-RP200

5.4

Regenerative Bus Supplies

4.0

2198-RP263

9.1

2198-RP312

2198-D006-ERSx

2198-D012-ERSx

1.4 (2)

5.5 (3)

Dual-axis Inverters

2198-D020-ERSx

4.0

2198-D032-ERSx

1.7 (2)

7.7 (3)

2198-D057-ERSx

2.3 (2)

8.3 (3)

2198-S086-ERSx

2198-S130-ERSx

Single-axis Inverters

2198-S160-ERSx

4.6

9.6 (4)

4.0

2198-S263-ERSx

2198-S312-ERSx

iTRAK Power Supply (1) 2198T-W25K-ER

1.3

2.2

Capacitor Module

2198-CAPMOD-2240 0.1

7.0

Extension Module

2198-CAPMOD-DCBUS-IO

DC-bus Conditioner Module 2198-DCBUSCOND-RP312 0.1

7.0

IMPORTANT

If the 24V control-power output current (based on your system calculation) exceeds 40 A, you can insert another control-power input wiring connector at any point in your drive cluster. However, the input connector must always extend the 24V DC-bus from left to right.

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Size Multi-axis Shared-bus Configurations Appendix C

24V DC Voltage Drop Calculation Example

1606-XLxxx 24V DC Control Power Allen-Bradley
1606-XL
Power Supply
(customer-supplied)
Input
AC Input Power
Kinetix 5700 Drive System (front view)

In this example, the 24V DC power supply is 21.3 m (70 ft) away from the Kinetix 5700 drive system. The drive system includes one 2198-RP312 regenerative bus supply, two 2198-S312-ERS4 single-axis inverters, and two 2198-D057-ERS4 dual-axis inverters. The inverters supply power to six nonbrake motors.

Figure 200 - 24V DC Voltage Drop Example System

21.3 m (70 ft)
2198-RP312 Regenerative Bus Supply

2198-S312-ERS4 Single-axis Inverter

Input Wiring Connector

MOD NET

I/O

OK+

EN+

2198-S312-ERS4 Single-axis Inverter

MOD NET

I/O

2198-D057-ERS4 Dual-axis Inverters

MOD NET

24V DC Shared Bus Control Power

I/O-A

I/O-B

10 5

UFB-A

UFB-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

21mm2 (4 AWG-250 kcmil) 15-20 Nm (132-177 lbin)

Follow these steps to calculate the voltage drop for your drive system. The system conditions remain the same, but the wire gauge (AWG) is increased to reduce the voltage drop.
1. Determine the 24V DC control power current demand.
In this example, the total current demand is 22.9 A. See Calculate 24V DC Control Power Current Demand on page 400 for current values.

Module 2198-RP312 2198-S312-ERS4 2198-D057-ERS4 Total current demand

Qty Current Demand 1 9.1 A 2 4.6 · 2 = 9.2 A 2 2.3 · 2 = 4.6 A
22.9 A

2. Determine the voltage drop across the wire that is used to supply 24V power to the drive system (voltage drop = current draw · resistance of the wire).

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You must obtain the wire resistance value from the wire manufacturer. Resistance values used below are only examples.

Wire Length 21.3 m (70 ft)

Wire Gauge Calculation mm2 (AWG)
1.5 (16) 22.9 A · 0.281
4.0 (12) 22.9 A · 0.111
6.0 (10) 22.9 A · 0.070

Voltage Drop
6.43V 2.54V 1.60V

3. Determine if the voltage supplied to the drive system is within its required input-voltage range; 24V ±10% (21.6...26.4V DC).

Wire Length 21.3 m (70 ft)

Wire Gauge
1.5 (16)
4.0 (12)
6.0 (10)

Calculation
24V 6.43V 24V 2.54V 24V 1.60V

Applied Voltage
17.57V (insufficient) 21.46V (insufficient) 22.40V (acceptable)

In this example, increasing the wire gauge to 6 mm2 (10 AWG) is one way to lower the voltage drop. See 24V Control Power Evaluation on page 47 for additional suggestions.

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Size Multi-axis Shared-bus Configurations Appendix C

System Sizing Example

This example shows how a single Kinetix 5700 drive cluster meets the total bus capacitance, power cable length, and 24V DC current limitations.
Figure 201 - Example DC-bus Group (single drive cluster)
2198-D006-ERSx Dual-axis Inverters 2198-D020-ERSx Dual-axis Inverters 2198-S086-ERSx Single-axis Inverter 2198-S160-ERSx Single-axis Inverter
2198-P208 DC-bus Power Supply

In this example, only 1 drive cluster defines the DC-bus group. · Maximum motor power cable length: 1200 m (3937 ft). See Drive to Motor Cable Lengths on page 153 for additional motor power cable-length limitations. Total motor power cable length is 337 m (1106 ft) · Maximum supported capacitance: 13,000 F Total system capacitance is 4840 F External bus capacitance is 4840-2050=2790 F · Maximum 24V DC control power current: 40 A Total 24V DC control power current is 20.3 A The Coil Current column shows how much of the 24V current is consumed by the motor brake circuit.
All of the total system values are within the acceptable range.

MOD NET

2
1 1 4
I/O

I/O

UFB

I/O

UFB

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

I/O-A

I/O-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

10 5

UFB-A

UFB-B

D+ D-
MF

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

D+

D-

MF-A

MF-B

MBRK
+

DC-bus Group Cat. No.

Internal Axis Capacitance
F

2198-P208 2198-S160-ERSx 2198-S086-ERSx 2198-D020-ERSx
2198-D020-ERSx
2198-D006-ERSx
2198-D006-ERSx

2050
1120
560
A 390
B
A 390
B
A 165
B
A 165
B
Totals 4840

Table 184 - System Sizing Example Data

Cable Length m (ft)
50 (164) 90 (295) 20 (66) 15 (49) 9 (30) 90 (295) 9 (30) 9 (30) 15 (49) 30 (98) 337 (1106)

Servo Motor

Servo Motor Cat. No.

Brake Option Yes/No

MPL-B980E

MPL-B660F

Yes

VPL-B1152F No

VPL-B1003C Yes

MPL-B310P

Yes

MPL-B310P

24V DC Control Power Current Calculations

Brake Current @ 24V DC A

24V Current (non-brake motor)

Total Current

ADC

1.9

4.6

2.1

4.6

6.7

1.4

0.50

1.4

2.4

0.50

1.4

1.9

1.4

3.6

16.7

20.3

For more information on motor and motor-brake specifications, refer to the Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001.

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Appendix C Size Multi-axis Shared-bus Configurations

System Sizing Application Example

This example shows how to size the DC-bus power supply for your multi-axis system by using the motor output power (kW). Sizing is based on the largest motor kW value in your drive system.

The Kinetix 5700 drive modules are zero-stacked and use the shared-bus connection system to extend power from the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply to multiple drive modules. For best results, use the Motion Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com.

Table 185 - Kinetix 5700 System Power Supply Continuous Output Power

DC-Bus Power Supply Cat. No.
2198-P031 2198-P070 2198-P141 2198-P208

Continuous Output Power kW
7
17
31
46

Regenerative Bus Supply Cat. No.

Continuous Output Power
kW

2198-RP088

2198-RP200

2198-RP263

119

2198-RP312

140

In this typical system, all axes are running in an asynchronous rapid acceleration/deceleration motion profile. Use this formula to calculate the minimum continuous output-power (kW) for your Kinetix 5700 drive system:

2198-Pxxx = Largest motor-rated kW x (axis-count x 0.6) + (axis-count x 0.2)

Table 186 - Motor/Drive System Example

Motor Quantity

Motor Cat. No.

Motor Rated Output (1) kW

Drive Cat. No.

MPM-B2153F

7.2

2198-S086-ERSx 2198-S086-ERSx

MPL-B660F

6.1

2198-S086-ERSx 2198-S086-ERSx

VPL-B0753

0.82

2198-D020-ERSx 2198-D020-ERSx

8 = axis count

(1) For more motor specifications, see the Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001.

Continuous Output Power, min (kW) = 7.2 x (8 x 0.6) + (8 x 0.2) kW = 7.2 x 4.8 + 1.6 kW = 36.16

In this example, the MPM-B2153F motor has the largest motor-rated output. As a result, the minimum continuous output-power = 36.16 kW, and the 2198-P208 DC-bus power supply or 2198-RP200 regenerative bus supply is required for the 8-axis system example.

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D Appendix
Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

This appendix provides information on maximum motor cable length limitations for Kinetix® 5700 drive systems.

Topic

Page

DC-bus Power Supply Configurations

406

Regenerative Bus Supply Configurations

409

Third-party Motor Configurations

410

Maximum motor cable lengths for the following configurations are dependent on these configuration variables:
· Kinetix 5700 power supply 2198-Pxxx DC-bus power supply 2198-RPxxx regenerative bus supply
· AC input power type WYE grounded WYE impedance grounded WYE/Delta corner grounded or ungrounded
· AC input voltage 240V AC 480V AC 400V AC
· Whether the regenerative bus supply is operating with DC bus regulation enabled or disabled For more information on DC bus voltage regulation, refer to DC-bus Voltage Regulation on page 40
· Whether the drive cluster includes a DC-bus conditioner module · Allen-Bradley® servo motor or actuator connected to the inverter

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Appendix D Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

DC-bus Power Supply Configurations

2198-RPxxx regenerative power supplies have the same maximum drive-tomotor cable length limits as 2198-Pxxx DC-bus power supplies when they operate with DC-bus regulation disabled.

Table 187 - DC-bus Power Supply (480V AC input)

AC Input Power Source Type

Motor/Actuator Cat. No.

Drive-to-Motor Cable Length, max
m (ft)

· LDAT-Sxxxxxx · LDC-Cxxxxxx · MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

· VPx-B063xx, VPx-B075xx · VPAR-B1xxxx, VPAR-B2xxxx

90 (295)

WYE Grounded

· MPL-B15xx, MPL-B2xx · MPAR-B1xxxx, MPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

20 (65)

· VPx-B100xx...VPx-B300xx · MPAR-B3xxxx · VPAR-B3xxxx · MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx · RDB-Bxxxxx

90 (295)

Delta Corner Grounded

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · MPAR-B1xxxx, MPAR-B2xxxx · VPAR-B1xxxx, VPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx
· VPx-B100xx...VPx-B300xx · MPAR-B3xxxx · VPAR-B3xxxx · MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx · RDB-Bxxxxx

15 (49.2) 50 (164)

· LDAT-Sxxxxxx · LDC-Cxxxxxx · MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

· VPx-B063xx, VPx-B075xx · VPAR-B1xxxx, VPAR-B2xxxx

90 (295)

· WYE Impedance Grounded (1) · WYE Ungrounded (2) · Delta Ungrounded (2)

· MPL-B15xx, MPL-B2xx · MPAR-B1xxxx, MPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

20 (65)

· VPx-B100xx...VPx-B300xx · MPAR-B3xxxx · VPAR-B3xxxx · MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx · RDB-Bxxxxx

90 (295)

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Table 188 - DC-bus Power Supply (400V AC input)

AC Input Power Source Type

Motor/Actuator Cat. No.

Drive-to-Motor Cable Length, max
m (ft)

· LDAT-Sxxxxxx · LDC-Cxxxxxx · MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

WYE Grounded

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · MPAR-B1xxxx, MPAR-B2xxxx · VPAR-B1xxxx, VPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

90 (295)

· VPx-B100xx...VPx-B300xx · MPAR-B3xxxx · VPAR-B3xxxx · MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx · RDB-Bxxxxx

90 (295)

Delta Corner Grounded

50 (164) 90 (295)

· LDAT-Sxxxxxx · LDC-Cxxxxxx · MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

· WYE Impedance Grounded (1) · WYE Ungrounded (2) · Delta Ungrounded (2)

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · MPAR-B1xxxx, MPAR-B2xxxx · VPAR-B1xxxx, VPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

90 (295)

· VPx-B100xx...VPx-B300xx · MPAR-B3xxxx · VPAR-B3xxxx · MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx · RDB-Bxxxxx

90 (295)

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Appendix D Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

Table 189 - DC-bus Power Supply (240V AC input)

AC Input Power Source Type

Servo Motor Cat. No.

Drive-to-Motor Cable Length, max
m (ft)

WYE Grounded

· VPx-A063xx, VPx-A075xx · MPL-A15xx, MPL-A2xx
· VPx-A100xx...VPx-A300xx · MPx-A3xxx...MPx-A5xxx · MPM-A115xx...MPM-A215xx

90 (295)

Delta Corner Grounded

· VPx-A063xx, VPx-A075xx · MPL-A15xx, MPL-A2xx
· VPx-A100xx...VPx-A300xx · MPx-A3xxx...MPx-A5xxx · MPM-A115xx...MPM-A215xx

50 (164) 90 (295)

· WYE Impedance Grounded (1) · WYE Ungrounded (2) · Delta Ungrounded (2)

· VPx-A063xx, VPx-A075xx · MPL-A15xx, MPL-A2xx
· VPx-A100xx...VPx-A300xx · MPx-A3xxx...MPx-A5xxx · MPM-A115xx...MPM-A215xx

90 (295)

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Regenerative Bus Supply Configurations

2198-RPxxx regenerative bus supplies have limited maximum drive-to-motor cable length when DC-bus regulation is enabled. However, the DC Bus can be extended up to 70 m (230 ft) to remote clusters of Kinetix 5700 inverters. The result is a shorter distance from the inverter to the motor and thus shorter individual motor cable lengths.

Table 190 - Regenerative Bus Supply (480V AC input)

AC Input Power Source Type (1)

Motor/Actuator Cat. No.

Drive-to-Motor Cable Length, max m (ft)

With DC-bus Conditioner

Without DC-bus Conditioner

· LDAT-Sxxxxxx · LDC-Cxxxxxx

· MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

WYE Grounded

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · VPAR-B1xxxx, VPAR-B2xxxx

· MPAR-B1xxxx, MPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

20 (65.6)

15 (49.2)

· VPx-B100xx...VPx-B300xx · VPAR-B3xxxx · MPAR-B3xxxx · RDB-Bxxxxx

· MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx

50 (164)

30 (98.4)

· LDAT-Sxxxxxx · LDC-Cxxxxxx

· MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

WYE Impedance Grounded (2)

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · VPAR-B1xxxx, VPAR-B2xxxx

· MPAR-B1xxxx, MPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

20 (65.6)

15 (49.2)

· VPx-B100xx...VPx-B300xx · VPAR-B3xxxx · MPAR-B3xxxx · RDB-Bxxxxx

· MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx

50 (164)

30 (98.4)

Table 191 - Regenerative Bus Supply (400V AC input)

AC Input Power Source Type (1)

Motor/Actuator Cat. No.

Drive-to-Motor Cable Length, max m (ft)

With DC-bus Conditioner

Without DC-bus Conditioner

· LDAT-Sxxxxxx · LDC-Cxxxxxx

· MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

WYE Grounded

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · VPAR-B1xxxx, VPAR-B2xxxx

· MPAR-B1xxxx, MPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

50 (164)

30 (98.4)

· VPx-B100xx...VPx-B300xx · VPAR-B3xxxx · MPAR-B3xxxx · RDB-Bxxxxx

· MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx

90 (295)

· LDAT-Sxxxxxx · LDC-Cxxxxxx

· MPAS-B8xxxF-ALM · MPAS-B9xxxL-ALM

10 (32.8)

WYE Impedance Grounded (2)

· VPx-B063xx, VPx-B075xx · MPL-B15xx, MPL-B2xx · VPAR-B1xxxx, VPAR-B2xxxx

· MPAR-B1xxxx, MPAR-B2xxxx · MPAS-Bxxxx1, MPAS-Bxxxx2 · MPAI-Bxxxxx

50 (164)

30 (98.4)

· VPx-B100xx...VPx-B300xx · VPAR-B3xxxx · MPAR-B3xxxx · RDB-Bxxxxx

· MPx-B3xxx...MPx-B9xxx · MPM-B115xx...MPM-B215xx · HPK-xxxxxx

90 (295)

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Appendix D Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

Third-party Motor Configurations

These tables provide maximum drive-to-motor cable lengths for third-party motors with Kinetix 5700 common-bus supplies.
IMPORTANT Kinetix 5700 drive systems do not support the use of disconnection devices between the servo drive and motor.

DC-bus Power Supply Configurations

These tables assume that no output reactor is used between the inverter and the motor. Contact Technical Support for help when applying output reactor solutions.

Table 192 - DC-bus Power Supply (480V AC input)

AC Input Power Source Type

Motor Insulation Rating (3)

Drive-to-Motor Cable Length, max (4) m (ft)

1000V

1200V WYE Grounded
1488V
1600V

15 (49.2) 90 (295)

1000V

1200V Delta Corner Grounded
1488V

30 (98.4)

1600V

90 (295)

· WYE Impedance Grounded (1) · WYE Ungrounded (2) · Delta Ungrounded (2)

1000V 1200V 1488V 1600V

15 (49.2)
90 (295)

(1) Impedance grounded systems running in ground fault conditions, for prolonged periods of time, cause additional stress to the motor insulation and can cause premature motor failure. (2) Unbalanced, floating, ungrounded systems can cause additional stress to the motor. (3) Motor Corona Inception Voltage (CIV) or Partial Discharge Inception Voltage (PDIV) ratings for motor phase-to-ground and phase-to-phase insulation systems. (4) Cable lengths are estimated assuming nominal DC-bus voltage at nominal AC line input voltage. Operation at high AC line voltage or increased DC-bus voltage for prolonged periods of time can cause
additional stress to the motor insulation and can cause premature motor failure.

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Table 193 - DC-bus Power Supply (400V AC input)

AC Input Power Source Type

Motor Insulation Rating (3)

Drive-to-Motor Cable Length, max (4) m (ft)

1000V

10 (32.8)

1200V WYE Grounded
1488V
1600V

50 (164) 90 (295)

1000V

1200V Delta Corner Grounded
1488V

15 (49.2) 50 (164)

1600V

90 (295)

· WYE Impedance Grounded (1) · WYE Ungrounded (2) · Delta Ungrounded (2)

1000V 1200V 1488V 1600V

10 (32.8) 50 (164)
90 (295)

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Appendix D Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies

Regenerative Bus Supply Configurations

These tables assume that no output reactor is used between the inverter and the motor. Contact Technical Support for help when applying output reactor solutions.

Table 194 - Regenerative Bus Supply (480V AC input)

AC Input Power Source Type (1)

Motor Insulation Rating (3)

Drive-to-Motor Cable Length, max (4) m (ft)

With DC-bus Conditioner

Without DC-bus Conditioner

1000V

1200V WYE Grounded
1488V

30 (98.4)

15 (49.2)

1600V

50 (164)

30 (98.4)

1000V

WYE Impedance Grounded (2)

1200V 1488V

30 (98.4)

15 (49.2)

1600V

50 (164)

30 (98.4)

(1) Corner-grounded and ungrounded input power can be used, but you must add an isolation transformer to the input power circuit to provide grounded-WYE power. Unbalanced, floating, or ungrounded systems can cause additional stress to the motor. For more information on these input power source types, see Input Power Configurations for Kinetix 5700 Power Supplies on page 123.
(2) Impedance grounded systems running in ground fault conditions, for prolonged periods of time, cause additional stress to the motor insulation and can cause premature motor failure. (3) Motor Corona Inception Voltage (CIV) or Partial Discharge Inception Voltage (PDIV) ratings for motor phase-to-ground and phase-to-phase insulation systems. (4) Cable lengths are estimated assuming nominal DC-bus voltage at nominal AC line input voltage. Operation at high AC line voltage or increased DC-bus voltage for prolonged periods of time can cause
additional stress to the motor insulation and can cause premature motor failure.

Table 195 - Regenerative Bus Supply (400V AC input)

AC Input Power Source Type (1)

Motor Insulation Rating (3)

Drive-to-Motor Cable Length, max (4) m (ft)

With DC-bus Conditioner

Without DC-bus Conditioner

1000V

1200V WYE Grounded
1488V
1600V

15 (49.2) 90 (295)

1000V

WYE Impedance Grounded (2)

1200V 1488V 1600V

15 (49.2) 90 (295)

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E Appendix
Regenerative Bus Supply Sequence Operation

In this appendix the sequencing of CIPTM axis states for Kinetix® 5700 regenerative bus supplies are explained. Timing diagrams illustrate when DC-bus voltage is applied and how the modules progress from PRECHARGE to RUNNING states. When in the RUNNING state, the regenerative bus supply is ready to provide full-line motoring and regenerative power to and from the Kinetix 5700 drive system.

Topic

Page

Converter Startup Method - Enable Request

414

Converter Startup Method - Automatic

417

Sequence Operation of Discharging

418

The Converter Startup Method is configured in the Studio 5000 Logix Designer® application. From the 2198-RPxxx module Axis Properties>General category, you can choose between Enable Request (default) and Automatic.
Figure 202 - Axis Properties>General Category

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Appendix E Regenerative Bus Supply Sequence Operation

Converter Startup Method Enable Request

When the Enable Request method is selected, a Motion Servo On (MSO) commend is required for the regenerative bus supply to transition from the STOPPED state to the RUNNING state.
Figure 203 - Sequence Operation of Precharging - Enable Request Method

DC-bus Voltage CIP Axis State INITIALIZING
CONT_EN Output Digital Input - Enable Enable Request (MSO)
DC Bus Up DC Bus Unload Power Structure Enabled Tracking Command

PRECHARGE

START INHIBITED

STOPPED

STARTING RUNNING

Initialization
The 2198-RPxxx regenerative bus supply uses the AB:MotionDevice_Diagnostics:S:0 tag data type.
Initialization consists of these four events: · A connection is established between the controller and regenerative bus supply, through a forward open request from the controller · The regenerative bus supply receives the configuration from the controller · The Group Sync Service synchronizes with the regenerative bus supply · The configuration and power are verified for the axes and associated modules in the Motion Group.
Following initialization, the regenerative bus supply transitions to the PRECHARGE state.

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Regenerative Bus Supply Sequence Operation Appendix E
Precharge
When initialization is complete, the contactor enable relay closes, causing the M1 contactor to close, and precharge begins through the DC-bus resistor (see Regenerative Bus Supply Configuration on page 348 for an example interconnect diagram).
There is approximately 2.4 seconds of DC-bus precharge time plus 1.0 second relay-closing time for approximately 3.4 seconds total precharge time. This is consistent across all four 2198-RPxxx units.
The DC-bus resistor is not field replaceable nor can we measure the resistance externally. Once in the PRECHARGE state, the DC Bus Up status goes high and the regenerative bus supply transitions to the START INHIBITED state.
Start Inhibited
The digital inputs associated with the regenerative bus supply can be configured to cause the Converter Axis CIP Drive to go to a START INHIBITED state.
Figure 204 - Configure Digital Inputs

Enable is the default setting for Digital Input 1. When the Enable input is wired in the system it provides the ability to physically control the transition into the RUNNING state.
External 24V DC to IN1 on the IOD connector through the Enable permissive circuit (possibly a red top mushroom E-stop) with 24V DC common to COM on the Digital Inputs (IOD) connector is required to remove the START INHIBITED condition.
See Contactor Wiring for Regenerative Bus Supply on page 358 for an example of how the digital input option is used.
If no Enable digital input is assigned or the correct inputs are seen, the regenerative bus supply moves to the STOPPED state.

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Appendix E Regenerative Bus Supply Sequence Operation
Stopped
With DC-bus Up high and DC-bus Unload low, the regenerative bus supply is in a STOPPED state.
When configured for Enable Request, a Motion Servo On (MSO) commend is required for the regenerative bus supply to transition from the STOPPED state to the RUNNING state.
· In the RUNNING state, the regenerative bus supply is ready to provide full-line motoring and regenerative power to and from the Kinetix 5700 drive system.
· While in the STOPPED state, the regenerative bus supply provides fullline motoring power, however, regeneration will not occur.
After issuing a Motion Servo On command, the regenerative bus supply transitions to the STARTING state.
Starting
When the regenerative bus supply is in the STARTING state, the PowerStructureEnabledStatus tag equals 1, the IGBTs turn on, and the DCbus increases by 5%. The regenerative bus supply then transitions to the RUNNING state.
Running
When the regenerative bus supply is in the RUNNING state, the TrackingCommandStatus tag equals 1 indicating that the regenerative bus supply is capable of both motoring and regenerating requirements.
The following code can be used to indicate that the regenerative bus supply is running and ready for both motoring and regeneration.
Figure 205 - Ready for Motoring and Regeneration

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Regenerative Bus Supply Sequence Operation Appendix E

Converter Startup Method Automatic

With the Automatic method, everything in the Enable Request sequence applies, except there is no STOPPED state or any need for the Motion Servo On (MSO) command. The regenerative bus supply automatically transitions to the RUNNING state.
Figure 206 - Sequence Operation of Precharging - Automatic Method

DC-bus Voltage

CIP Axis State INITIALIZING PRECHARGE

START INHIBITED

STARTING RUNNING

CONT_EN Output Digital Input - Enable Enable Request (MSO)

Enable Request (MSO) command not used in the Automatic method.

DC Bus Up

DC Bus Unload

Power Structure Enabled Tracking Command

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Appendix E Regenerative Bus Supply Sequence Operation

Sequence Operation of Discharging

In the discharging sequence, the regenerative bus supply begins in the RUNNING state and transitions to the STOPPED state following a Motion Servo Off (MSF) command. If a Motion Axis Shutdown (MASD) command is executed, the regenerative bus supply transitions to the SHUTDOWN state, and a Motion Axis Shutdown Reset (MASR) command must be executed to transition out of the SHUTDOWN state.
Figure 207 - Sequence Operation of Discharging - Enable Request Method

DC-bus Voltage CIP Axis State
CONT_EN Output Digital Input - Enable Enable Request (MSO) Shutdown Request (MASD)

RUNNING

DC Bus Up DC Bus Unload Power Structure Enabled Tracking Command

STOPPED

START INHIBITED

SHUTDOWN

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F Appendix
Motor Control Feature Support

This appendix provides feature descriptions for the induction motors and permanent-magnet motors that are supported by Kinetix® 5700 servo drives.

Topic

Page

Frequency Control Methods

420

Current Limiting for Frequency Control

424

Stability Control for Frequency Control

427

Skip Speeds

429

Flux Up

431

Current Regulator Loop Settings

434

Motor Category

434

Selection of Motor Thermal Models

440

Speed Limited Adjustable Torque (SLAT)

442

Motor Overload Retention

453

Phase Loss Detection

454

Velocity Droop

457

Commutation Self-sensing Startup

458

Commutation Test

460

Adaptive Tuning

460

Virtual Torque Sensor

461

Field Weakening Mode

462

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Appendix F Motor Control Feature Support

Frequency Control Methods

The Kinetix 5700 servo drives support three open-loop frequency control methods. These are the choices:
· Basic Volts/Hertz - This method is used in single asynchronous-motor applications
· Basic Volts/Hertz - Fan Pump - This method is similar to Basic Volts/ Hertz, but is specifically tailored for fan/pump applications
· Sensorless Vector with Slip Compensation - This method is used for most constant torque applications. Provides excellent starting, acceleration, and running torque

To configure your induction motor in the Logix Designer application, refer to Configure Induction-motor Frequency-control Axis Properties on page 233.

Open-loop frequency control is suitable in applications such as conveyors, pumps, and fans. Features include the following:
· Start Boost and Run Boost · Electronic motor thermal-overload protection per Class 10
requirements · Two skip frequencies, in which the drive does not operate · All three-phase induction motors, suitable for variable speed drive
(VFD) operation, are supported

Table 196 - Motor Specifications

Attribute

Value

Output frequency, max

590 Hz

Pole pairs, max Motor cable length, max

50 90 m (295 ft) (1)

(1) Applies to all Kinetix 5700 drives and compatible motors/actuators with Hiperface and Hiperface DSL high-resolution absolute feedback. For compatible motors/actuators with incremental feedback, 30 m (98 ft) is the maximum cable length.

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Motor Control Feature Support Appendix F

Basic Volts/Hertz

Volts/hertz operation creates a fixed relationship between output voltage and output frequency. Voltage is applied to the motor, which is based on the operating frequency command at a fixed volts/hertz ratio. The ratio is calculated from the motor nameplate data and entered into the Logix Designer application>Axis Properties>Frequency Control category.

The Basic Volts/Hertz method provides various patterns. The default configuration is a straight line from zero to rated voltage and frequency. As seen in Figure 208, you can change the volts/hertz ratio to provide increased torque performance when required by programming five distinct points on the curve.

Table 197 - Basic Volts/Hertz Definitions

Curve Feature Start boost
Run boost
Break voltage/frequency Motor nameplate voltage/ frequency Maximum voltage/frequency

Definition
Used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds.
Used to create additional running torque at low speeds. The value is typically less than the required acceleration torque. The drive lowers the boost voltage to this level when running at low speeds (not accelerating). This reduces excess motor heating that could result if the higher start/accel boost level were used.
Used to increase the slope of the lower portion of the Volts/Hertz curve, providing additional torque.
Sets the upper portion of the curve to match the motor design. Marks the beginning of the constant power region.
Slopes the portion of the curve that is used above base speed.

Figure 208 - Basic Volts/Hertz Method

Voltage, max
Base Voltage (nameplate)

Break Voltage Start/Accel Boost
Run Boost

Break Frequency

Base Frequency, (nameplate)

Frequency, max

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Appendix F Motor Control Feature Support

Basic Volts/Hertz for Fan/Pump Applications

The Basic Volts/Hertz Fan/Pump (fan/pump) method is based on the Basic Volts/Hertz (V/Hz) method, but is specifically tailored for fan/pump applications.
Figure 209 - Output Voltage Equation

Vx =

fx fn

Vn Vboost + Vboost

Where: Vx = Output voltage fx = Output frequency Vn = Rated voltage Fn = Rated frequency Vboost = Run boost voltage

For maximum system efficiency, fan/pump loads use variable frequency drives that are equipped with a specific V/Hz curve where voltage is proportional to square of the frequency.
Figure 210 - Basic Volts/Hertz Fan/Pump Method

Voltage, max

Base Voltage (nameplate)

Voltage

Run Boost

Frequency (Hz)

Base Frequency, Frequency, (nameplate) max

TIP The Fan/Pump control method supports the run-boost attribute, but does not support break-voltage, break-frequency, or start-boost.

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Motor Control Feature Support Appendix F

Sensorless Vector

Velocity Trim Velocity Command
+

The Sensorless Vector method uses a volts/hertz core enhanced by a current resolver, slip estimator, and a voltage-boost compensator based on the operating conditions of the motor.
Figure 211 - Sensorless Vector Method
Motor Pole Pairs

V/Hz

Voltage

Inverter

Motor

Control

Vboost Estimator

Slip Speed Slip Estimation

Torque Estimate

Load Torque Estimator

Current Resolver

Current Feedback

The algorithms operate on the knowledge of the relationship between the rated slip and torque of the motor. The drive uses applied voltages and measured currents to estimate operating slip-frequency. You can enter values to identify the motor resistance value or you can run a motor test to identify the motor resistance value (see Motor Tests and Autotune Procedure on page 436). Motor nameplate data and test results are ways to accurately estimate the required boost voltage.
The sensorless vector method offers better torque production and speed regulation over a wider speed range than basic volts/hertz.
Dynamic boost is applied internally to compensate voltage drop and improve starting torque.
Figure 212 - Approximate Load Curve

Voltage, max
Base Voltage (nameplate)

Dynamic Boost Applied

Ideal, volts/hertz
Base Frequency, Frequency, (nameplate) max

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Appendix F Motor Control Feature Support
Current Limiting for Frequency Control

The current limiting module prevents the OutputCurrent value from exceeding the OperativeCurrentLimit value when the drive is configured in Frequency Control mode.

Figure 213 - Current Limiting Module
Velocity from Planner (MAJ)

Fine Command Velocity

Velocity Reference

Operative

Current Limit

Output Current

In Frequency Control mode, OperativeCurrentLimit is the minimum value of the motor-thermal current limit, inverter-thermal current limit, motor-peak current limit, drive-peak current limit, and the CurrentVectorLimit value.

The Effects of Current Limiting
Indirect current limiting is available for induction motors configured for frequency control. You can use this feature to help prevent overcurrent faults due to aggressive acceleration/deceleration profiles or impact loads. The Current Limiting attribute uses a PI regulator to control the OutputCurrent by adjusting the velocity reference.

IMPORTANT When configured for Frequency Control (induction motors only), select the Decel and disable stopping action only when the Current Limiting feature is enabled.

Figure 214 - Effects of Current Limiting on an Aggressive Acceleration

Aggressive Acceleration, No Current Limiting

Aggressive Acceleration, Current Limiting Active

-10

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

Output Current

Operative Current Limit

Output Frequency

-10

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Time (ms)

Output Current

Operative Current Limit

Output Frequency

Output Current (Arms), Operative Current Limit (rms) Frequency (Hz)
Output Current (Arms), Operative Current Limit (rms) Frequency (Hz)

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Output Current (Arms), Operative Current Limit (rms) Frequency (Hz)
Output Current (Arms), Operative Current Limit (rms) Frequency (Hz)

Motor Control Feature Support Appendix F

Figure 215 - Effects of Current Limiting on an Impact Load

Impact Load, No Current Limiting
12

Impact Load, Current Limiting Active
70

0 4000 4200 4400
Output Current

-10 4600 4800 5000 5200 5400 5600 5800
Time (ms)

Operative Current Limit

Output Frequency

0 4000 4200 4400
Output Current

-10 4600 4800 5000 5200 5400 5600 5800
Time (ms)

Operative Current Limit

Output Frequency

Current limiting for frequency control is not enabled by default. You can enable via messaging by using the following device-specific attributes.
TIP We recommend you leave the Kp, Ki, Kd gains at the default values.

Attribute Offset

Type

3022 SINT

3023 REAL 3024 REAL 3025 REAL

Table 198 - Enable Current Limiting via Messaging

Attribute Name
Current Limiting Enable
Current Limiting Kd Current Limiting Ki Current Limiting Kp

Conditional Implementation
Frequency Control Induction Motor only

Description
When enabled, limits the rate of change to the velocity reference during high-current situations for improved current limiting. This feature is only active when executing an MDS command and when configured for Frequency Control. 0 = Current Limiting is disabled 1 = Current Limiting is enabled
Derivative gain for the current limiting function. Only functional when configured for Frequency Control and when executing an MDS command. Units of seconds.
Integral gain for the current limiting function. Only functional when configured for Frequency Control and when executing an MDS command. Units of feedback counts / (Amp, inst* Seconds).
Proportional gain for the current limiting function. Only functional when configured for Frequency Control and when executing an MDS command. Units of feedback counts / Amp, inst.

IMPORTANT For induction motors greater than 5 Hp, it is recommended that the Stability Control feature also be enabled when Current Limiting is enabled.

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Appendix F Motor Control Feature Support

Enable the Current Limiting Feature
In this example, a Message Configuration (MSG) instruction is configured to set the CurrentLimitingEnable attribute for axis 3 of a dual-axis inverter. The Instance field is used to direct the message to the proper axis. For single-axis inverters the value of 1 is used for Instance.

Set the CurrentVectorLimit Attribute Value
For current limiting, the CurrentVectorLimit attribute is used to help determine the OperativeCurrentLimit of the drive. Set the CurrentVectorLimit value to artificially lower OperativeCurrentLimit below the drive or motor peak current limits.
1. Select the Parameter List category and scroll to CurrentVectorLimit.

2. Set the CurrentVectorLimit value appropriate for your application.

IMPORTANT

The CurrentVectorLimit attribute appears in the Parameter List of the Logix Designer application, version 29.00 and later. If you are using a previous version, the CurrentVectorLimit attribute must be set via a Message Configuration (MSG) instruction.

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Stability Control for Frequency Control

Stability control is available for induction motors configured for frequency control. This feature can be used to help remove resonances that are sometimes seen on larger motors. The stability control feature adjusts the OutputFrequency and OutputVoltage commands to stabilize the OutputCurrent.

Id Feedback, Iq Feedback A-pk Id Feedback, Iq Feedback A-pk

Figure 216 - Effects of Stability Control

Id Feedback, Iq Feedback versus Commanded Speed with Stability Control Disabled
60

Id Feedback, Iq Feedback versus Commanded Speed with Stability Control Enabled
25

50 20
40 15
30

-10

-20 Commanded Frequency, Hz

Iq Feedback

Id Feedback

-5 Commanded Frequency, Hz

Iq Feedback

Id Feedback

Stability control for frequency control is not enabled by default. You can enable via messaging by using the following device-specific attributes.
TIP We recommend you leave the angle, voltage gains, and filter bandwidth at the default values.

Attribute Offset

Type

3026 SINT

3027 REAL 3028 REAL 3029 REAL

Table 199 - Enable Current Limiting via Messaging

Attribute Name

Conditional Implementation

Stability Control Enable

Stability Filter Bandwidth
Stability Voltage Gain

Frequency Control Induction Motor only

Stability Angle Gain

Description
Enables stability control when configured for frequency control. 0 = Stability Control is disabled 1 = Stability Control is enabled
Sets the bandwidth of the low-pass filter applied to the current feedback signal. This bandwidth is common to both the angle and voltage stability control algorithms. Units of radians/second.
The gain of the voltage stability control function. Only active when configured for frequency control. Units of Volt (inst,p-n)/Amp (inst).
The gain of the electrical angle stability control function. Only active when configured for frequency control. Units of radians/Amp (inst).

IMPORTANT Because the stability control feature works by manipulating the OutputVoltage and OutputFrequency signals, these signals may appear 'noisy' when the feature is enabled.

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Enable the Stability Control Feature
In this example, a Message Configuration (MSG) instruction is configured to enable the StabilityControl attribute for axis 3 of a dual-axis inverter. The Instance field is used to direct the message to the proper axis. For single-axis inverters the value of 1 is used for Instance.

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Skip Speeds

Motor Control Feature Support Appendix F

Some machines have a resonant operating frequency (vibration speed) that is undesirable or could cause equipment damage. To guard against continuous operation at one or more resonant points, you can configure the skip-speed attributes in the Logix Designer application>Axis Properties>Parameter List category.

The value that is programmed into the SkipSpeed1 or SkipSpeed2 attribute sets the central speed of a skip-speed band within which the drive does not operate. The width of the band is determined by the SkipSpeedBand attribute. The range is split, half above and half below the SkipSpeedx attribute. Any command set-point within this band is adjusted by the skip-speed feature to fall at either the upper or lower skip-speed band boundary value. The skipspeed feature contains hysteresis (25% of the SkipSpeedBand value) to prevent frequent switching of VelocityReference.

Figure 217 - Single Skip Speed Example

Speed

Velocity

Setpoint

SkipSpeedBand Upper Boundary SkipSpeed
SkipSpeedBand Lower Boundary

Velocity Reference

Time
A SkipSpeedBand value of 0 disables the skip-speed feature.
IMPORTANT When a single SkipSpeed value is desired, the SkipSpeed1 and SkipSpeed2 settings must be the same.
IMPORTANT Acceleration and deceleration are affected by the skip-speed feature. Too large of a SkipSpeedBand value can result in an overcurrent drive fault.
IMPORTANT The MaximumFrequency attribute is always enforced. Skip-speed band boundary values beyond the MaximumFrequency value do not apply.

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Multiple Skip Speeds
The Kinetix 5700 drives feature two independent skip-speed attributes (SkipSpeed1 and SkipSpeed2) that use the same SkipSpeedBand.
Figure 218 - Multiple Skip Speed Example

SkipSpeed2

SkipSpeedBand

Speed

SkipSpeed1

SkipSpeedBand

Time

When skip-speed band boundaries of SkipSpeed1 and SkipSpeed2 overlap, the skip-speed hysteresis is calculated using the effective skip band.

In Figure 219, SkipSpeed1 is set to 0 and SkipSpeed2 is set to 15 hz. The skip band is 10 Hz wide.

At point A the axis is enabled, and the motor begins to rotate at -5 Hz even though the command is 0 Hz. As the command reaches hysteresis point the output frequency begins to follow the command. During deceleration, when the command decreases to 0 Hz, the output frequency continues at 5 Hz until the axis is disabled (point B), or the command is changed outside of the skip band.

Figure 219 - Zero-speed Skip Frequency 30

25 20 15 10 5 0 -5 -10
0

SkipSpeed1 = 0 Hz SkipSpeed2 = 15 Hz Skip Band = 10 Hz

A B

5000 10,000 15,000 20,000 25,000 30,000 35,000 40,000

Output Frequency

Command Frequency

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Flux Up

Frequency

Motor Control Feature Support Appendix F
AC induction motors require that flux builds in the motor stator before controlled torque can develop. To build flux, voltage is applied. There are two methods to flux the motor and three configurable FluxUpControl settings.
With the No Delay setting (normal start), flux is established when the output voltage and frequency are applied to the motor. While flux is building, the unpredictable nature of the developed torque can cause the rotor to oscillate even though acceleration of the load can occur. In the motor, the acceleration profile does not follow the commanded acceleration profile due to the lack of developed torque.
Figure 220 - Acceleration Profile during Normal Start - No Flux Up
Frequency Reference
Rated Flux
Stator Rotor
Oscillation due to flux being established. 0
Time
With the Automatic setting (default) DC current is applied to the motor so that flux builds before rotation. The flux-up time period is based on the level of flux-up current and the rotor time constant of the motor. The flux-up current is not adjustable.
In the Manual setting, DC current is applied to the motor so that flux builds before rotation. The flux-up time period is determined by the FluxUpTime attribute. The flux-up current is not adjustable.
Figure 221 - Flux Up Current versus Flux Up Time
Flux Up Current = Maximum DC Current

Flux Up Current

Rated Flux Current

Rated Motor Flux

0 T1 T2 T3 T4 Flux Up Time
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Once rated flux is reached in the motor, normal operation can begin and the desired acceleration profile achieved.
Figure 222 - Rated Flux Reached

Flux Up Voltage

IR Voltage - SVC Greater of IR Voltage or Voltage Boost - V/Hz

Stator Voltage Rotor Speed Motor Flux
Stator Frequency

Flux Up

Normal Operation Time

Flux Up Attributes

Access Attribute

Conditional Implementation

558

Set Flux Up Control

Ind Motor only 0 = No Delay 1 = Manual Delay 2 = Automatic Delay

559

Set

Flux Up Time (1)

Ind Motor only Units: Seconds Default: 0.0000 Min/Max: 0.0000 / 1000.00

(1) This is the time designated for the Manual Delay setting. This attribute is not supported by the Automatic delay method. The flux-up feature is disabled if FluxUpControl is set to Manual Delay and FluxUpTime is set to 0.

FluxUpControl Attribute

When the motion axis is enabled, DC current is applied to an induction motor to build stator flux before transitioning to the Running state. This attribute controls how an induction motor is to be fluxed in the Starting state prior to transitioning to the Running state.

Table 200 - FluxUp Control Delay Methods

Delay Method No delay Manual delay
Automatic delay

Description
The axis transitions immediately to the Running state while the motor flux is building.
The axis remains in the Starting state while the motor stator flux is building according to the Flux Up Time attribute.
The drive determines the amount of delay time to fully flux the motor based on the motor configuration attribute data or measurements.

FluxUpTime Attribute

When FluxUpControl is configured for Manual Delay, this attribute sets the length of delay time to fully flux the motor before transitioning to the Running state.

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Configure the Flux Up Attributes
Follow these steps to configure the flux-up attributes. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to FluxUpControl.

3. From the FluxUpControl pull-down menu, choose the proper delay value appropriate for your application.
4. If you chose Manual Delay in step 3, enter a value in the FluxUpTime attribute appropriate for your application. If you chose No Delay or Automatic Delay in step 3, the FluxUpTime attribute does not apply.

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Current Regulator Loop Settings

Current loop bandwidth is set differently based on the selected motor type.

Table 201 - Current Regulator Loop Settings

Motor Type
Rotary permanent magnet Rotary interior permanent magnet Linear permanent magnet Rotary induction

Default Torque/Current Loop Bandwidth Hz
1000
400

IMPORTANT

The Logix Designer application does not perform calculations when the Torque/Current Loop Bandwidth attribute is updated. This bandwidth affects many other gains and limits. Changing, (lowering) the torque loop bandwidth without updating all the dependent attributes can result in drive/motor instability.

Motor Category

From the Motor category you can enter motor nameplate or datasheet values (phase-to-phase parameters) for rotary induction motors.
In this example, the Motor category>Nameplate / Datasheet parameters, were taken from a typical motor performance datasheet. Max Speed and Peak Current values are typically application dependent.
Figure 223 - Motor Nameplate / Datasheet Example

See Figure 224 for motor manufacturer performance data sheet example.

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Figure 224 - Motor Manufacturer Performance Data Sheet
C E R T I FI C AT I ON DAT A SHE E T T Y PI C AL MOT OR PE R FOR MANC E DAT A

HP kW

. 75

SY NC. R PM 1800

F.L. R PM 1725

F R AME 56C

ENCL OSUR E TENV

K V A CODE P

DESIG N A

PH Hz 3 60

VOLTS 23406/0

FL AMPS 3/ 1.5

STAR T TY PE INV ER TER ONL Y

DUT Y C ONTINUOUS

INSL S.F . AMB°C

1. 0

ELEVATION 3300

F UL L L O AD E F F : 84 F UL L L O AD PF : 75

3/4 L O AD E F F : 82.5 3/4 L O AD PF : 65.5

1/2 L O AD E F F : 78.5 1/2 L O AD PF : 51

G TD. EFF 81. 5

ELEC. TYPE SQ CAGE INV DUTY

NO LOAD AMPS

2 /

F.L. TOR QUE 3 L B -F T

LOCK ED ROTOR AMPS 30 / 15

L.R . TOR QUE 10.8 L B -F T 360%

B.D. TOR QUE 15 L B -F T 500%

F .L . R ISE°C 65

SOUND PR ESSUR E @ 3 FT. 62 dB A
R1 8. 378

SOUND POW ER 72 dB A

R O T O R W K ^2 0.11 L B -F T ^2

M A X . W K ^2 0 L B -F T ^2

SAFE STAL L TIME 0 SE C.

STAR TS / H O UR
0

APPR OX . MOTOR WGT
42 L B S .

E QUI V AL E NT W Y E C K T .PAR AME T E R S (OHMS PE R PHASE )

5. 6232

10. 7068

9. 9116

XM 278. 036

ZR EF

T D0

11132. 8

284

1. 7

0. 0071

0. 136

Motor>Model Category

From the Motor>Model category you can enter additional motor nameplate or datasheet values (phase-to-neutral parameters) for induction motors.
The Motor>Model parameters are used in closed-loop induction-motor control mode, sensorless vector control mode, and when FluxUp is enabled, and are estimated automatically by the Logix Designer application based on the motor nameplate data. You can also enter these parameter values directly from the motor nameplate/datasheet or indirectly by running a Motor>Analyzer test.
Figure 225 - Phase-to-Neutral Parameters

IMPORTANT If you do not know the Stator Leakage, Rotor Leakage, Stator Resistance, Rated Flux Current, and system inertia, you can run the static motor test and Autotune procedure to determine the parameter values.

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Motor>Analyzer Category
From the Motor>Analyzer category you can perform three types of tests to identify motor parameters.
In this example, the Calculate Model test was run. If the Motor>Analyzer test executes successfully, and you accept the test values, they populate the Model Parameter attributes.
Figure 226 - Motor Analyzer Category

Motor Tests and Autotune Procedure

You can perform three types of tests to identify motor parameters and one test for motor/system inertia. These parameters are used by sensorless-vector frequency-control and induction motor closed-loop modes. Table 202 recommends which test to use based on the control mode and application.

Table 202 - Motor Tests and Autotune Matrix

Control Mode

Description Calculate Static

Dynamic

Autotune (inertia test)

Basic volts/hertz Not required Not required

Not required

Induction motor - Frequency control Induction motor - Closed-loop control

Basic volts/hertz for Fan/Pump
Sensorless vector

Not required
Required (1) Required (1)

Not required
Preferred Preferred (2)

Not required Not required Preferred

Not required
Not required Required (1) (3)

(1) Not required for the Logix Designer application, version 29.00 and later. (2) If it is not desired to rotate the motor (due to coupled load) you can perform this test for induction motor closed-loop mode and skip the Dynamic test. The dynamic test
provides the best results for induction motor closed-loop mode. (3) The motor inertia value must be non-zero prior to running a dynamic test. The motor inertia value is estimated automatically based upon the Motor Nameplate data in
the Logix Designer application, version 29.00 and later. For previous versions, an Autotune test must be run or the motor inertia value entered directly.

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The Motor>Analyzer category offers three choices for calculating or measuring electrical motor data.
Follow these steps to run motor tests and identify motor parameters.
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Motor>Analyzer category.
Nameplate data was entered on page 434. The nameplate data must be entered before running the Calculate test.

3. Click Start to run the test. 4. Click Accept Test Results to save the values. 5. Click OK.

Motor Analyzer Category Troubleshooting
Calculate Model
When a Calculate test is run, the drive uses motor nameplate data to estimate the motor's Rated Flux Current, Stator Resistance (Rs), Stator Leakage Reactance (X1) and Rotor Leakage Reactance (X2). The drive also calculates the rated slip speed based on rated speed and rated frequency. No measurements are taken when using the Calculate test.
Static Motor Test
Use the Static test if the motor shaft cannot rotate or if it is already coupled to the load. Only tests that do not create motor movement are run. During this test, the Stator Resistance (Rs), Stator Leakage Reactance (X1), and Rotor Leakage Reactance (X2) values are measured during a series of static tests. The Rated Flux Current is estimated, since measurement of this value requires

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motor movement. The drive also calculates the rated slip speed based on rated speed and rated frequency.
The Static test requires that you enter initial estimates for Rated Flux Current, Rated Slip Speed, Stator Resistance (Rs), Stator Leakage Reactance (X1), and Rotor Leakage Reactance (X2) into the Motor Model fields.
· For the Logix Designer application, version 29.00 or later, initial estimates are populated by the controller.
· For the Logix Designer application, version 28.00 or earlier, this can be done by running and accepting the results of a Calculate test, or by entering the values directly into the Logix Designer application.
Dynamic Motor Test
Dynamic tests are run with the motor disconnected from the load because the motor shaft turns and there are no travel limits. This is often the most accurate test method. During this test, the Stator Resistance (Rs), Stator Leakage Reactance (X1) and Rotor Leakage Reactance (X2) values are measured in a series of static tests. The Rated Flux Current is measured during a rotational test, in which the drive commands 75% of the motor rated speed.
The rated slip speed is measured during a second rotational test, in which the drive commands a speed (default of 100% of the motor rated speed) and set a torque limit (default of 50% of the motor rated torque). This quickly accelerates the motor to rated speed and then decelerates back to zero speed.
IMPORTANT The Dynamic test does not support travel limits.
The Dynamic test also requires that you enter initial estimates for Rated Flux Current, Rated Slip Speed, Stator Resistance (Rs), Stator Leakage Reactance (X1), and Rotor Leakage Reactance (X2) into the Motor Model fields.
· For the Logix Designer application, version 29.00 or later, initial estimates are automatically populated by the controller.
· For the Logix Designer application, version 28.00 or earlier, this can be done by running and accepting the results of a Calculate test, or by entering the values directly into the Logix Designer application.
The Dynamic test uses the Ramp Acceleration and Ramp Deceleration attributes to set the rotational test ramp-up and ramp-down times. If the resulting acceleration/deceleration times are less than 10 seconds, 10 seconds is used. If these attributes are not supported, 10 seconds is also used.
The Dynamic test also uses the IM Slip Test Velocity Command (percent of rated speed) and IM Slip Test Torque Limit (percent of rated torque) attributes to define the motion profile for the slip measurement. The default values are 100.0 and 50.0 respectively. The speed command dictates the speed that the motor spins up to and the torque dictates how quickly the motor reaches that speed. In general, A higher speed and lower torque results in a longer acceleration and a more accurate rated slip speed.

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Motor Control Feature Support Appendix F

Attribute Offset

Type

3095 REAL

3096 REAL

However, be aware that the dynamic test will not return expected results if the torque limit is set below 30.0.

Table 203 - Slip Test via Messaging

Attribute Name

Conditional Implementation

Description

IM Slip Test Torque Limit IM Slip Test Velocity Command

Closed loop induction motor only

Sets positive and negative torque limits for the slip test within the Dynamic motor test (similar to the torque limits in the inertia test). Units are in percent of rated torque.
Sets the velocity command for the slip test within the Dynamic motor test, (similar to the velocity command in the inertia test). Units are in percent of motor rated speed.

The Dynamic test requires the Positive and Negative Torque Limits for said axis are not over-written while the test is in progress. This can be satisfied by making sure that (1) these cyclic attributes are not checked as writable within the Drive Parameters tab of the axis properties and (2) these parameters are not being messaged via an MSG instruction.
When configured for closed-loop control, the Dynamic test requires that an accurate system inertia is set in the Logix Designer application.
· For the Logix Designer application, version 29.00 or later, a default value is automatically populated by the controller.
· For the Logix Designer application, version 28.00 or earlier, this can be done by running and accepting the results of an Autotune test, or by entering the motor inertia value directly into the Logix Designer application.
When configured for closed-loop control, the Dynamic test uses the velocity regulator tuning as entered into the Logix Designer application. If the motor is coupled to a load, the velocity regulator tuning may need to be adjusted to make sure the velocity response is well controlled. The Dynamic test fails if the steady-state velocity feedback is not within a ±30% tolerance of the commanded velocity.

IMPORTANT The Dynamic test is not supported in closed-loop Torque Control.

If using the Dynamic test in Frequency Control mode, uncouple the motor from any load or results may not be valid. In closed-loop control, either a coupled or uncoupled load produces valid results.

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Selection of Motor Thermal The Kinetix 5700 drives contain two motor thermal-overload protection

Models

algorithms that you can use to prevent the motor from overheating.

Generic Motors
The default thermal model is a generic I2T Class 10 overload protection algorithm. This model is active if the MotorWindingToAmbientResistance or the MotorWindingToAmbientCapacitance values are 0.0. The purpose of this algorithm is to limit the time a motor is operating with excessive levels of current. The relationship between Motor Overload Factory Limit trip-time and motor output current is shown in Figure 227.
Figure 227 - Motor Overload Curve

100,000 10,000
1000 100 10
0 100 125 150 175 200 225 250

You can use the MotorOverloadLimit attribute (default of 100%, max of 200%) to increase the motor overload trip-time by artificially increasing the motor rated current (for thermal protection only). MotorOverloadLimit should only be increased above 100% if cooling options are applied. Increasing MotorOverloadLimit causes MotorCapacity to increase more slowly.
The generic motor thermal model also derates the motor rated current (for thermal protection only) when operating at low speeds. The derating factor is 30% at 0 Hz and 0% at 20 Hz, with linear interpolation between. Operating at output frequencies less than 20 Hz causes MotorCapacity to increase more quickly.
When the generic motor thermal-model is active, the MotorCapacity attribute increases only if the motor output current is greater than the effective motor rated current (taking into account the MotorOverloadLimit and low speed derating factor). The default MotorThermalOverloadFactoryLimit and MotorThermalOverloadUserLimit values for this thermal model are both 100%.
IMPORTANT The generic motor-thermal model does not support Current Foldback as a Motor Overload Action.

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Thermally Characterized Motors
If the MotorWindingToAmbientResistance and MotorWindingToAmbientCapacitance attribute values are both non-zero, the motor is considered thermally characterized and an alternate motor thermal model is run. The purpose of this algorithm is to limit the time a motor is operating with excessive levels of current. This thermal model uses the firstorder time constant determined from the MotorWindingToAmbientResistance and MotorWindingToAmbientCapacitance values to estimate the motor thermal capacity based on the motor output current.
The MotorOverloadLimit attribute (default of 100%, max of 200%) can be used to increase the motor overload trip-time by increasing the MotorThermalOverloadFactoryLimit value. The MotorOverloadLimit should be increased above 100% only if cooling options are applied. Increasing MotorOverloadLimit does not change the behavior of MotorCapacity.
This thermal model supports setting the MotorOverloadAction attribute as Current Foldback. Selecting the Current Foldback action results in a reduction in the current reference via the MotorThermalCurrentLimit attribute value that is reduced in proportion the percentage difference between the MotorCapacity and the MotorOverloadLimit values.
When this thermal model is active, the MotorCapacity attribute is non-zero if the motor output current is non-zero. The default MotorThermalOverloadFactoryLimit and MotorThermalOverloadUserLimit values for this thermal model are both 110%.
IMPORTANT This thermal model does not derate the motor-rated current when operating at low speeds. Operating at low output frequencies does not cause the MotorCapacity behavior to change.

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Appendix F Motor Control Feature Support

Speed Limited Adjustable Torque (SLAT)

Speed limited adjustable torque (SLAT) is a special mode of operation used primarily in web handling applications. While configured for SLAT, the drive typically operates as a torque regulator. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output, relative to the applied TorqueTrim attribute.

A torque regulated application can be described as any process requiring tension control. For example, a winder or unwinder with material being drawn or pulled with a specific tension required. The process also requires that another element set the speed.

When operating as a torque regulator, the motor current is adjusted to achieve the desired torque. If the material being wound or unwound breaks, the load decreases dramatically and the motor can potentially go into a runaway condition.

The SLAT feature is used to support applications that require a robust transition from torque regulation to velocity regulation (and vice versa). The SLAT feature can be configured via the SLATConfiguration attribute as:

Table 204 - SLAT Configuration Descriptions

Name

Description

SLAT Disable

SLAT function is disabled. Normal Velocity Loop operation.

Drive automatically switches from Torque regulation to Velocity regulation if SLAT Min Speed/Torque VelocityError < 0 and switches back to Torque regulation if VelocityError > SLATSetPoint
for SLATTimeDelay.

Drive automatically switches from Torque regulation to Velocity regulation if SLAT Max Speed/Torque VelocityError > 0 and switches back to Torque regulation if VelocityError < SLATSetPoint
for SLATTimeDelay.

Direction of the applied torque and direction of the material movement determine whether SLAT minimum or SLAT maximum mode should be used.

Motion Polarity Setting
The Motion Polarity setting in the Logix Designer application>Axis Properties>Polarity does not affect SLAT behavior, however, you may require clarification on whether to use the SLAT Min Speed/Torque or SLAT Max Speed/Torque configuration when Motion Polarity is set to Inverted. In this case, the velocity error displayed in the Logix Designer application is inverted compared to what is actually used by the axis to control the SLAT function. So, if the SLAT configuration is set to Min and then Motion Polarity is switched to Inverted, change the SLAT configuration to Max.

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Motor Control Feature Support Appendix F

Table 205 - SLAT Operation When Motion Polarity Is Inverted

Velocity Command Positive (clockwise) Negative (CCW)

Motion Polarity Normal Inverted Normal Inverted

SLAT Configuration Min Max Min Max

SLAT Min Speed/Torque

SLAT Min Speed/Torque is a special mode of operation primarily used in web handling applications. The drive typically operates as a torque regulator, provided that the TorqueTrim attribute is less than the torque output due to the velocity regulator's control effort. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output relative to the torque reference.

When used for SLAT control, an application dependent VelocityCommand value is applied to the drive via an MAJ instruction or MDS instruction (2198xxxx-ERS4 and 2198-xxxx-ERS3 series B drives, firmware 9.001 or later). An application dependent TorqueTrim value is also applied via cyclic write. Under normal operation, VelocityCommand is set to a level that results in the velocity regulator's control effort becoming saturated when the motor's speed is mechanically limited. The TorqueReference value equals the TorqueTrim value, resulting in a positive VelocityError value.

Should the mechanical speed limitation be removed (example: web break), the motor accelerates and VelocityError becomes negative. At this time, a forced transition to velocity regulation occurs, and the motor's speed is regulated to the VelocityCommand attribute.

The axis remains in velocity regulation until VelocityError exceeds SLATSetPoint for a time specified by SLATTimeDelay. At this point, the axis returns to operating as a torque regulator.

Figure 228 - SLAT Min Speed/Torque

Select Minimum of Velocity Loop Output or Torque Command (speed control is OFF)

Velocity Error < 0 Velocity Error > SLAT Setpoint for SLAT Time

Select Velocity Loop Output (speed control is ON)

See the Integrated Motion on the EtherNet/IPTM Network Reference Manual, publication MOTION-RM003, for more information on SLAT attributes.

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SLAT Max Speed/Torque

SLAT Max Speed/Torque is a special mode of operation primarily used in web handling applications. The drive typically operates as a torque regulator, provided that the TorqueTrim attribute is greater than the torque output due to the velocity regulator's control effort. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output relative to the torque reference.

Should the mechanical speed limitation be removed (example: web break), the motor accelerates and VelocityError becomes positive. At this time, a forced transition to velocity regulation occurs, and the motor's speed is regulated to the VelocityCommand attribute.

The axis remains in velocity regulation until VelocityError is less than SLATSetPoint for a time specified by SLATTimeDelay. At this point, the axis returns to operating as a torque regulator.

Figure 229 - SLAT Max Speed/Torque

Select Maximum of Velocity Loop Output or Torque Command (speed control is OFF)

Velocity Error > 0 Velocity Error < SLAT Setpoint for SLAT Time

Select Velocity Loop Output (speed control is ON)

See the Integrated Motion on the EtherNet/IP Network Reference Manual, publication MOTION-RM003, for more information on SLAT attributes.

SLAT Attributes

Access Attribute

833

Set SLAT Configuration

Conditional Implementation
0 = SLAT Disable (1) 1 = SLAT Min Speed/Torque 2 = SLAT Max Speed/Torque

834

Set SLAT Set Point

Velocity Units

835

Set SLAT Time Delay

Seconds

(1) SLAT Disable, when viewed in version 28.00 (and earlier) of the Logix Designer application, reads Torque Only.

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Motor Control Feature Support Appendix F
Configure the Axis for SLAT
Follow these steps to configure the SLAT attributes. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category. The General dialog box appears.

3. From the Axis Configuration pull-down menu, choose Velocity Loop. The Velocity Loop dialog box appears.

4. Enter values for the Velocity Loop attributes appropriate for your application.

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5. Click Apply. 6. Select the Parameters List category.
The Motion Axis Parameters dialog box appears.

7. From the SLATConfiguration pull-down menu, choose the SLAT configuration appropriate for your application.
IMPORTANT SLAT parameters are configurable only when Velocity Loop is chosen from the General category, Axis Configuration pull-down menu.
8. Click Apply. 9. Enter values for SLATSetPoint and SLATTimeDelay attributes
appropriate for your application.
10. Click OK. 11. Select the Drive Parameters category.

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The Drive Parameters to Controller Mapping dialog box appears.

When using SLAT with Kinetix 5700 drives, the velocity command is sent to the drive via an MAJ instruction or MDS instruction (2198-xxxx-ERS4 and 2198-xxxx-ERS3 series B drives, firmware 9.001 or later). The torque command is sent via the cyclic write TorqueTrim attribute. See the Integrated Motion on the EtherNet/IP Network Reference Manual, publication MOTION-RM003, for more information on cyclic read and cyclic write.
For MAJ instructions:
· When using SLAT, start the axis with the MSO instruction. · The VelocityCommand is sent via the MAJ instruction. · The TorqueCommand is sent to AxisTag.TorqueTrim. · To make changes to the VelocityCommand, you must re-trigger the
MAJ with the Speed value or use a MCD (motion change dynamics) instruction. · To stop the axis use a MAS instruction. · The axis accelerates and decelerates at the MAJ instruction programmed Acceleration and Deceleration rates. · You can also change the rates using the MCD instruction.

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For MDS instruction (2198-xxxx-ERS4 and 2198-xxxx-ERS3 series B drives, firmware 9.001 or later):
· When using SLAT, start the axis with an MDS instruction. · The MDS instruction turns on the power structure enable and tracking
command status and also executes the velocity command.
See sample code in Motion Drive Start (MDS) Instruction.
· The acceleration and deceleration rate is controlled by Ramped Acceleration and Ramped Deceleration by using the SSV instruction.
· The Torque Command is set to Axis Tag.Torque Trim. Make sure the Torque Trim Write is checked in the drive parameter (see Drive Parameters dialog box above). The value can be changed. Alternatively, you can use the Axis Tag.DirectCommandVelocity to alter the Velocity Command when the existing MDS instruction is being executed.

· To stop the axis, use MAS instructions, keeping the Change Decel to NO and by using an SSV instruction to change Ramped Deceleration for the desired rate.
Motion Drive Start (MDS) Instruction
Kinetix 5700 inverters, catalog numbers 2198-xxxx-ERS4 and 2198-xxxx-ERS3 (series B) with firmware revision 9.001 or later, provide access to the Motion Drive Start (MDS) instruction. Use the MDS instruction to activate the drive control loops for the specified axis and run the motor at the specified speed.
For information regarding the MDS instruction, refer to the Logix 5000TM Controllers Motion Instructions Reference Manual, publication MOTION-RM002.
For the Kinetix 5700 drive, the MDS instruction is valid only when the axis configuration is set to one of these control modes:
· Frequency Control · Velocity Loop · Torque Loop
IMPORTANT The MDS instruction is not valid when the axis configuration is set to Position Loop.

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Motion Drive Start Instruction Configuration
The MDS instruction is configured in a similar fashion to most motion instructions, as seen in this example.
Figure 230 - Typical MDS Instruction
Selected Axis
Motion Instruction Tag
Speed Reference
Units per sec or
% of Maximum
The MDS instruction is similar to a Motion Axis Jog (MAJ) instruction, however, the MDS instruction does not set the acceleration/deceleration rates. The acceleration rate is dynamically set by the ramp attributes configured in a Set System Value (SSV) instruction. See Ramp Attributes on page 451.
TIP The K5700_Axis was configured for revolutions. Therefore, the Speed Units are revolutions per second (rev/s).
Motion Drive Start (MDS) Sample Code
Figure 231 - Start

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The speed is increased by updating the speed reference and then re-executing the MDS instruction.
Figure 232 - Increase Speed

The speed is decreased by updating the speed reference and then re-executing the MDS instruction.
Figure 233 - Decrease Speed

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When the axis configuration is in Torque Loop, the Speed attribute within the MDS instruction is not used to command the speed of the drive. The speed is determined by the amount of torque specified in the CommandTorque and/or TorqueTrim attributes.
Figure 234 - Torque Mode

IMPORTANT

You must command zero torque in the CommandTorque and TorqueTrim attributes before you can use the Motion Axis Stop (MAS) instruction to stop a specific motion process on an axis or to stop the axis completely. To use the MAS instruction, you must set Change Decel to No. Otherwise, an instruction error can occur. The deceleration rate is set based on the Ramp Deceleration attribute. The Motion Servo Off (MSF) instruction is used to deactivate the drive output for the specified axis and to deactivate the axis'servo loop. If you execute an MSF instruction while the axis is moving, the axis coasts to an uncontrolled stop.

Ramp Attributes
The MDS instruction is validated if the Integrated Motion on EtherNet/IP drive device supports the following five ramp attributes:
· RampAcceleration · RampDeceleration · RampVelocity - Positive · RampVelocity - Negative · RampJerk - Control

IMPORTANT

Ramp attributes are available only when the Kinetix 5700 drive axis configuration is set to Frequency Control or Velocity Loop. Ramp attributes are not available when the axis configuration is set to Torque Loop or Position Loop.

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Ramp Attribute RampVelocity - Positive RampVelocity - Negative RampAcceleration RampDeceleration

Access Set Set Set Set

RampJerk - Control

Set

Table 206 - Ramp Attributes

Description

374

Ramp Velocity - Positive attribute is a positive value that defines the maximum positive velocity command output of the Ramp Generator.

375

Ramp Velocity - Negative attribute is a negative value that defines the maximum negative velocity command output of the Ramp Generator.

376

The Ramp Acceleration attribute is a positive value that defines the maximum acceleration (increasing speed) of the velocity command output by the Ramp Generator.

377

The Ramp Deceleration attribute is a positive value that defines the maximum deceleration (decreasing speed) of the velocity command output by the Ramp Generator.

The Ramp Jerk Control attribute sets the percentage of acceleration or deceleration time that is applied to the

speed ramp as jerk limited S-Curve based on a step change in velocity. The S-Curve time is added half at the

beginning and half at the end of the ramp. A value of 0 results in no S-Curve, for example, a linear

379

acceleration or deceleration ramp. A value of 100% results in a triangular acceleration profile with the peak being the configured ramp acceleration or deceleration. As the Jerk Control value increases, the derived

accelerating jerk value decreases based on the following: 0.5 · 0.01 · Jerk Control · Ramp Vel Positive/Ramp

Accel. The decelerating Jerk limit value also decreases according to the following: 0.5 · 0.01 · Jerk Control ·

Ramp Vel Negative/Ramp Decel.

IMPORTANT The Ramp attributes can be viewed and set with only an SSV or GSV instruction.
Figure 235 - Ramp Attribute Sample Code

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Motor Control Feature Support Appendix F

Motor Overload Retention

The motor overload retention feature protects the motor in the event of a drive power-cycle, in which the motor thermal state is lost.
With motor overload retention, upon drive power-up the MotorCapacity attribute initially reads:
· 20% if the motor is configured to use an integral thermal switch or an integral motor winding temperature is available
· 50% if the motor is not configured to use an integral thermal switch or an integral motor winding temperature is not available
If you have a separate monitoring algorithm within your Logix 5000 controller, you can use the InitialMotorCapacity attribute (3075)10 or (C03)16 to change the initial MotorCapacity value that the motor overload retention feature populates.
· You can write to the InitialMotorCapacity attribute only in the Stopped state after power-up
· You cannot write to the InitialMotorCapacity attribute after the first time the axis is enabled following a power cycle.
Use a message instruction to write to the InitialMotorCapacity value.
In this example, the source element tag motorcapacity is a REAL Data type.

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Phase Loss Detection

The phase-loss detection feature is designed to determine if motor power wiring is electrically connected to a motor and that reasonable current control exists. This attribute enables the operation of the drive's torque proving functions that work in conjunction with mechanical brake control.
When the ProvingConfiguration attribute is enabled, the drive performs a torque prove test of the motor current while in the Starting state to prove that current is properly flowing through each of the motor phases before releasing the brake. If the torque prove test fails, the motor brake stays engaged and a FLT-S09 Motor Phase Loss exception (fault) is generated.

IMPORTANT

The mechanical brake must be set as soon as the drive is disabled. When the brake is under the control of the axis state machine, this is automatic. But, when controlled externally, failure to set the brake when the drive is disabled can cause a free-fall condition on a vertical application.

Table 207 - Phase-loss Detection Startup Sequence

Startup Phase Phase 1 Phase 2
Phase 3

Description
When the drive receives an enable request, the Starting state begins execution and torque proving starts.
The torque proving feature ramps current to the motor-phase output connector and verifies that the current feedback circuitry detects current on each of the phases.
Once motor-current feedback has been verified in each motor phase, the drive attempts to enable the current control loop at a user-specified current level, and verifies that the currentloop error tolerance is within range.

Torque proving is available for all motoring configurations including closedloop servo control and induction motors.

For permanent magnet (PM) motors, the drive attempts to apply current to the motor phases such that all current through the motor is flux current. However, due to the electrical angle of the motor at the time of the MSO instruction, it may not be possible to verify the motor phase wiring with only flux current. Therefore, with a PM motor it is possible that the motor shaft can move slightly during torque proving if no motor brake exists to hold the load.

Phase-loss Detection Attributes

Access Attribute

590

SSV ProvingConfiguration

591

SSV TorqueProveCurrent

Conditional Implementation
0 = Disabled 1 = Enabled
% Motor Rated Units: Amps Default: 0.000 Min/Max: 0/10,000

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Phase-loss Detection Configuration
Follow these steps to configure the phase-loss detection attributes. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to ProvingConfiguration.

3. From the ProvingConfiguration pull-down menu, choose Enabled to enable the torque proving feature.
4. Enter a value in the TorqueProveCurrent attribute appropriate for your application.
5. Click OK.
The TorqueProveCurrent attribute is active only if ProvingConfiguration is set to Enabled. TorqueProveCurrent lets you specify the amount of current that is used during the torque proving test and calculated as a percentage of motor rating. The higher the TorqueProveCurrent value the more current the drive delivers to the motor to verify that the motor phase wiring is available and capable of that current level. High current levels conversely cause more thermal stress and (potentially) can cause more torque to be driven against the motor brake during the test. If the TorqueProveCurrent level selected is too small, the drive cannot distinguish the proving current from noise, and in this case the drive posts an INHIBIT M04 torque-proving configuration fault code. The minimum amount of torque proving current depends on catalog number of the drive.

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Phase Loss Detection Current Example
In this example, a 2198-D032-ERS3 dual-axis inverter is paired with a VPL-B1003T-C motor with 9.58 A rms rated current. Use the phase-loss detection equation and table to calculate the initial minimum torque-proving current as a percentage of motor rated current. Depending on the unique characteristics of your application, the required torque-proving current value can be larger than the initial recommended value.
Figure 236 - Phase-loss Detection Equation
Rating From Table = 0.9337 A = 9.75% motor rated current. Motor Rated Current 9.58 A

Table 208 - Recommended Phase-loss Detection Current

Drive Cat. No.
2198-S086-ERSx 2198-S130-ERSx 2198-S160-ERSx 2198-S263-ERSx 2198-S312-ERSx 2198-D006-ERSx 2198-D012-ERSx 2198-D020-ERSx 2198-D032-ERSx 2198-D057-ERSx

Phase-loss Detection Current, min A, rms 7.183 9.337 12.21 21.492 27.436 0.1796 0.3591 0.5746 0.9337 1.6520

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Velocity Droop

Motor Control Feature Support Appendix F
The velocity droop function can be useful when some level of compliance is required due to rigid mechanical coupling between two motors. The feature is supported when the axis is configured for Frequency Control, Velocity Control, or Position Control.
Closed Loop Control
The closed-loop velocity droop function is supported when configured for either Velocity or Position control. The velocity error input to the integral term is reduced by a fraction of the velocity regulator's output, as controlled by the VelocityDroop attribute. Therefore, as torque loading on the motor increases, actual motor speed is reduced in proportion to the droop gain. This is helpful when some level of compliance is required due to rigid mechanical coupling between two motors.
IMPORTANT The closed-loop velocity droop function acts to reduce the velocity error input to the integral term, but never changes the polarity of the velocity error.
IMPORTANT When configured for closed-loop control, the units of the VelocityDroop attribute are Velocity Control Units / Sec / % Rated Torque.

Frequency Control
The velocity droop function is also supported when configured for Frequency Control. As the estimated Iq current within the motor increases, the velocity reference is reduced in proportion to the VelocityDroop attribute. Therefore, as torque loading on the motor increases, actual motor speed is reduced in proportion to the droop gain. This is helpful when some level of compliance is required due to rigid mechanical coupling between two motors.
IMPORTANT The frequency-control velocity droop function acts to reduce the velocity reference, but never changes the direction of the velocity reference.
IMPORTANT When configured for frequency control, the units of the VelocityDroop attribute are Velocity Control Units / Sec / % Rated Iq Current.

Velocity Droop Attribute

ID 464/321

Access Attribute SSV Velocity Droop

Conditional Implementation Velocity Units / Sec / % Rated

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Velocity Droop Configuration
Follow these steps to configure the velocity droop attribute. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to VelocityDroop.

3. Enter a value in the Velocity Droop attribute appropriate for your application.
4. Click OK.

Commutation Self-sensing Startup

The commutation self-sensing feature is used to determine the initial electrical angle for permanent magnet (PM) motors with an incremental encoder that do not have Hall effect sensors. For PM motors that use encoders with Hall sensors, the drive can still be configured to use this feature, however, the Hall effect signals are ignored. When enabled, this feature is executed automatically at powerup and when the system is enabled.
IMPORTANT Following a connection loss to the controller after the initial power-up, the commutation self-sense feature is run again when connection is re-established and motion is commanded.

The self-sense feature takes approximately 5 seconds to execute. Five seconds is the default amount time assuming no retries are required. The axis stays in the Starting state while self-sense executes.

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The sequencing of events is as follows. 1. One-second current ramp time 2. One second delay 3. One-second move time 4. One second delay 5. One-second current ramp time
IMPORTANT Self-sensing startup is not commutation diagnostics. You can perform commutation diagnostics on Hall effect or self-sensing motors at any time.
To use the self-sense feature, select the Motor Feedback category and from the Commutation Alignment pull-down menu, choose Self-Sense.

Table 209 - Self-sense Feature Attributes

CIPTM Attribute Number

CIP Attribute Name

562

Commutation SelfSensing Current

3102

Self-Sense Direction

3103

Self-Sense Lock Time

3104

Self-Sense Lock Delay

3105

Self-Sense Move Time

3106

Self-Sense Move Delay

Data Type REAL
USINT REAL REAL REAL REAL

Description

Semantics of Values

The percent of the motors rated peak current to use for self-sensing startup. This value can be adjusted when the motor is moving a high inertia load.

% Motor Rated Peak Current [default = 100]

· Forward indicates the motor moves in only the positive direction during self-sensing startup.
· Negative indicates the motor moves in only the negative direction during self-sensing startup.

0 = Forward - CW (rotary) or Positive (linear) [default]
1 = Reverse - CCW (rotary) or Negative (linear)

The amount of time the drive uses to build up current to Seconds

the Self-Sensing Current level specified above.

[default = 1.0]

The amount of time the motor must be in the locked position after reaching the full Self-Sensing Current.

Seconds [default = 1.0]

The amount of time the drive uses for the verification move during self-sensing startup. Applies only to motors with self-sensing startup.

Seconds [default = 1.0]

The amount of time the drive holds the final position Seconds after the verification move during self-sensing startup. [default = 1.0]

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Commutation Test

The commutation test determines an unknown commutation offset and can also be used to determine the unknown polarity of the start-up commutation wiring. You can also use the commutation test to verify a known commutation offset and the polarity start-up commutation wiring.
IMPORTANT This test applies to third-party or custom permanent-magnet motors equipped with (TTL with Hall and Sine/Cosine with Hall) incremental encoders that are not available as a catalog number in the Motion Database.
IMPORTANT When motors have an unknown commutation offset and are not listed in the Motion Database by catalog number, you cannot enable the axis.
Figure 237 - Hookup Tests - Commutation Tab

Adaptive Tuning
460

To run the commutation test, see Test the Axes on page 269.
The adaptive tuning feature is an algorithm inside the Kinetix 5700 servo drives. The algorithm continuously monitors and, if necessary, adjusts or adapts various filter parameters and, in some cases, control-loop gains to compensate for unknown and changing load conditions while the drive is running. Its primary function is to:
· Automatically adjust torque-loop notch and low-pass filter parameters to suppress resonances
· Automatically adjust control-loop gains to avoid instability when detected
See Motion System Tuning Application Techniques, publication MOTIONAT005, for more information on the AdaptiveTuningConfiguration attribute.
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Virtual Torque Sensor

Motor Control Feature Support Appendix F
The virtual torque sensor feature provides an estimate of the motor torque without having a physical torque sensor. The virtual torque sensor can be leveraged to improve the commissioning and maintenance experience with mechanical systems and to optimize production quality. Some examples of how the feature can be applied include the following:
· Indication of shaft misalignment during commissioning · Verification of appropriate mechanical belt tensioning during
maintenance · Detection of a material jam during operation
The feature provides an estimate of the motor air-gap torque under dynamic and steady state operating conditions. The air-gap torque is the torque that includes the load torque, motor torque losses, and rotor acceleration torque. The estimated torque does not affect motion control or drive performance.
The virtual torque sensor is available with the following hardware and software:
· Studio 5000 Logix Designer® version 33 and later · Kinetix 5700 servo drives (catalog numbers 2198-xxxx-ERS3 Series B
and 2198-xxxx-ERS4 Series A) with drive firmware revision 13 and later
For more information on how to apply the virtual torque sensor feature, see Virtual Torque Sensor Application Technique, publication 2198-AT003.

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Appendix F Motor Control Feature Support

Field Weakening Mode

Kinetix VPC interior permanent-magnet (IPM) motors are designed to operate in Field Weakening mode to widen the speed range. Operation in Field Weakening mode can result in Back EMF voltage increasing to a level that exceeds the DC-bus voltage if a loss of control occurs. When this loss of control occurs, the Back EMF voltage can charge the DC-bus to a level that can overvoltage the DC-bus caps and result in a failure of the common DC-bus.
Figure 238 - Field Weakening Region

Peak (intermittent) Operation

Maximum Speed (Kinetix VPC motors without cooling fans)

Torque (N·m)

Continuous Operation

Field Weakening Region

Speed (rpm)

Rated

Speed

Bus Overvoltage Speed

Maximum Speed

ATTENTION: DC-bus failure can cause damage to all drive modules in the bus group, not just the inverter connected to the Kinetix VPC motor.

Extended Speed Feature
The Extended Speed feature is implemented in the Logix Designer application to help prevent accidental operation at unsafe speeds. With this feature, the controller calculates a Bus Overvoltage Speed based upon the drive's maximum allowable bus-voltage and the Back EMF of the motor. This is the maximum speed that does not risk damaging the drive modules in the bus group. By default, the Extended Speed feature limits motor velocity to the Bus Overvoltage Speed.

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Motor Control Feature Support Appendix F
Configure Extended Speed Operation
The extended speed feature is only configurable with Kinetix 5700 drives and Kinetix VPC continuous-duty IPM motors. You can configure the Extended Speed feature in Axis Properties>Motor category of the Logix Designer application (version 29.00 or later).

Follow these steps to enable operating at speeds greater than the Bus Overvoltage Speed.
1. In the Extended Speed field, check Extended Speed Permissive. 2. Set the Max Extended Speed attribute as required by your application.
WARNING: Operation at speeds exceeding the Bus Overvoltage Speed requires use of an auxiliary device to protect the DC bus system from an overvoltage condition.

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Notes:

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History of Changes

G Appendix

This appendix contains the new or updated information for each revision of this publication. These lists include substantive updates only and are not intended to reflect all changes. Translated versions are not always available for each revision.
2198-UM002J-EN-P, June 2020
Change Corrected the number of motor modules supported by two iTRAK® power supplies. Added additional settings for drive firmware revision 12.001 to Navigating the iTRAK Power Supply Settings Menu. Added Configure the iTRAK Power Supply. Added IMPORTANT message to Apply Power to the Kinetix® 5700 Drive System regarding configurations with multiple iTRAK power supplies. Added additional fault codes for drive firmware revision 12.001 to iTRAK Power Supply Behavior. Updated drive behavior of FLT S33 - BUS UNDERVOLT FL. Corrected system operation timing diagrams. Corrected the encoder voltage used by VPC-Bxxxx-Y servo motors. Added IMPORTANT messages regarding iTRAK power supplies configured for normal and standalone operation. Added cable length restrictions for Third-party Motor Configurations. Added callout to Field Weakening Region diagram identifying Bus Overvoltage Speed as the maximum speed for Kinetix VPC motors without cooling fans.

2198-UM002I-EN-P, November 2019
Change Added references to Knowledgebase Answer ID: 1091727, for fault codes and descriptions. Added Kinetix 5700 drive compatibility with 2090-CSxM1xx-xxVAxx (PVC) and 2090-CSBM1xx-xxLFxx (Halogen-free PUR) single motor-cables. Added Kinetix 5700 drive compatibility with VPC-B3004x-M servo motors with multi-turn encoder.

2198-UM002H-EN-P, May 2019
Change
Studio 5000 Logix Designer® application is the rebranding of RSLogix 5000® software. General references to RSLogix 5000 software have been replaced by the Logix Designer application. References to specific RSLogix 5000 software versions did not change.
Updated references to safe-off (SO) as safe torque-off (STO), per EN61800-5-2.
Updated references to series A and B drives. The 230V drive modules previously labeled as series A are now series A and C. The 460V drives previously labeled as series B are now series B and C.
Added Kinetix 5700 drive compatibility with Kinetix VP (Bulletin VPH) hygienic stainless-steel servo motors.

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2198-UM002H-EN-P, May 2019 (continued)
Change
Added information about the CIP SecurityTM feature.
Updated Drive to Motor Cable Lengths specifications to distinguish maximum cable length depending on DC-bus power supply (catalog number 2198-Pxxx).
Added specification that applies to Kinetix 5700 drives that use the CIP Security feature.
Updated ground screw setting for iTRAK power supply.
Added the power conductor AWG to the description for 2198-Sxxx-ERSx single-axis inverters.
Updated Navigating the Inverter Settings Menu selections. Added settings for the Factory Reset menu selection.
Updated the AOP Installation Requirement table with drive firmware, version 11.001 (CIP Security feature).
Added Regenerative Bus Supply Sequence Operation appendix.
2198-UM002G-EN-P, February 2019
Change
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.
Added the 2198-BARCON-220DC200 DC-bus link to support the 2198-S263-ERSx and 2198-S312-ERSx single-axis inverters.
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.
Added DC-bus Voltage Regulation that explains how the regenerative bus supply can be configured to operate as a DC-bus power supply.
Added AC Line Filter Selection that matches line filter catalog numbers to Kinetix 5700 power supplies.
Added AC Line Impedance Considerations that provides guidelines for transformer and line reactor selection.
Added 24V Control Power Evaluation that provides guidelines to minimize 24V control power voltage drop.
Added Passive Shunt Considerations and Active Shunt Considerations that provide guidelines for shunt module selection.
Added Multi-axis Shared DC-bus Configurations that provides guidelines for system sizing.
· 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.
Added accessory module flowcharts designed to help determine the minimum number of accessory modules required.
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.
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History of Changes Appendix G
2198-UM002G-EN-P, February 2019 (continued)
Change
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) to DC-bus Power Supply Wiring Requirements table that further specify wire size to meet CE requirements for 2198-P070 DC-bus power supplies.
Updated Maximum Cable Lengths with examples for 2198-RPxxx regenerative bus supplies.
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-shunt 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.
Added Active Shunt Wiring Examples.
Added external-bus capacitance calculations and updated the System Sizing Example with the external-bus capacitance value.
Added the Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies (Appendix D).
Updated Motor Analyzer Category Troubleshooting with rated slip-speed information.
2198-UM002F-EN-P, May 2018
Change
Added features that apply to 2198-xxxx-ERS3 (series B) drives. · In many instances, 2198-xxxx-ERS3 (series B) drives share features of 2198-xxxx-ERS4 drives and this was added
to the text · In many instances, it was necessary to distinguish 2198-xxxx-ERS3 (series A) drive operation from series B and
this was added to the text · Updated single-axis and dual-axis inverter line drawings with locking-leaver I/O (IOD) and safety (STO)
connectors that are included with 2198-xxxx-ERS3 (series B) and 2198-xxxx-ERS4 drives
Added Kinetix 5700 Servo Drives Series Change to describe new features that are available with 2198-xxxx-ERS3 (series B) drives.
Updated AC Line Filters installation guidelines.
Corrected the DC-bus power supply IOD-4 description and signal name.
Added information for IEC 61800-3 category C3/C4 compliance with regard to the use of AC line filters on AC input power.
Added bullet statements and other text to describe features of 2198-xxxx-ERS3 (series B) drives, including when to use Compatible Module and Exact Match electronic keying options in the Module Definition.
Updated Safety Application Definitions table with safety functions specific to 2198-xxxx-ERS3 (series A) drives and 2198-xxxx-ERS3 (series B) drives.
Updated content regarding fault code NODE FLT 06 fault behavior.
Added Replacing 2198-xxxx-ERS3 (series A) Drives with Series B Drives with text, dialog boxes, and a flowchart to describe when to use Compatible Module and Exact Match electronic keying options in the Module Definition.
Added STO tag name changes to help describe changes in the safe torque-off tag names.
Updated single-axis inverter and dual-axis inverter integrated STO specifications to reflect safe torque-off tag name changes.
Added ladder logic examples to show how STO function tag name changes can appear in your application program.
Added information about changes in drive firmware revision 9.001 and later (2198-xxxx-ERS4 and 2198-xxxx-ERS3 series B drives) that provides for the use of MDS instructions with Speed Limited Adjustable Torque (SLAT) operation.

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Appendix G History of Changes
Notes:

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Index

Numerics
1321 line reactors 13, 18, 45
2090-CFBM7DF-CD 18 2090-CFBM7DF-CE 18
2090-CPBM7DF 18, 158
2090-CPWM7DF 158
2090-CSBM1DE 18, 28, 154 2090-CSBM1DG 18, 28, 154
2090-XXNFMF 18 2198-BARCON-55DC200 17
2198-CAPMOD-2240 36, 57 2198-CAPMOD-DCBUS-IO 36, 57 2198-DBRxx-F 18, 38 2198-DBxx-F 18, 38 2198-DCBUSCOND-RP312 36, 57 2198-H2DCK 17, 28, 112, 167, 172
pinout 168
2198-K57CK-D15M 17, 28, 112, 167, 172
pinout 168
2198-KITCON-DSL 17, 28, 155
2198-KITCON-ENDCAP200 17
2198T-CHBFLS8 18, 22
24V input power connector evaluation 47 pinouts 100 wiring 140
842E-CM 116 842HR 116 843ES 117 844D 116 847H 116 847T 116 8720MC-RPS 17
interconnect diagram 356 minimum accessory modules 62 8720MC-RPS065 interconnect diagram 352 8720MC-RPS190 interconnect diagram 354
A
about this publication 11 absolute position feature 119 AC line filters
2198-DBRxx-F 18, 38 2198-DBxx-F 18, 38
noise reduction 71
accessory modules 57, 81 capacitor 17, 57
catalog number 36
connector locations 98, 176 DC-bus conditioner 17, 57 extension 17, 57
minimum accessory modules flowchart 63
minimum modules required 57, 59, 62 actions category 245, 249, 254

active shunt
interconnect diagram 360 pinouts 101 use cases 50 wiring 178 actuators
compatible actuators 167 adaptive tuning 460
additional resources 13
alarm 281
AOP
drive module firmware 195
PCDC download 195 application requirements 323
applying power 264
associated axes 202, 206, 210, 216, 221 category 220, 258
audience for this manual 11
automatic 417
auxiliary feedback encoders 116
axis properties 231, 233, 242, 246, 251, 260
axis unstable 278
B
back EMF 462
basic volts/hertz 235, 421
BC connector
pinouts 103 wiring 158 behavior
DC-bus power supply 282, 284
drive module 287 iTRAK power supply 286 Beldon 159
block diagrams
capacitor module 378 DC-bus conditioner module 379 DC-bus power supply 373 dual-axis inverter 376 iTRAK power supply 377 regenerative bus supply 374 single-axis inverter 375 bonding
EMI (electromagnetic interference) 65 examples 66 high frequency 40 high frequency energy 67 subpanels 67 brake relay specifications 109
Bulletin
MPAI electric cylinders 28 MPAR electric cylinders 28 MPAS linear stages 28 Bus Observer 228
bus overvoltage speed 462

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

469

Index

bus-sharing
configuration 201, 205, 209, 218 group 201, 205, 209, 218
group example 266 groups 265
regulator 201, 209
BusVoltageReferenceSource 228
BusVoltageSetPoint 225
C
cables
Bulletin 2090 18
cable lengths, max 150, 153, 405
cable preparation customer-supplied motor power 173 dual-axis power cable 160 motor feedback 169 single-axis power cable 163
catalog numbers 154, 158
categories 70 Ethernet cable length 181 induction motors 159
shield clamp 156, 170
calculate model 437
capacitor module 17, 57, 378
interconnect diagram 345 status indicator 277 wiring requirements 176 catalog numbers
accessory modules 36 DC-bus power supply 36 inverters 36 iTRAK power supply 36
motor cables 154, 158
regenerative bus supply 36 shared-bus connection system 37 category 3
stop category definitions 304 CE compliance 37
CED connector
pinouts 100 wiring 143 certification
application requirements 323 PL and SIL 304 TÜV Rheinland 304 user responsibilities 304 website 304 CIP axis states 413
CIP Security 12
circuit breaker selection 46
clamp 156, 170
spacers 161 clearance requirements 54
cluster 395
commutation offset 270, 460
commutation self-sensing 458
CompactLogix
Ethernet connections 181

compatibility
motor feedback 259 motors and actuators 167 configuration
24V DC voltage drop 401 8720MC-RPS 27 DC-bus power supply 19 extended DC-bus 21 extended regenerative bus supply 26 feedback examples 28 input power to multiple drive systems 25 iTRAK power supply 22 multiple DC-bus power supply 20
regenerative bus supply 23, 24
configuring
actions category 245, 249, 254
axis properties 260 Bus Observer 228 BusVoltageReferenceSource 228 BusVoltageSetPoint 225 converter startup method 225 general category 225
basic volts/hertz 235
CIP axis states 193, 413
controller 196 converter startup method 413 DC-bus power supply 199 download program 263
exceptions category 249, 255
fan/pump volts/hertz 240
feedback-only axis 222, 231
flux up 433
frequency control category 235, 237, 240 general category 231, 233, 242, 246, 251
home screen 184 hookup test 269 induction-motor closed-loop axis properties
251 induction-motor frequency-control axis 233 inverters 212 IP address 194 IPM motor closed-loop axis properties 242 iTRAK power supply 207
load category 244, 248, 256
master feedback 232 MDS instruction 449
menu screens 185, 186, 187, 188 module properties 200, 201, 202, 204, 205,
206, 208, 210, 211, 213, 217, 219, 220, 222, 223, 258
inhibit module 383 motion
group 224 safety 216 motor
analyzer category 239, 257 category 234, 243, 247, 252, 434, 463
feedback 259
feedback category 253, 260, 261, 262,
263 test 268 network parameters 194
parameter list category 236, 238, 241, 245, 250, 255
polarity category 252 power category

470

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Index

bus-sharing group example 266 bus-sharing groups 265 regenerative bus supply 203 safety application 215 connection 216
scaling category 244, 248, 254
sensorless vector 237 setup
menu 189, 190, 191, 192
screens 188 SLAT 445 SPM motor closed-loop axis properties 246 startup sequence 193 torque proving 455 valid feedback types 260 velocity droop 458 Connected Drive mode 288
connecting
CompactLogix 181 connector kit shield clamp 170 ControlLogix 181 Ethernet cables 181 motor shield clamp 156 Connection mode 216
connector kit
2198-BARCON-55DC200 17 2198-H2DCK 167
2198-K57CK-D15M 17, 167 2198-KITCON-DSL 17, 155
2198-KITCON-ENDCAP200 17 24V
drive system 17 iTRAK PS system 17 cable preparation motor feedback 169
connector locations 95, 96 accessory modules 98, 176
DC-Bus power supply 92 dual-axis inverters 94 iTRAK power supply 97 regenerative bus supply 93
single-axis inverters 95, 96
contactor enable
connector pinouts 100 relay 108 contactor selection 48
control power
input specifications 111 pinouts 100 wiring 140 ControlFLASH
firmware upgrade 381 troubleshooting 392 ControlFLASH Plus
firmware upgrade 381, 384, 387
troubleshooting 381 controller
and drive behavior 281 CompactLogix 196 configure 196 ControlLogix 196 properties
date/time tab 198

enable time synchronization 198 controller-based
monitoring functions 16 stopping functions 16 ControlLogix
Ethernet connections 181 conventions used in this manual 12
converter kit
2198-H2DCK 17, 167
converter OK
relay 109
converter startup method 225, 413
automatic 417 enable request 414
corner-grounded power configuration 124,
128
CP connector
pinouts 100 wiring 140 current limiting 424
current regulator loop 434
customer supplied cable 173
D
date/time tab 198
DC bus connector
pinouts 101
DC-bus conditioner module 17, 57, 379
interconnect diagram 349 DC-bus group 395
DC-bus power supply 16, 136, 373 behavior 282, 284
catalog numbers 36 configuring 199 connector locations 92 ground screw/jumper 129 menu screen 186 minimum accessory modules 57 setup menu 190 DC-bus Unload 416
DC-bus Up 416
DC-bus voltage regulation
specifications 40, 405
digital encoder
AqB TTL 260 AqB with UVW 261 digital inputs
category 201, 205, 210, 223
pinouts 101 series A connector 144 series B connector 145 specifications 106
wiring 144, 146 disable 281, 286
display 184
download program 263
drilling hole patterns 85
DC-bus power supply 86 regenerative bus supply 87 system mounting toolkit 88

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

471

Index

drive module behavior 287 firmware 195 replacement 329
dual-axis inverter 17, 376
connector locations 94 shield clamp 161 wiring requirements 139 dynamic motor test 438
E
earth ground 134 EMC
motor ground termination 156 EMI (electromagnetic interference)
bonding 65 enable request 414 enable time synchronization 198 enclosure
power dissipation 53 requirements 39 sizing 52 encoder 116 phasing 117 support
DSL 112 universal 112 erratic operation 279 Ethernet connector pinouts 103 EtherNet/IP connecting cables 181 connections 107 PORT1 and PORT2 connectors 181 exception 281 action 281 exception actions 281
exceptions category 249, 255
extended cluster 395
DC-bus 395, 396 speed 180, 462
extended DC-bus
interconnect diagram 350, 351
extended speed configure 463
extension module 17, 57 external active shunt 74, 75
wiring 178
external passive shunt resistor 72, 73
wiring 177
F
fan/pump 422 volts/hertz 240
fault code overview 274 code summary 275

feedback configurations 28
feedback-only axis 222, 231
specifications 112 field weakening 462 firmware upgrade
ControlFLASH Plus 384, 387
ControlFLASH Plus software 381 ControlFLASH software 381 system requirements 381 verify upgrade 393 flux up 431 attributes 432
frequency control category 235, 237, 240
fuse selection 46
G
general
category 200, 204, 208, 213, 231, 233, 242, 246, 251
ground multiple subpanels 135 screw/jumper 129
grounded-wye power configuration 123, 126
Group Sync Service 414
H
hardwired STO mode 32, 120, 306, 312
operation 312 pinouts 316 HF bonding 65 high-frequency (HF) bonding 40 energy 67 Hiperface-to-DSL feedback converter kit 167 hold 286
hole patterns 85, 88
DC-bus power supply 86 regenerative bus supply 87 home screen soft menu 184
hookup test 269, 460
I
I/O digital inputs specifications 106
IEC 61508 304 IEC 62061 304 ignore 281 impedance
equations 44 impedance-grounded power configuration
124, 127
induction motor control 159 closed-loop axis properties 251 configure flux up 433 control methods

472

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Index

basic volts/hertz 421 fan/pump 422 sensorless vector 423 flux up 431 attributes 432 frequency-control axis 233 motor analyzer category 436 and inertia tests 436 data sheet 435 model category 435 multiple skip speed 430
open-loop frequency control 420, 424, 427
skip speed 429 SLAT 444 inhibit module 383
input power wiring
24V control 140 contactor enable 143
corner-grounded power configuration 124,
128 determine input power 123 ground screw/jumper 129
grounded-wye power configuration 123,
126 impedance-grounded power configuration
124, 127
mains 142
remove ground screws 132, 133 ungrounded power configuration 125, 128
installing drive accessories
AC line filters 71
external active shunt 74, 75 external passive shunt resistor 72, 73
installing your drive 39
active shunts 50 bonding
examples 66 subpanels 67 cable categories 70 circuit breakers 46 clearance requirements 54 contactor selection 48 enclosure sizing 52 fuse selection 46 HF bonding 65 noise zones 68 passive shunts 49 shared-bus configurations 56 system mounting requirements 39 integrated SS1 mode 35
integrated STO mode 33, 34, 120, 322
drive module replacement 329
operation 324 STO bypass 332 STO state reset 327

interconnect diagrams
2198 drive with 8720MC-RPS 356 2198 drive with 8720MC-RPS065 leader/
follower 352 2198 drive with 8720MC-RPS190 354 2198 drive with HPK 365 2198 drive with LDAT 368
2198 drive with LDC 371, 372
2198 drive with MPAR/MPAI 370 2198 drive with MPAS 369 2198 drive with MPL/VPC-S/MPM/MPF/MPS
364 2198 drive with RDB 366 2198 drive with VPAR 367 2198 drive with VPC-Y 363 2198 drive with VPL/VPC-Q/VPF/VPH/VPS
362 active shunt 360 capacitor module 345 DC-bus conditioner module 349
extended system 350, 351 module status 357, 358
multiple converter 344 iTRAK power supplies 347
notes 341 passive shunt resistor 359 regenerative bus supply 348 single
converter 343 iTRAK power supply 346 motor cable 362
inverters 94, 95, 96
catalog numbers 36 configuring 212 dual-axis 17 ground screw/jumper 130 menu screen 185 setup menu 189 single-axis 16 IOD connector
pinouts 101
wiring 144, 146
IP address 194
IPD connector
pinouts 100 wiring 142 IPM motor closed-loop axis properties 242
ISO 13849-1 304
stop category definitions 304
iTRAK power supply 137, 377
behavior 286 catalog numbers 36 configuring 207 connector locations 97 ground screw 131 menu screen 188 setup menu 192

L
Lapp 159 LCD display 184
messages 274

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

473

Index

LDAT-Series linear thrusters 28
LDC-Series linear motors 28
line impedance
adding line reactor or transformer for lightning strikes 43 power interruptions 43 voltage dips 43 voltage spikes 43
line reactor use cases 43 transformer 43 line reactor
use cases 43 link
link/activity status indicator 276 speed status indicator 276
load category 244, 248, 256 Logix Designer 194, 196
M
mains input power connector
pinouts 100 wiring 142 major fault 281
MAS instruction 451
master feedback 232
MDS instruction
configure 448 decrease speed sample code 450 increase speed sample code 450
ramp attributes 451, 452
ramp attributes sample code 452 start sample code 449 torque mode sample code 451
menu screens 185, 186, 187, 188
MF connector
pinouts 104
wiring 155, 167
minor fault 281
module definition 214, 215, 258
motion safety 216 safety application 215 safety connection 216 module properties 258
associated axes category 202, 206, 210, 220, 258
digital input category 201, 205, 210, 223 general category 200, 204, 208, 213 module definition 214, 215, 258 new tag 202, 206, 211, 222 power category 200, 204, 208, 217
safety category 219 module status
DC-bus power supply 357 indicator 276
regenerative bus supply 357, 358
module status connector
pinouts 105 monitored safe stop (SS1) 16
motion
direct commands STO bypass 332

warning messages 333 drive start instruction 448 group 224 safety 216 Motion Analyzer website 13
motor
accel/decel problems 278
analyzer category 239, 257, 436
brake connector pinouts 103 wiring 158
cable
catalog numbers 154, 158
length 38
length, max 153, 405 category 234, 243, 247, 252
compatible motors 167 data sheet 435 extended speed 463 feedback
category 253, 260, 261, 262, 263
compatibility 259 connector wiring 167 feedback connector pinouts 104
wiring 155, 167
ground termination 156 induction 159 interconnect diagram 362 model category 435 motor and inertia tests 436 overheating 279 overload retention 453 power connector
pinouts 103
wiring 148, 158
power/brake cable preparation 160
shield clamp wiring 156, 170
testing 268 thermal models 440 tuning 268 universal feedback connector
pinouts 105 velocity 278 mounting your drive
attaching to the panel 88 drilling hole patterns 85 mounting order
accessory modules 57, 81 drive modules 78, 79, 80
shared-bus connection system 82 system mounting toolkit 88 zero-stack tab and cutout 82 MP connector
pinouts 103
wiring 148, 158
MPAI electric cylinders 28
MPAR electric cylinders 28
MPAS linear stages 28
MS connector
pinouts 105 MSF instruction 451
multi-cluster system 81

474

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Index

multiple converter interconnect diagram 344 iTRAK PS interconnect diagram 347 skip speed 430
N
navigation buttons 184 network
parameters 194 status indicator 276 network encoders 116 new tag
data type 202, 206, 211, 222
noise abnormal 279 feedback 278 reduction 71 zones 68
O
open-loop frequency control 420 out of box state 306 overtravel fault code 274
P
panel requirements 39
parameter list category 236, 238, 241, 245, 250, 255
passive shunt connector wiring 177 interconnect diagram 359 pinouts 101 use cases 49
PCDC download 195 PFH definition 305 pinouts
2198-H2DCK 168 2198-K57CK-D15M 168 24V input power connector 100 contactor enable connector 100 DC bus connector 101 digital inputs connector 101 Ethernet connector 103 mains input power connector 100 module status connector 105 motor
brake connector 103 feedback connector 104 power connector 103 safe torque-off 316 shunt connector 101 universal feedback connector 105 planning your installation 39 polarity category 252 power category bus
configuration 201, 205, 209, 218

regulator 201, 209
bus-sharing
group 201, 205, 209, 218, 265
group example 266
power structure 200, 204, 208, 217
power dissipation 53 power supply
cluster 395 DC-bus power supply 16 regenerative bus supply 16 power up 264 power/brake cable preparation 160 precharge time 415 publications, related 13
R
ramp attributes 452 rated slip speed 437
regenerative bus supply 16, 374
Bus Observer 228 BusVoltageReferenceSource 228 catalog numbers 36 configure axis properties
BusVoltageSetPoint 225 general category 225 configure module properties 203 connector locations 93 converter startup method 225 ground screw/jumper 129 interconnect diagram 348 menu screen 187 minimum accessory modules 59 precharge time 415 sequence operation 413 setup menu 191 wiring requirements 137 related publications 13
remove ground screws 132, 133
remove/replace remove drive 298 remove power 294 replace drive 299 startup and configure 300
requirements UL and CE 39
restoring hardwired STO mode 307 routing power and signal wiring 122 Running Controller mode 289
S
SAB 159 safe direction (SDI) 16 safe operational stop (SOS) 16 safe stop 1
integrated configuration 35 safe torque-off 319
bypass wiring 320 cascaded wiring 320 configurations

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475

Index

hardwired 32
integrated 33, 34
explicit messages 309 feature 305
hardwired STO mode 120, 306, 312
specifications 322 timing diagram 313 troubleshooting 314
integrated STO mode 120, 322
specifications 338 STO bypass 332 STO state reset 327 troubleshooting 328 out of box state 306 PFH 305 restoring hardwired STO mode 307 status bits 309 safe torque-off (STO) 16
safely limited position (SLP) 16
safely limited speed (SLS) 16
safety
actions connected drive 288 running controller 289
application 215 category 219 connection 216 safety feedback interface (SFX) 16
scaling category 244, 248, 254
SDI 16
sensorless vector 237, 423
sequence operation
automatic method 417 discharging 418 enable request method 414 regenerative bus supply 413 series change 16
setup screens 188, 189, 190, 191, 192
SFX 16
shared-bus
connection system 82 catalog numbers 37
shared-bus configurations 56
shield clamp 156, 170
dual-axis inverter 161 single-axis inverter 163 shunt connector
pinouts 101 shunts
active 50 passive 49
shutdown 281, 286
sine/cosine 262
with Hall 263 single
converter interconnect diagram 343 iTRAK PS interconnect diagram 346 motor cable 362
single-axis inverter 16, 95, 96, 375 shield clamp 147, 163
wiring requirements 138

sizing
24V current 400 cluster 395 DC-bus group 395 extended cluster 395
extended DC-bus 395, 396
general guidelines 397 power supply cluster 395 shared-bus configurations 395 system sizing 397
example 403, 404
total system capacitance 398 skip speed 429
SLAT 442
attributes 444 configuring 445 slip test messaging 439
SLP 16
SLS 16
soft menu
home screen 184 software
Logix Designer application 196 overtravel 274 SOS 16
specifications
auxiliary feedback 112 feedback encoders 116
brake relay 109 contactor enable relay 108 control power input 111 converter OK relay 109
DC-bus voltage regulation 40, 405
digital inputs 106 encoder phasing 117 EtherNet/IP connections 107 hardwired STO mode 322 integrated STO mode 338 motor feedback 112
absolute position 119 EnDat digital 114 EnDat sine/cosine 114 generic TTL incremental 114 Hiperface 113 sin/cos incremental 114 network encoders 116 speed limited adjustable torque 442
SPM motor closed-loop axis properties 246
SS1 stopping function 16, 35
stability control 427
standard actions 288
startup sequence 193
CIP axis states 193 static motor test 437
status indicators
capacitor module 277 link speed status 276 link/activity status 276 module status 276 network status 276 troubleshooting 276

476

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Index

STO connector
pinouts 316 wiring 319 STO stopping function 16
stop
drive 281 planner 281 stopping actions
configure 287 Studio 5000 Logix Designer 194
system
block diagrams capacitor module 378 DC-bus conditioner module 379 DC-bus power supply 373 dual-axis inverter 376 iTRAK power supply 377 regenerative bus supply 374 single-axis inverter 375
components 16 ground 134 mounting requirements 39 mounting toolkit 88 overview
24V DC voltage drop 401 8720MC-RPS 27 DC-bus power supply 19
EtherNet/IP 29, 30, 31 extended DC-bus 21, 26
iTRAK power supply 22 multiple DC-bus power supplies 20
regenerative bus supply 23, 24
shared DC-bus 25 sizing
example 403, 404
system sizing 397
T
testing axes
hookup test 269 time synchronization 198
timed safe stop (SS1) 16
torque proving 453
attributes 453 configuring 455 total system capacitance 398
transformer 43
troubleshooting
alarm 281 capacitor module status 277 ControlFLASH 392 ControlFLASH Plus 381 controller/drive fault behavior 281
DC-bus supply behavior 282, 284 disable 281, 286
exceptions 281 fault
code overview 274 code summary 275 general system problems abnormal noise 279 axis unstable 278

erratic operation 279 feedback noise 278 motor accel/decel 278 motor overheating 279 motor velocity 278 no rotation 279 hold 286 ignore 281 inverter behavior 287 iTRAK power supply behavior 286 LCD display messages 274 link speed status indicator 276 link/activity status indicator 276 major fault 281 minor fault 281 module status indicator 276 network status indicator 276 safe torque-off hardwired STO mode 314 integrated STO mode 328 safety actions 288 precautions 273
shutdown 281, 286
standard actions 288 status indicators 276 status only 281 stop
drive 281 planner 281 stopping actions 287 definitions 288 typical installation
24V DC voltage drop 401 8720MC-RPS 27 DC-bus power supply 19
EtherNet/IP 29, 30, 31 extended DC-bus 21, 26
iTRAK power supply 22 multiple DC-bus power supplies 20
regenerative bus supply 23, 24
shared DC-bus 25
U
UFB connector
pinouts 105 wiring 167 UL and CE requirements 39
ungrounded power configuration 125, 128
universal feedback connector kit 167
use cases
active shunt 50 passive shunt 49
V
valid feedback types 260
digital AqB TTL 260 digital AqB with UVW 261 sine/cosine 262 sine/cosine with Hall 263

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

477

Index
velocity droop 457 attribute 457 configure 458
verify upgrade 393 virtual torque sensor 461 voltage drop
24V input power 47
voltage regulation 40, 405
W
website certifications 304 Motion Analyzer 13
wiring active shunt 178 BC connector 158 CED contactor enable 143 connector kit shield clamp 170
corner-grounded power configuration 124,
128 CP connector 140 customer supplied cable 173 earth ground 134 Ethernet cables 181 external
active shunt 178 passive shunt resistor 177 ground screw/jumper 129
grounded-wye power configuration 123,
126 guidelines 140 impedance-grounded power configuration
124, 127
input power type 123 IOD connector 146 IOD digital inputs 144 IPD connector 142
MF connector 155, 167
motor cable shield clamp 156
MP connector 148, 158
passive shunt 177
remove ground screws 132, 133
requirements 122 capacitor module 176 DC-bus power supply 136 dual-axis inverter 139 iTRAK power supply 137 regenerative bus supply 137 single-axis inverter 138
routing power and signal wiring 122 safe torque-off
bypass 320 cascaded 320 STO connector 319 UFB connector 167
ungrounded power configuration 125, 128
Z
zero-stack tab and cutout 82

478

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

Notes:

Kinetix 5700 Servo Drives User Manual

Rockwell Automation Publication 2198-UM002K-EN-P - October 2020

479

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Allen-Bradley, CompactLogix, ControlFLASH, ControlFLASH Plus, ControlLogix, Encompass, expanding human possibility, FactoryTalk, GuardLogix, iTRAK, Kinetix, LDC-Series, Logix 5000, PanelView, POINT Guard I/O, POINT I/O, PowerFlex, Rockwell Automation, RSLinx, RSLogix 5000, Stratix, Studio 5000, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. CIP, CIP Motion, CIP Safety, CIP Security, CIP Sync, and EtherNet/IP are trademarks of ODVA, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
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