Rockwell Automation Allen-Bradley 2198-P141 Application Technique

Application Technique

Original Instructions

Drives in Common Bus Configurations with Kinetix 5700 Bus Supplies

Catalog Numbers 2198-P031, 2198-P070, 2198-P141, 2198-P208, 2198-RP088, 2198-RP200, 2198-RP263, 2198-RP312

Drives in Common Bus Configurations with Kinetix 5700 Bus Supplies Application Technique

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).

2 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Table of Contents

DC-bus Wiring Guidelines

Non-regenerative Common

DC-bus Configurations

Non-regenerative Common

DC-bus Configurations

With Passive or Active Shunt

Regenerative Bus Supply

Configurations

Preface

Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 1

Drive Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DC-bus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 2

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Typical System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

AC Line Impedance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Disconnect Switch Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Drive Ground Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Kinetix 5700 Non-Regenerative Bus Supply Considerations . . . . . . . . . . . . . . . . . . . . . . 22

Power Supply Ground Screw Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

System Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Capacitance Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 3

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Typical System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

AC Line Impedance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Disconnect Switch Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Drive Ground Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Active Shunt Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Kinetix 5700 Non-Regenerative Bus Supply Considerations . . . . . . . . . . . . . . . . . . . . . . 32

Shunt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Power Supply Ground Screw Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

System Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Capacitance Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 4

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Typical System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 3

4

Table of Contents

Regenerative Bus Supply

Configurations With Active

Shunt

AC Line Impedance Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Disconnect Switch Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Drive Ground Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Kinetix 5700 Regenerative Bus Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Bus Supply Ground Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Converter OK Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

System Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Capacitance Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chapter 5

Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Typical System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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

Kinetix 5700 Regenerative Bus Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 53

System Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Kinetix and PowerFlex Drive

Specifications

Appendix A

Kinetix 5700 Drive Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Kinetix 6000 Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Kinetix 6200 and Kinetix 6500 Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Kinetix 7000 Drive Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

PowerFlex 750-Series Drive Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fuse Certification and Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

JKS Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

170M Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix B

Kinetix 5700 Accessory Modules Accessory Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Capacitor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

DC-Bus Conditioner Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Preface

An increasing number of drive systems, in a wide range of applications and power ranges, are being configured today in common bus configurations. These system configurations provide significant advantages, such as design flexibility, high efficiency, and cost savings.

It is the objective of this publication to provide the necessary guidelines, considerations, and limitations for the proper application of

Kinetix® and PowerFlex® drives that are used in common-bus configurations with Kinetix 5700 bus supplies.

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 .

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 5

Preface

Notes:

6 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Chapter

1

DC-bus Wiring Guidelines

This chapter provides guidelines for wiring DC common-bus drive systems. Common-bus configurations can be regenerative or nonregenerative. Other variations include active and passive shunt resistors.

Common Bus Configuration

Non-regenerative (diode-front-end)

Regenerative with active shunt

Definition

The non-regenerative common DC-bus topology uses a pulse-width modulated (PWM) controlled insulated-gate bipolar transistor (IGBT) converter that provides single-direction power flow from the incoming AC line. The full-wave bridge rectifier converts three-phase AC voltage to a fixed DC-bus voltage. This configuration contains one or more inverter drives connected directly to the DC common bus.

Non-regenerative with passive or active shunt Same as non-regenerative, but with an added shunt module to dissipate excess regenerative DC-bus energy to a resistor.

Regenerative (active-front-end)

The regenerative bus supply, active front end (AFE) topology, uses a pulse-width modulated (PWM) controlled insulatedgate bipolar transistor (IGBT) converter that enables bidirectional power flow from and back to the incoming AC line. The full-wave bridge rectifier converts three-phase AC voltage to a fixed DC-bus voltage. When the DC-bus voltage is increased above a threshold, a portion of the DC-bus voltage is converted back to three-phase AC voltage. This configuration contains one or more inverter drives connected directly to the DC common bus.

Same as regenerative, but with an added shunt module. In this configuration, some regenerative DC-bus energy flows to the incoming AC line, and the excess DC-bus energy (that is not regenerated) is dissipated to an external active shunt module. See Kinetix® 5700 Servo Drives User Manual, publication 2198-UM002 , for specific active shunt recommendations to be used with the 2198-RP xxx

regenerative bus supply.

Drive Systems

Generally, it is desirable to have the Kinetix 5700 drive mounting order match the machine layout. However, if a mix of drive frame sizes is used in the system, we recommend that the inverter modules are mounted according to power rating (highest to lowest) from left to right (or right to left) starting with the highest power rating. The DC-bus power supply or regenerative bus supply can be mounted anywhere within the cluster.

It is often advantageous to place the Kinetix 5700 bus supply in the middle of the line-up to minimize the distance to the farthest loads.

Shorter distances can minimize the energy that is stored in the parasitic inductance of the bus structure, which helps to lower peak-bus

voltages and mitigate voltage transients during operation. The Extended DC-bus Installation Example on page 8 , illustrates a Kinetix 5700

drive system with a PowerFlex® 750-Series drive, Kinetix 7000 drive, and Kinetix 6000 drive system all powered by the 2198-RP xxx regenerative bus supply.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 7

Chapter 1 DC-bus Wiring Guidelines

Figure 1 - Extended DC-bus Installation Example

Regenerative

Bus Supply

Single-axis

Inverter

Dual-axis

Inverters

Accessory

Modules

Kinetix 5700

Servo Drive System

MOD

NET

MOD

NET

MOD

NET

MOD

NET

MOD

NET

MOD

DC BUS

2

1

1

I/O

6

5 10

OK+

OK–

EN–

EN+

2

1

1

I/O

6

5

UFB

10

2

1

1

I/O-A

6 1

I/O-B

6

2

1

1

I/O-A

6 1

I/O-B

6

5

UFB-A

10 5 10

UFB-B

5

UFB-A

10 5

UFB-B

10

MODULE

STATUS

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

D+

D-

MF

D+

D-

D+

D-

MF-A MF-B

D+

D-

MF-A

D+

D-

MF-B

-

MBRK

+ Line

Disconnect

Device

Circuit

Protection

Magnetic (M1)

Contactor

AC Line Filter

Bulletin 1321

Line Reactor

DC-bus

Extension

DC-bus Circuit

Protection

2198-CAPMOD-2240

Capacitor Module

Bulletin 1492 Power Distribution

Terminal Block

2094-BM xx

-M xx-

S

IAM Module

Common Bus Follower

2094-PRS x

Power Rail

Bonded Cabinet

Ground Bus

PowerFlex

750-Series AC Drive

2099-BM xx-

S

Servo Drive

Kinetix 6000 Servo Drive System

Kinetix 7000

Servo Drive

2094-BM xx

-S

Axis Modules (5)

DC-bus Circuit

Protection

DC-bus Circuit

Protection

DC-bus Connections

DC-bus cables and bus bars are used to connect drives in common-bus configurations.

IMPORTANT The interconnection of drives to the DC-bus, and the inductance levels between the drives, must be kept to a minimum for optimum system operation.

DC-bus Cable

When using cables to connect drives to the system bus, observe the following guidelines:

• 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, however, it is recommended to make sure the DC cables are routed close to each other.

• The maximum DC-bus cable length (power supply cluster to extended cluster) is 70 m (230 ft).

• No single external DC-bus connection from the power supply cluster can exceed 70 m (230 ft). You can extend the DC-bus from the right and left of the power supply cluster, but the total DC-bus length (including DC-bus cabling and DC bus-bar) from the power supply cluster to all extended clusters cannot exceed 140 m (459 ft).

• The Bus Voltage Reference Source is configurable. When it is set to Automatic, the converter optimizes the Bus Voltage Reference for the best converter setting. When it is set to Manual, you configure the desired Bus Voltage Set Point value for the Bus Voltage

Reference signal.

• To prevent nuisance bus-overvoltage faults, the maximum Bus Voltage Set Point of the regenerative bus supply 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.

8 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

DC-bus Wiring Guidelines Chapter 1

Figure 2 - DC-bus Cable Length per Cluster

735

730

725

720

750

0

745

740

715

0

32.8

10

DC-bus Cable Length per Cluster (ft)

65.6

98.4

131 164

20 30 40 50

DC-bus Cable Length per Cluster (m)

197

60

230

70

IMPORTANT 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). Low-inductance DC-bus connection, a feature of the Kinetix 5700 drive system, is also achieved by using

2198-BARCONxxxx

200 DC-bus link connector kits that are included in each Kinetix 5700 inverter.

Size the DC cable in accordance with UL or applicable agency guidelines. Because voltage drop is directly proportional to cable resistance, you can further reduce the voltage drop across the DC cable by using a larger AWG cable size.

Table 1 - Recommended DC-bus Cable Gauge

Recommended DC-bus Cable Gauge mm

2

(AWG/MCM)

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

53.5 (1/0)

152 (300 MCM)

Recommended DC-bus Cable Gauge mm

2

(AWG/MCM)

53.5 (1/0)

152 (300 MCM)

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 9

Chapter 1 DC-bus Wiring Guidelines

Wire the External DC-bus Connections

The 2198-CAPMOD-2240 capacitor module and 2198-CAPMOD-DCBUS-IO extension module are used to extend the DC-bus voltage to external inverter drives. They also provide energy storage. The capacitor module is used alone when the external DC-bus current is ≤104 A. The capacitor module, combined with a DC-bus module or an extension module, is required when the external DC-bus current is >104 A, up to a maximum 208 A.

Figure 3 is an example of a system requiring >104 A of external DC-bus current. For more information on the use of

accessory modules, see

Kinetix 5700 Accessory Modules

on

page 71 .

Figure 3 - Kinetix 5700 External DC-bus Connection Wiring Example

Flexible Bus-bars

User-supplied External DC-bus

Wire Lug Connections

Kinetix 5700

2198-P xxx

DC-bus Power Supply

Kinetix 5700

2198-S xxx

2198-D

-ERS xxx x

or

-ERS x

Inverter

To External

Inverter Drives or

Active Shunt Modules

DC+

DC-

1

2

24V_COM

+24V

PE Ground

DC+

DC-

24V_COM

+24V

DC+

DC-

DC+

DC-

DC-bus

(DC) Connectors

2198-CAPMOD-DCBUS-IO

Extension Module

24V_COM

+24V

Control Power

(CP) Connectors

PE Ground

Module Status

(MS) Connector

MS

MS

1

2

Monitor capacitor module status by wiring to digital input Bus Capacitor OK on the DC-bus power supply or to a Logix 5000™ controller.

2198-CAPMOD-2240

Capacitor Module

PE Ground PE Ground

Bonded Cabinet Ground Bus (user-supplied component)

DC Bus Bar

When using DC bus-bar to connect drives to the system bus, observe the following guidelines:

• DC-bus fuses are required between the Kinetix 5700 power supply cluster and the common DC bus-bar. DC-bus fuses are also required between the DC bus-bar and the DC input of any external inverter drives. See

Kinetix and PowerFlex Drive Specifications on page 59

for the recommended common DC-bus circuit protection devices.

• No single external DC-bus connection from the power supply cluster can exceed 70 m (230 ft). You can extend the DC-bus from the right and left of the power supply cluster, but the total DC-bus length (including DC-bus cabling and DC bus-bar) from the power supply cluster to all extended clusters cannot exceed 140 m (459 ft).

10 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

DC-bus Wiring Guidelines Chapter 1

Figure 4 - DC Bus-bar Application

Regenerative Bus Supply

Accessory

Modules

MOD

NET

Kinetix 5700

Servo Drive System

(power supply cluster #1)

2

1

1

I/O

6

5 10

OK+

OK–

EN–

EN+

MODULE

STATUS

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

2198-CAPMOD-2240

Capacitor Module

DC-bus

Extension

DC-bus Circuit

Protection

DC-bus Bar

DC-bus Circuit

Protection

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

Accessory

Modules Dual-axis Inverters

MOD

DC BUS

MODULE

STATUS

MOD

DC BUS

MOD

NET

MOD

NET

MOD

NET

MOD

NET

2

1

1

I/O-A

6 1

I/O-B

6

MODULE

STATUS 5

UFB-A

10 5

UFB-B

10

I/O-A

6 1

I/O-B

6

2

1

1

I/O-A

6 1

I/O-B

6

I/O-A

6 1

I/O-B

6

UFB-A

10 5

UFB-B

10 5

UFB-A

10 5

UFB-B

10

UFB-A

10 5

UFB-B

10

Kinetix 5700

Servo Drive System

(cluster #2)

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

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

2198-CAPMOD-2240

Capacitor Module

Kinetix 6000 Servo Drive System

2094-BM xx

-M xx-

S

IAM Module

Common Bus Follower

2094-PRS x

Power Rail

2094-BM xx

-S

Axis Modules (5)

Precharge

Precharge is the process of gradually increasing the DC-bus voltage. During this increase in DC-bus voltage, the DC-bus filter capacitors are charged in a controlled manner. The precharge assembly can be part of the drive design or for some drives it can be externally provided and controlled.

ATTENTION: An external source of power can be present. To avoid an electric shock hazard, verify that the AC power supply has been removed before any maintenance is performed.

If an external voltage source is used to power the logic boards of the PowerFlex drives, take precautions to control the precharge sequence.

We recommend that you use the Precharge Enable digital input on the drive for common bus operation. The logic input can be coordinated through a PLC or system-level control to sequence the precharge. The sequencing lets charge time constants for various horsepower drives settle out before the precharge completes. Generally, a three second delay is acceptable after power has been applied. See Drives in

Common Bus Configurations Application Technique, publication DRIVES-AT002 , for precharge functionality on all Powerflex drive frame types.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 11

Chapter 1 DC-bus Wiring Guidelines

ATTENTION: The Precharge Enable digital input is only available on PowerFlex 750-Series common-bus inverter drives. The Kinetix servo drives do not include a Precharge Enable digital input.

When multiple drives are connected through disconnects to a common DC-bus, it is necessary to provide an input to the drive that enables the precharge to finish. Often, an auxiliary contact on the drive disconnect switch controls this input.

Figure 5 - Common DC-bus Example

L1

L2

L3

DC+

DC–

M1 M2

ATTENTION: The bus capacitors in the individual drives act as a low-impedance voltage source. Extra care is needed when connecting individual drives to an energized bus.

ATTENTION: Kinetix drives have no method for you to control the precharge sequence. To avoid severe drive and/or equipment damage due to uncontrolled precharge, do not connect Kinetix servo drives to an energized DC-bus.

If Precharge Enable is selected as a digital input, it must be energized to let the initial bus precharge complete. If Precharge Enable is deenergized, it is treated as a coast-to-stop command that forces the drive to the initial bus-precharge state. Fuse failure is probable unless coordination of precharge circuits in individual drives is implemented.

When Kinetix 6000 drives are used in common bus configurations, they must have firmware revision 1.92 or later. Kinetix 6200/6500 drives with any firmware revision can be used.

PowerFlex 750-Series (Frame 1…4) AC Drives

For PowerFlex 750-Series frame 1…4 AC drives, the precharge hardware is on the power circuit board. It is composed of a resistor in series with the positive DC-bus, between the DC link and the bus capacitors. The resistor has a relay contact that is connected in parallel, which closes to bypass the Precharge resistor when the bus precharge level is attained. The precharge function operates the same way for either

AC or DC input power.

Figure 6 - AC and DC Input Schematic for PowerFlex 750-Series (Frame 1…4) AC Drives

DC+ BR1

L1

L2

L3

+

BR2

U

V

W

12

DC –

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

DC-bus Wiring Guidelines Chapter 1

PowerFlex 750-Series (Frame 5 and 6) AC Drives

When ordered as an AC input drive, DC terminals are not provided on Frame 6 drives. During precharge, the SCRs of the front-end rectifier are open and the bus capacitors are charged through the diodes and resistors from the AC input. After the DC-bus has reached precharge level, the SCRs (when turned on) bypass the diode resistor configuration.

ATTENTION: PowerFlex 750-Series (Frames 5 and 6) AC input drives have no method for you to control the precharge sequence. To avoid severe drive and/or equipment damage due to uncontrolled precharge, do not connect these drives to an energized DC-bus.

Figure 7 - AC and DC Input Schematic for PowerFlex 750-Series (Frame 5 and 6) AC Drives

DC+ BR1

L1

L2

L3

Voltage Rating

Catalog Codes 1 and A

+

BR2

U

V

W

DC – Optional for PowerFlex Frame 6 Drives

PowerFlex 750-Series (Frame 5 and 6) DC Input Common-bus Drives

The precharge has a resistor in series with the positive DC-bus, ahead of the bus capacitors. An SCR is connected in parallel and when gated on, it bypasses the resistor.

Figure 8 - DC Input Schematic for PowerFlex 750-Series (Frame 5 and 6) DC Input Drives

D C + B R 1

Input Type Catalog Number

Position 5, Code 4

+

BR2

U

V

W

DC – Optional for PowerFlex Frame 6 Drives

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 13

Chapter 1 DC-bus Wiring Guidelines

Kinetix 7000 Servo Drives

For 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S servo drives, the precharge hardware is located on the power circuit board. It is composed of a resistor in series with the positive DC-bus between the DC link and the bus capacitors. The resistor has a relay contact connected in parallel that closes when the bus precharge level has been reached, bypassing the precharge resistor. The precharge function operates the same way for AC and DC power.

Figure 9 - AC and DC Input Schematic for Kinetix 7000 (2099-BM06-S…2099-BM08-S) Servo Drives

DC+

L1

L2

L3

+

U

V

W

DC –

For 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, and 2099-BM12-S servo drives, the precharge capability must be provided at the system level.

Disconnect switches must not be used between the input of the drive and a common DC-bus without the use of an external precharge device. The precharge hardware is implemented with an SCR rectifier such that the SCRs are phase advanced to limit the inrush current into the bus capacitors. This phase-advanced precharge is not controlled by the drive and must normally be completed by the minimum precharge time required by the drive. The drive does not complete precharge until the bus voltage is stable and above the undervoltage level.

Figure 10 - AC Input Schematic for Kinetix 7000 (2099-BM09-S…2099-BM12-S) Servo Drives

DC +

L1

L2

L3

+

U

V

W

DC –

14 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

DC-bus Wiring Guidelines Chapter 1

Kinetix 6000 and Kinetix 6200/6500 Multi-axis Servo Drives

The Kinetix 6000 (400V-class) and Kinetix 6200/6500 drives are packaged, highly configurable, common bus products with one converter module (IAM) and multiple inverter modules (AM) mounted on a shared backplane. Precharge hardware, which consists of a resistor in series with a DC link inductor and the positive rail of the DC-bus, is mounted in the converter module. In all recommended common bus configurations, the converter is not used; therefore, any non-Kinetix 6000 common-bus leader module that does not provide precharge is required to add an additional external precharge circuit before connecting to any Kinetix 6000 common-bus follower IAM module.

IMPORTANT Do not connect three-phase AC power to the Kinetix 6000 (follower) converter in mixed Kinetix 5700 common-bus configurations.

An internal shunt resister (braking chopper) is included with each inverter module. To be used in a common bus system with Kinetix 5700 drives, the Kinetix 6000 system must be set to common-bus follower mode with the internal shunt modules disabled.

Figure 11 - AC and DC Input Schematic for Kinetix 6000 and Kinetix 6200/6500 Servo Drives

DC+

L1

L2

L3

DC –

+

2094-BC xx

-BM xx-

S

2094-BC or xx

-BM xx-

M

U

V

W

2094-BM xx-

S or

2094-BM xx-

M

(up to 7 additional axes)

U

V

W

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 15

Chapter 1 DC-bus Wiring Guidelines

Notes:

16 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Chapter

2

Non-regenerative Common DC-bus Configurations

Non-regenerative bus supplies are characterized by a diode-front-end unit that converts three-phase AC line voltage into a non-filtered

DC-bus voltage. No provisions exist for line regeneration or power dissipation of any recovered energy from the motor/load system.

Supported Products

At the time of publication, the following Kinetix® 5700 non-regenerative DC-bus supplies and drives are supported.

Table 2 - Kinetix 5700 Non-regenerative Drive Modules

DC-bus Power Supply

Cat. No.

Supported Drives

• 2198-P031

• 2198-P070

• 2198-P141

• 2198-P208

PowerFlex® 750-Series: Frames 1…6

(1)

Kinetix 7000: All power ratings

Kinetix 6000: All 460V configurations

(2)

Kinetix 6200/6500: All configurations

(1) PowerFlex 750-Series (Frames 5 and 6) DC input drives with precharge must be selected.

(2) Kinetix 6000 configurations require firmware revision 1.92 or later.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 17

Chapter 2 Non-regenerative Common DC-bus Configurations

Typical System Configuration

In this example, standalone AC drives, Kinetix 6000 drives, and Kinetix 7000 drives receive DC-bus power from three 2198-P208 DC-bus power supplies.

Figure 12 - DC-bus Supply with Standalone AC Drives, Kinetix 6 x 00 Drives, and Kinetix 7000 Drives

Three-phase

Source

Circuit

Protection

Three-phase

Contactor

DC-Bus

Power Supply

DC-Bus

Power Supply

DC-Bus

Power Supply

Capacitor

Module

DC Bus

Extension

Module

DC+ DCDC+ DCDC+ DC-

Three-phase

AC Line Filter

AC Drive AC Drive

Circuit

Protection

Line

Reactor

(1)

M M

M

Integrated

Axis Module

M M M

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

Circuit

Protection

Line

Reactor

(1)

Circuit

Protection

Line

Reactor

(1)

(1) Line reactors are required when three 2198-P208 DC-bus supplies are configured. For line reactor considerations and selection when one or two 2198-P208 DC-bus supplies are configured, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

Table 3 - Special Bus Requirements

Drawing Designation

AC drives

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000: All 460V configurations

(1)

Kinetix 6200/6500: All 460V configurations

(1)

(1) No internal precharge. Drives must be placed in common-bus follower configuration.

Special Bus Requirements

None

None

18 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations Chapter 2

General Considerations

This section includes information on AC line impedance, disconnect switch connections, and ground screw/jumper settings, depending on the drive family.

ATTENTION: The incorrect use or configuration of third-party assemblies can result in reduced system reliability and drive damage.

• All system components (bus supply and PowerFlex or Kinetix drives) must be selected for the same AC-line voltage.

• Low-inductance type DC-bus must be used. See

DC-bus Connections

on

page 8

for details.

• To be used in a common-bus system with a Kinetix 5700 bus supply, the Kinetix 6000 or Kinetix 6200/6500 drive systems must be configured as common-bus follower (internal IGBT for shunting is disabled).

IMPORTANT Do not include the 2094-BSP2 shunt module on the 2094 power rail.

• Refer to

Additional Resources

on

page 81 for user documentation with the maximum motor cable length requirements of the drives

specific to your application.

AC Line Impedance Considerations

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 input power source.

• Powering 2198-P xxx

DC-bus power supply and 2198-RP xxx

regenerative bus supply from the same AC input-power source.

- 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.

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional AC line impedance considerations.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 19

Chapter 2 Non-regenerative Common DC-bus Configurations

Disconnect Switch Considerations

If a disconnect switch is used between the common DC-bus and a PowerFlex 750-Series drive input, connect an auxiliary contact on the disconnect switch to a digital input of the drive. The corresponding digital input must be set to Precharge Enable. This setting provides the proper precharge interlocking, which guards against possible damage to the drive when reconnecting the drive to an energized DC-bus.

Under this condition, the drives must have an internal or externally supplied precharge. Precharge handshaking is required before inverter operation. For more information on precharge handshaking, see Drives in Common Bus Configurations Application Technique, publication

DRIVES-AT002 .

Table 4 - PowerFlex 750-Series Drive Precharge Parameters

Number

189 [DI Precharge]

Parameter

Setting

Digital Input

See PowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001

ATTENTION: To avoid personal injury and/or equipment damage, 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.

ATTENTION: The Kinetix 6000 (400V-class), Kinetix 6200/6500, Kinetix 7000, and PowerFlex 750-Series (Frames 5 and 6) AC input drives have no method for you to control the precharge sequence. To avoid sever drive and/or equipment damage due to uncontrolled precharge, do not connect these drives to an energized bus. If a disconnect switch is used between the inputs of the drives and the common DC-bus, an external precharge device must be used.

When an external precharge device is required, a fuse combination switch can be used. These switches provide precharge of capacitive loads, have integrated fuse protection, and perform automatic pre-load type functions with an internal coil.

Input and Output Signals

For the Kinetix 7000 drives, wire the control and interface signals on the General Purpose Relay (GPR) connector as described in the following table. See the Kinetix 7000 High Power Servo Drives User Manual, publication 2099-UM001 , for more information on the terminal block connections.

Table 5 - General Purpose Relay Connections

Signal

DRIVE OK+

DRIVE OK-

Terminal

5

6

Description

Programmable N.O. Relay 2 output

Programmable Relay 2 common

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

ATTENTION: For Kinetix 7000 drives, wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your control string.

20 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations Chapter 2

Drive Ground Jumper Settings

Set the ground jumpers for the Kinetix 6000 (400V-class), Kinetix 6200/6500, and Kinetix 7000 drives according to the following tables. Refer

to Additional Resources on page 81 for the user manual with instructions on how to set the ground jumpers/screws for your servo drive.

Table 6 - Ground Jumper Settings for Kinetix 6000 (400V-class) and Kinetix 6200/6500 Drives

Ground Configuration

2198-P xxx

Ground Jumper Setting Based on Selected Power Supply

DC-bus Power Supply

Grounded power (default setting)

(1)

2198-P xxx

DC-bus Power Supply

(2)

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

Set for ungrounded power

(1) 2198-P xxx

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-P xxx

DC-bus power supply when 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filter is used.

Set for ungrounded power

Table 7 - Ground Jumper Settings for Kinetix 7000 Drives

Ground Configuration

Grounded (wye)

Ground Jumper Setting Based on Selected Power Supply

2198-P xxx

DC-bus Power Supply

Installed (default setting)

(1)

2198-P xxx

DC-bus Power Supply

(2)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

Removed

(1) 2198-P xxx

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-P xxx

DC-bus power supply when 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filter is used.

Removed

PowerFlex 750-Series drives contain protective metal-oxide varistors (MOV) and common mode capacitors referenced to ground. To guard against unstable operation and/or damage, the drive must be properly configured as shown in the following table.

Table 8 - Power Jumper Settings for PowerFlex 750-Series Drives (Frames 1…6)

Ground Configuration

Ground Jumper Setting Based on Selected Power Supply

2198-P xxx

DC-bus Power Supply

(1)

2198-P xxx

DC-bus Power Supply

(2)

Grounded (wye)

• Jumper PE-A connected

(3) (4)

(MOV/input filter caps)

• Jumper PE-B connected (DC-bus common mode caps)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

• Jumper PE-A disconnected (MOV/input filter caps)

• Jumper PE-B disconnected (DC-bus common mode caps)

• Jumper PE-A disconnected (MOV/input filter caps)

• Jumper PE-B disconnected (DC-bus common mode caps)

(1) 2198-P xxx

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-P xxx

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 MOVs are disconnected, the power system must have its own transient protection to maintain known and controlled voltages.

(4) Frame 5 and 6 common DC input drives do not have the PE-A jumper.

For instructions on how to disconnect the PE jumpers, refer to PowerFlex 750-Series Power Jumpers Installation Instructions, publication

750-IN011 .

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 21

Chapter 2 Non-regenerative Common DC-bus Configurations

Kinetix 5700 Non-Regenerative Bus Supply Considerations

When extending the DC-bus from the power supply cluster, a capacitor module must be used to extend the bus. Refer to

Kinetix 5700

Accessory Modules on page 71 for more information on when accessory modules are required.

The 2198-P xxx

DC-bus power supplies do not have a digital output, however, the CIPAxisState tag can be used either programmatically or with an external digital output to indicate that the drives can pull power from the bus. Refer to Integrated Motion on the EtherNet/IP Network

Reference Manual, publication MOTION-RM003 , and Knowledgebase Answer ID: QA35126 , for more information on programming with

Integrated Motion drives

Power Supply Ground Screw Setting

The 2198-P xxx

DC-bus power supply has a factory-installed ground screw for grounded-wye power distribution. The following table summarizes the ground screw/jumper settings for the 2198-P xxx

DC-bus power supply.

Table 9 - Ground Screw Settings for the DC-bus Power Supply

Ground Configuration

2198-P xxx

DC-bus Power Supply

Ground screw installed (default setting)

(1) Grounded (wye)

• Impedance grounded

• Corner grounded

• AC-fed ungrounded

(1) Ground screw is factory installed.

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.

22 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations Chapter 2

Contactor Enable Relay

The contactor-enable circuitry includes a relay-driven contact within the 2198-P xxx

DC-bus power supply. The relay protects the Kinetix 5700 drive system in the event of overloads or other fault conditions.

Figure 13 - Contactor-enable Control String

Kinetix 5700

2198-P208

DC-bus Power Supply

Kinetix 6 x 00

2094-BC xx -M xx -S

Integrated Axis Module

* Indicates User Supplied Component

Kinetix 7000

2099-BM xx -S

Servo Drive

24V AC/DC

50/60 Hz

CR1 *

CR1 *

M1 *

STOP *

START *

CR1 *

CONT EN+ CONT EN– CONT EN+ CONT EN–

GPR2+ GPR2–

An AC three-phase mains contactor must be wired in series between the branch circuit protection and the power supply. In addition, the AC three-phase contactor control string must be wired in series with the contactor-enable relay at the contactor-enable terminals.

PowerFlex 750-Series drives are not required to include a contactor-enable control string and they do not have a dedicated contactor enable relay. Although not required, if leveraging Integrated Motion with a PowerFlex 755 drive, we recommend that you configure a digital output from the drive as Contactor Enable and include it in the contactor enable control string.

A Contactor Enable output can be configured in the PowerFlex 755 drive in integrated motion only. The operation of this output is tied to fault processing in the drive. The drive de-energizes the Contactor Enable output when an exception causes the axis to go to the Shutdown state.

This configuration is only valid when an auxiliary power supply is used for control power with frames 1…7 drives.

ATTENTION: Wiring the contactor enable relay is required for Kinetix 5700, Kinetix 6 x

00, and Kinetix 7000 drive systems to help prevent personal injury or damage to Kinetix drive modules. Wire the contactor enable relay into your control string so that:

• three-phase power is removed and the 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 14 - Contactor-enable Relay Circuit

CONT EN+

Normally

Open

Relay

CONT EN-

Power Supply

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on the contactor-enable circuitry.

ATTENTION: For Kinetix 6000 (400V-class) and Kinetix 6200/6500 drive in common-bus configurations, the contactor enable connections for leader and follower drives must be wired in series to the control string.

A contactor or other device that routinely disconnects and reapplies the AC line to the bus supply can cause drive hardware damage. If an input device is used, operation must not exceed two cycles per minute (maximum) or damage can occur to the precharge circuit.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 23

Chapter 2 Non-regenerative Common DC-bus Configurations

System Sizing

These limitations apply to systems supplied by a single 2198-P xxx

or multiple 2198-P208 DC-bus power 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 IEC 61800-3 (category C3) requirements when used with 2198-DBR xx

-F line filters. 2198-DB xx

-F line filters have a total motor cable length limit of 400 m (1312 ft). See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , 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

Kinetix and PowerFlex Drive Specifications on page 59

.

• 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, add another 24V power supply when control input power to a cluster of drive modules exceeds 40 A.

• The Kinetix 5700 system can have multiple drive clusters in a single DC-bus group. See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on extended clusters.

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on system sizing guidelines.

The motor required for a particular application determines the drive required for full motor performance. For best results, use Motion

Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com/ .

Capacitance Sizing

Total system capacitance is the sum of all internal capacitance values from each of the drive modules (AC drives, single-axis inverters, dualaxis 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 (refer to

Kinetix and

PowerFlex Drive Specifications on page 59

).

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-P xxx

DC-bus power supply

• Use multiple 2198-P208 DC-bus power supplies (1…3 power supplies are possible with only 2198-P208 power supply)

• Decrease the total system capacitance by removing inverters or capacitor modules from the DC-bus group

• Separate clusters into multiple DC-bus groups

All drives have a DC-bus capacitance that is proportional to their power ratings. When used in a common DC-bus configuration, these capacitors are directly connected in parallel. This connection results in the DC-bus ripple being shared proportional to the power rating of the drive. When the ratio of the capacitance to the drive-rated current is consistent, it provides the best DC-bus ripple sharing.

For 400/480V AC, the target ratio is 40 µF/A ±10% or greater. For all drives supported in this publication, the target ratio is met when a capacitor module is used to extend the DC-bus, proper DC-bus cable length guidelines are followed, and low-inductance DC cable is used.

See DC-bus Connections

on

page 8 for more information.

Circuit Protection

Do not daisy chain drives to share DC-bus fusing. Configure the shared DC-bus in a star configuration to enable proper fusing. Use fast semiconductor fuses in the DC links to minimize destructive energy in the event of a part or control malfunction. Size fuses to handle large peak currents at the end of precharge.

• See

Kinetix and PowerFlex Drive Specifications on page 59

for the recommended common DC-bus circuit protection devices.

• See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for recommended AC input circuit protection for the Bulletin

2198 power supply.

24 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Chapter

3

Non-regenerative Common DC-bus Configurations

With Passive or Active Shunt

This system also uses a diode-front-end power supply that converts the three-phase AC line voltage into a non-filtered DC-bus voltage.

However, in this configuration the drive uses the internal IGBT shunt resistor or an external passive or active shunt for power dissipation of excess regenerative energy. Rockwell Automation does not offer external active shunt products. Contact our Encompass™ Partners for these shunt resistor (braking chopper) products.

Supported Products

At the time of publication, the following Kinetix® 5700 non-regenerative DC-bus supplies and drives are supported.

Table 10 - Kinetix 5700 Non-regenerative Drive Modules

DC-bus Power Supply

Cat. No.

• 2198-P031

• 2198-P070

• 2198-P141

• 2198-P208

Supported Drives

PowerFlex® 750-Series: Frames 1…6

(1)

Kinetix 7000: 2099-BM06-S…2099-BM12-S

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(2)

(1) PowerFlex 750-Series (Frames 5 and 6) DC input version drives with precharge must be selected.

(2) Kinetix 6000 configurations require firmware revision 1.92 or later.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 25

Chapter 3 Non-regenerative Common DC-bus Configurations With Passive or Active Shunt

Typical System Configurations

In this example, standalone AC drives, Kinetix 6000 drives, and Kinetix 7000 drives receive DC-bus power from three 2198-P208 DC-bus power supplies. An external passive shunt is wired to one of the 2198-P208 DC-bus supplies.

Figure 15 - DC-bus Supply with Multiple AC Drives and External Passive Shunt

Three-phase

Source

Circuit

Protection

Three-phase

Contactor

(2)

DC-Bus

Power Supply

External Bulletin 2198 Passive Shunt

DC-Bus

Power Supply

DC-Bus

Power Supply

Capacitor

Module

DC Bus

Extension

Module

DC+ DCDC+ DCDC+ DC-

Three-phase

AC Line Filter

Circuit

Protection

Line

Reactor

(1)

AC Drive

M

AC Drive

M

M

Integrated

Axis Module

M M M

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

Circuit

Protection

Line

Reactor

(1)

Circuit

Protection

Line

Reactor

(1)

(1) Line reactors are required when three 2198-P208 DC-bus supplies are configured. For line reactor requirements and selection when one or two 2198-P208 DC-bus supplies are configured, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(2) For passive shunt wiring and mounting information, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

Table 11 - Special Bus Requirements

Drawing Designation

AC drives

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000: All 460V configurations

(1)

Kinetix 6200/6500: All 460V configurations

(1)

(1) No internal precharge. Drives must be placed in common-bus follower configuration.

Special Bus Requirements

None

None

26 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations With Passive or Active Shunt Chapter 3

Figure 16 - DC-bus Supply with Multiple AC Drives and External Active Shunt

Three-phase

Source

Circuit

Protection

Three-phase

Contactor

DC-Bus

Power Supply

DC-Bus

Power Supply

DC-Bus

Power Supply

Capacitor

Module

DC-bus (2)

Conditioner

DC Bus

Three-phase

AC Line Filter

Circuit

Protection

Line

Reactor

(1)

DC+ DCDC+

External Active

Shunt

(3)

BR1 BR2 AC Drive

DC-

BR

M

DC+ DC-

M

Integrated

Axis Module

M M M

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

Circuit

Protection

Line

Reactor

(1)

Circuit

Protection

Line

Reactor

(1)

(1) Line reactors are required when three 2198-P208 DC-bus supplies are configured. For line reactor requirements and selection when one or two 2198-P208 DC-bus supplies are configured, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(2) A DC-bus conditioner module is required to limit DC-bus voltage overshoot at power-on.

(3) Locate the external active shunt close to the DC-bus conditioner. For active shunt wiring and mounting information, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

Table 12 - Special Bus Requirements

Drawing Designation

AC drives

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

(1)

Kinetix 6000: All 460V configurations

(2)

Kinetix 6200/6500: All 460V configurations

(2)

Special Bus Requirements

None

None

(1) External precharge must be provided if a disconnect between the DC-bus and the drive DC input is used.

(2) No internal precharge. Drives must be placed in common-bus follower configuration.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 27

Chapter 3 Non-regenerative Common DC-bus Configurations With Passive or Active Shunt

General Considerations

This section includes information on AC line impedance, disconnect switch connections, and ground screw/jumper settings, depending on the drive family.

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

• All system components (bus supply and PowerFlex or Kinetix drives) must be selected for the same AC-line voltage.

• Low-inductance type DC-bus must be used. See

DC-bus Connections

on

page 8

for details.

• To be used in a common-bus system with a Kinetix 5700 bus supply, the Kinetix 6000 or Kinetix 6200/6500 drive systems must be configured as common-bus follower (internal IGBT for shunting is disabled).

IMPORTANT Do not include the 2094-BSP2 shunt module on the 2094 power rail.

• The Kinetix 7000 drive internal IGBT for shunting is not used by the drive main control for bus regulation. Therefore, any type of regulation must come from an external source.

• Refer to

Additional Resources

on

page 81 for user documentation with the maximum motor cable length requirements of the drives

specific to your application.

AC Line Impedance Considerations

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 input power source.

• Powering 2198-P xxx

DC-bus power supply and 2198-RP xxx

regenerative bus supply from the same AC input-power source.

- 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.

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional AC line impedance considerations.

28 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations With Passive or Active Shunt Chapter 3

Disconnect Switch Considerations

If a disconnect switch is used between the common DC-bus and a PowerFlex 750-Series drive input, connect an auxiliary contact on the disconnect switch to a digital input of the drive. The corresponding digital input must be set to Precharge Enable. This setting provides the proper precharge interlocking, which guards against possible damage to the drive when reconnecting the drive to an energized DC-bus.

Under this condition, the drives must have an internal or externally supplied precharge. Precharge handshaking is required before inverter operation.

Table 13 - PowerFlex 750-Series Drive Precharge Parameter

Number

189 [DI Precharge]

Parameter

Setting

Digital Input

See PowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001

ATTENTION: To avoid personal injury and/or equipment damage, 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.

ATTENTION: The Kinetix 6000 (400V-class), Kinetix 6200/6500, Kinetix 7000, and PowerFlex 750-Series (Frames 5 and 6) AC input drives have no method for you to control the precharge sequence. To avoid sever drive and/or equipment damage due to uncontrolled precharge, do not connect these drives to an energized bus. If a disconnect switch is used between the inputs of the drives and the common DC-bus, an external precharge device must be used.

When an external precharge device is required, a fuse combination switch can be used. These switches provide precharge of capacitive loads, have integrated fuse protection, and perform automatic pre-load type functions with an internal coil.

Input and Output Signals

For the Kinetix 7000 drives, wire the control and interface signals on the General Purpose Relay (GPR) connector as described in the following table. See the Kinetix 7000 High Power Servo Drives User Manual, publication 2099-UM001 , for more information on the terminal block connections.

Table 14 - General Purpose Relay Connections

Signal

DRIVE OK+

DRIVE OK-

Terminal

5

6

Description

Programmable N.O. Relay 2 output

Programmable Relay 2 common

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

ATTENTION: For the Kinetix 7000 drives, wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your control string.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 29

Chapter 3 Non-regenerative Common DC-bus Configurations With Passive or Active Shunt

Drive Ground Jumper Settings

Set the ground jumpers for the Kinetix 6000 (400V-class), Kinetix 6200/6500, and Kinetix 7000 drives according to the following tables. Refer

to Additional Resources on page 81 for the user manual with instructions on how to set the ground jumpers/screws for your servo drive.

Table 15 - Ground Jumper Settings for Kinetix 6000 (400V-class) and Kinetix 6200/6500 Drives

Ground Configuration

2198-P xxx

Ground Jumper Setting Based on Selected Power Supply

DC-bus Power Supply

Grounded power (default setting)

(1)

2198-P xxx

DC-bus Power Supply

(2)

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

Set for ungrounded power

Set for ungrounded power

(1) 2198-P xxx

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-P xxx

DC-bus power supply when 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filter is used.

Table 16 - Ground Jumper Settings for Kinetix 7000 Drives

Ground Configuration

Grounded (wye)

Ground Jumper Setting Based on Selected Power Supply

2198-P xxx

DC-bus Power Supply

Installed (default setting)

(1)

2198-P xxx

DC-bus Power Supply

(2)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

Removed

Removed

(1) 2198-P xxx

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-P xxx

DC-bus power supply when 2198-DBR20-F, 2198-DBR40-F, 2198-DBR90-F, or 2198-DBR200-F AC line filter is used.

PowerFlex 750-Series drives contain protective metal-oxide varistors (MOV) and common mode capacitors referenced to ground. To guard against unstable operation and/or damage, the drive must be properly configured as shown in the following table.

Table 17 - Power Jumper Settings for PowerFlex 750-Series Drives (Frames 1…6)

Ground Configuration

Ground Jumper Setting Based on Selected Power Supply

2198-P xxx

DC-bus Power Supply

(1)

2198-P xxx

DC-bus Power Supply

(2)

Grounded (wye)

• Jumper PE-A connected

(3) (4)

(MOV/input filter caps)

• Jumper PE-B connected (DC-bus common mode caps)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

• Jumper PE-A disconnected (MOV/input filter caps)

• Jumper PE-B disconnected (DC-bus common mode caps)

• Jumper PE-A disconnected (MOV/input filter caps)

• Jumper PE-B disconnected (DC-bus common mode caps)

(1) 2198-P xxx

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-P xxx

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 MOVs are disconnected, the power system must have its own transient protection to maintain known and controlled voltages.

(4) Frames 5 and 6 common DC input drives do not have the PE-A jumper.

For instructions on how to disconnect the PE jumpers, refer to PowerFlex 750-Series Power Jumpers Installation Instructions, publication

750-IN011 .

30 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations With Passive or Active Shunt Chapter 3

Active Shunt Considerations

External active shunts are required in the following use cases:

• One permanent magnet motor runs above its bus overvoltage speed. See Kinetix 5700 Servo Drives User Manual, publication

2198-UM002 , information on the Field Weakening Mode feature.

• One permanent magnet motor drives a vertical load that could make the motor accelerate above the bus overvoltage speed during 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 Encompass partner Powerohm Resistors, Inc. See http://www.powerohm.com

for more information on Powerohm active shunts.

IMPORTANT Powerohm Bulletin PKB xxx

active shunt modules use built-in internal brake resistors. Bulletin PWB xxx

active shunt modules require appropriately sized external brake resistors.

Table 18 - Compatible Active Shunt Specifications (internal brake resistor)

Kinetix 5700 Power Supply

2198-P xxx

DC-bus power supply

Powerohm

Resistors

Cat. No.

(1)

PKB005

PKB010

Input Voltage, nom

480V AC

Turn -on

Bus Voltage

750V DC

Continuous

Power kW

1.50

2.06

Resistance

(internal)

Ω

108

52.7

Resistance

(minimum)

Ω

–

–

Continuous

Current

Amps

2.00

2.75

Peak

Current

Amps

6.9

14.2

PKB050 7.00

10.5

– 9.30

71.4

(1) How the Powerohm PKB xxx

shunts connect to the 2198-P xxx

regenerative bus supply is explained in 2198-Pxxx Power Supply with External Active Shunt (built-in brake resistor) on page 33

.

Table 19 - Compatible Active Shunt Specifications (no internal brake resistor)

Kinetix 5700 Power Supply

2198-P xxx

DC-bus power supply

Powerohm

Resistors

Cat. No.

(1)

PWB035

PWB110

Input Voltage, nom

480V AC

Turn -on

Bus Voltage

750V DC

Continuous

Power kW

26.25

82.5

Resistance

(internal)

Ω

–

–

Resistance

(minimum)

Ω

7.5

2.5

Continuous

Current

Amps

35

110

Peak

Current

Amps

100

300

(1) How the Powerohm PWB xxx

shunts connect to the 2198-P xxx

regenerative bus supply is explained in 2198-Pxxx Power Supply with External Active Shunt (external brake resistor) on page 34 .

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.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 31

Chapter 3 Non-regenerative Common DC-bus Configurations With Passive or Active Shunt

Kinetix 5700 Non-Regenerative Bus Supply Considerations

When extending the DC-bus from the power supply cluster, a capacitor module must be used to extend the bus. Refer to

Kinetix 5700

Accessory Modules on page 71 for more information on when accessory modules are required.

The 2198-P xxx

DC-bus power supplies do not have a digital output, however, the CIPAxisState tag can be used either programmatically or with an external digital output to indicate that the drives can pull power from the bus. Refer to Integrated Motion on the EtherNet/IP Network

Reference Manual, publication MOTION-RM003 , and Knowledgebase Answer ID: QA35126 , for more information on programming with

Integrated Motion drives

Shunt Connections

The 2198-P xxx

DC-bus power supplies all include an internal shunt that is wired to the shunt resistor (RC) connector at the factory. Bulletin

2198-R xxx

external passive shunts are available to provide additional shunt capacity for applications where the internal shunt capacity is exceeded.

Connect an external passive shunt to only the DC-bus power supply. You must disconnect the internal shunt wires at the RC connector before connecting external passive-shunt resistor wires.

Table 20 - DC-bus Power Supply Passive-shunt Options

DC-bus Power Supply

Cat. No.

Internal Shunt Specifications

2198-P031

2198-P070

2198-P141

2198-P208

Ω

37.5

13.5

W

75

200

2198-R127

–

–

X

X

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

–

X

X

External Shunt Module Compatibility

Cat. No.

(1)

2198-R031

–

2198-R014

X

X

X

X

X

X

2198-R004

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 17 - External Passive Shunts

2198-R014, 2198-R031, and 2198-R127

Shunt Modules

2198-R004

Shunt Resistor

Table 21 - External Shunt Module Specifications

Shunt Module

Cat. No.

2198-R004

2198-R014

2198-R031

2198-R127

(1)

Resistance

W

33

9.4

33

13

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

Continuous Power

W

400

1400

3100

12,700

Weight, approx kg (lb)

1.8 (4.0)

9.1 (20)

16.8 (37)

22.2 (49)

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for passive shunt wiring and mounting considerations.

32 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations With Passive or Active Shunt Chapter 3

For drive systems that include the 2198-P xxx

DC-bus power supply and Powerohm PKB xxx

or PWB xxx

active shunts, make the active shunt connections at the external DC-bus studs on accessory modules.

Accessory modules are equipped with spacers that slide onto 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.

Figure 18 - Active Shunt Connections

Spacer

Active Shunt

Lug Connections

(above spacer)

DC-bus

Lug Connections and

Flexible Bus-bars

(2)

(below 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 Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , 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.

For compatible Powerohm active shunts paired with 2198-P xxx

DC-bus power supplies, refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

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 Studio 5000 Logix Designer® application.

Figure 19 - 2198-P xxx Power Supply with External Active Shunt (built-in brake resistor)

2198-P xxx

DC-Bus Power Supply

2198xxxx

-ERS x

Inverter

2198-CAPMOD-2240

Capacitor Module 4.6 m (15 ft) Maximum Cable Length

DC+

External DC-bus

DC+

DC–

Powerohm

Bulletin PKB xxx-xxx

Active Shunt Module

Resistor

DC–

3

4

Fault Contact

Digital Input

(IOD) Connector

IN x

COM

(1)

24V DC

9

10

(2)

120V AC

(1) Configure any available digital input as Shunt Thermal Switch OK.

(2) Powerohm PKB050 and PKB050-800 shunts require 120V AC between pins 9 and 10 to supply power to the cooling fans.

For more information on wiring to these Powerohm Bulletin PKB xxx

active shunts, see the Knowledgebase Answer ID: 1082776 .

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 33

Chapter 3 Non-regenerative Common DC-bus Configurations With Passive or Active Shunt

Figure 20 - 2198-P xxx Power Supply with External Active Shunt (external brake resistor)

2198-P xxx

DC-Bus

Power Supply

2198xxxx

-ERS

Inverter x

2198-CAPMOD-2240

Capacitor Module

Powerohm

Bulletin PWB xxx-xxx

Active Shunt Module

DC+

External DC-bus

DC+

DC–

DC+

DC–

DC–

4.6 m (15 ft)

Maximum Cable Length

9.1 m (30 ft)

Maximum Cable Length

R1

R2

Powerohm

External Passive

Shunt Module

Resistor

3

4

Fault Contact

9

10

(2)

120V AC

Digital Input

(IOD) Connector

IN x

COM

(1)

24V DC

TS

TS

Thermal

Switch

(1) Configure any available digital input as Shunt Thermal Switch OK. See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on configuring digital inputs.

(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 PWB xxx

active shunts.

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).

Power Supply Ground Screw Setting

The 2198-P xxx

DC-bus power supply has a factory-installed ground screw for grounded-wye power distribution. This table summarizes the ground screw settings for the 2198-P xxx

DC-bus power supply.

Table 22 - Ground Screw Settings for the DC-bus Power Supply

Ground Configuration

2198-P xxx

DC-bus Power Supply

Ground screw installed (default setting)

(1) Grounded (wye)

• Impedance grounded

• Corner grounded

• AC-fed ungrounded

(1) Ground screw is factory installed.

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.

34 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Non-regenerative Common DC-bus Configurations With Passive or Active Shunt Chapter 3

Contactor Enable Relay

The contactor-enable circuitry includes a relay-driven contact within the 2198-P xxx

DC-bus power supply. The relay protects the Kinetix 5700 drive system in the event of overloads or other fault conditions.

Figure 21 - Contactor-enable Control String

Kinetix 5700

2198-P208

DC-bus Power Supply

Kinetix 6 x 00

2094-BC xx -M xx -S

Integrated Axis Module

* Indicates User Supplied Component

Kinetix 7000

2099-BM xx -S

Servo Drive

24V AC/DC

50/60 Hz

CR1 *

CR1 *

M1 *

STOP *

START *

CR1 *

CONT EN+ CONT EN– CONT EN+ CONT EN–

GPR2+ GPR2–

An AC three-phase mains contactor must be wired in series between the branch circuit protection and the power supply. In addition, the AC three-phase contactor control string must be wired in series with the contactor-enable relay at the contactor-enable terminals.

PowerFlex 750-Series drives are not required to include a contactor-enable control string and they do not have a dedicated contactor enable relay. Although not required, if leveraging Integrated Motion with a PowerFlex 755 drive, we recommend that you configure a digital output from the drive as Contactor Enable and include it in the contactor enable control string.

A Contactor Enable output can be configured in the PowerFlex 755 drive in integrated motion only. The operation of this output is tied to fault processing in the drive. The drive de-energizes the Contactor Enable output when an exception causes the axis to go to the Shutdown state.

This configuration is only valid when an auxiliary power supply is used for control power with frames 1…7 drives.

ATTENTION: Wiring the contactor enable relay is required for Kinetix 5700, Kinetix 6 x

00, and Kinetix 7000 drive systems to help prevent personal injury or damage to Kinetix drive modules. Wire the contactor enable relay into your control string so that:

• three-phase power is removed and the 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 22 - Contactor-enable Relay Circuit

CONT EN+

Normally

Open

Relay

CONT EN-

Power Supply

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on the contactor-enable circuitry.

ATTENTION: For Kinetix 6000 (400V-class) and Kinetix 6200/6500 drive in common-bus configurations, the contactor enable connections for leader and follower drives must be wired in series to the control string.

A contactor or other device that routinely disconnects and reapplies the AC line to the bus supply can cause drive hardware damage. If an input device is used, operation must not exceed two cycles per minute (maximum) or damage can occur to the precharge circuit.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 35

Chapter 3 Non-regenerative Common DC-bus Configurations With Passive or Active Shunt

System Sizing

These limitations apply to systems supplied by a single 2198-P xxx

or multiple 2198-P208 DC-bus power 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 IEC 61800-3 (category C3) requirements when used with 2198-DBR xx

-F line filters. 2198-DB xx

-F line filters have a total motor cable length limit of 400 m (1312 ft). See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , 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

Kinetix and PowerFlex Drive Specifications on page 59

.

• 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, add another 24V power supply when control input power to a cluster of drive modules exceeds 40 A.

• The Kinetix 5700 system can have multiple drive clusters in a single DC-bus group. See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on extended clusters.

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on system sizing guidelines.

The motor required for a particular application determines the drive required for full motor performance. For best results, use Motion

Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com/ .

Capacitance Sizing

Total system capacitance is the sum of all internal capacitance values from each of the drive modules (AC drives, single-axis inverters, dualaxis 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 (refer to

Kinetix and

PowerFlex Drive Specifications on page 59

).

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-P xxx

DC-bus power supply

• Use multiple 2198-P208 DC-bus power supplies (1…3 power supplies are possible with only 2198-P208 power supply)

• Decrease the total system capacitance by removing inverters or capacitor modules from the DC-bus group

• Separate clusters into multiple DC-bus groups

All drives have a DC-bus capacitance that is proportional to their power ratings. When used in a common DC-bus configuration, these capacitors are directly connected in parallel. This connection results in the DC-bus ripple being shared proportional to the power rating of the drive. When the ratio of the capacitance to the drive-rated current is consistent, it provides the best DC-bus ripple sharing.

For 400/480V AC, the target ratio is 40 µF/A ±10% or greater. For all drives supported in this publication, the target ratio is met when a capacitor module is used to extend the DC-bus, proper DC-bus cable length guidelines are followed, and low-inductance DC cable is used.

See DC-bus Connections

on

page 8 for more information.

Circuit Protection

Do not daisy chain drives to share DC-bus fusing. Configure the shared DC-bus in a star configuration to enable proper fusing. Use fast semiconductor fuses in the DC links to minimize destructive energy in the event of a part or control malfunction. Size fuses to handle large peak currents at the end of precharge.

• See

Kinetix and PowerFlex Drive Specifications on page 59

for the recommended common DC-bus circuit protection devices.

• See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for recommended AC input circuit protection for the Bulletin

2198 power supply.

36 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Chapter

4

Regenerative Bus Supply Configurations

Regenerative bus supplies use a PWM-controlled IGBT converter for full regeneration of power to the AC line. The regenerative bus supply returns energy back to the distribution system instead of dissipating energy with shunt resistor (braking) technology. This configuration provides low AC-line harmonics and can be used to meet IEEE-519.

Supported Products

At the time of publication, the following products are supported.

Table 23 - Kinetix 5700 Regenerative Bus Supply Modules

Regenerative Bus Supply

Cat. No.

• 2198-RP088

• 2198-RP200

• 2198-RP263

• 2198-RP312

Supported Drives

PowerFlex® 750-Series: Frames 1…6

(1)

Kinetix® 7000: 2099-BM06-S…2099-BM12-S

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(2)

(1) PowerFlex 750-Series (Frames 5 and 6) DC input version drives with precharge must be selected.

(2) Kinetix 6000 configurations require firmware revision 1.92 or later.

IMPORTANT The internal IGBT in Kinetix 6000 (460V) drives and Kinetix 6200/6500 drives are disabled in Common Bus Follower mode.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 37

Chapter 4 Regenerative Bus Supply Configurations

Typical System Configuration

In this example, standalone AC drives, Kinetix 6 x

00 drives, and Kinetix 7000 drives receive DC-bus power from the 2198-RP200 regenerative bus supply.

Figure 23 - Regenerative Bus Supply with Standalone AC Drives, Kinetix 6 x 00 Drives, and Kinetix 7000 Drives

Three-phase

Source

(2)

Three-phase

Contactor

Line

Reactor

(1)

Regenerative

Bus Supply

Capacitor

Module

DC-bus Conditioner

Module

(3)

DC Bus

DC+ DCDC+ DCDC+ DC-

AC Drive AC Drive

M M

M

Integrated

Axis Module

M M M

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

(1) A line reactor can be required. For line reactor selection, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(2) Kinetix 5700 regenerative bus supplies require an isolation transformer when connected to corner-grounded or ungrounded facility power.

(3) Kinetix 5700 regenerative bus supplies in mixed common-bus systems require a DC-bus conditioner module in the power supply cluster.

Table 24 - Special Bus Requirements

Drawing Designation

AC drives

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000: All 460V configurations

(1)

Kinetix 6200/6500: All 460V configurations

(1)

(1) No internal precharge. Drives must be placed in common-bus follower configuration.

Special Bus Requirements

None

None

General Considerations

This section includes information on AC line impedance, disconnect switch connections, and ground screw/jumper settings, depending on the drive family.

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

• All system components (bus supply and PowerFlex or Kinetix drives) must be selected for the same AC-line voltage.

• Low-inductance type DC-bus must be used. See

DC-bus Connections

on

page 8

for details.

• To be used in a common-bus system with a Kinetix 5700 bus supply, the Kinetix 6000 or Kinetix 6200/6500 drive systems must be configured as common-bus follower (internal IGBT for shunting is disabled).

IMPORTANT Do not include the 2094-BSP2 shunt module on the 2094 power rail.

• The Kinetix 7000 drive internal IGBT for shunting is not used by the drive main control for bus regulation, therefore any type of regulation must come from an external source.

• Refer to

Additional Resources

on

page 81 for user documentation with the maximum motor cable length requirements of the drives

specific to your application.

38 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations Chapter 4

AC Line Impedance Considerations

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 input power 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 faults.

• 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-P xxx

DC-bus power supply and 2198-RP xxx

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.

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional AC line impedance considerations.

Disconnect Switch Considerations

If a disconnect switch is used between the common DC-bus and a PowerFlex 750-Series drive input, connect an auxiliary contact on the disconnect switch to a digital input of the drive. The corresponding digital input must be set to Precharge Enable. This setting provides the proper precharge interlocking, which guards against possible damage to the drive when reconnecting the drive to an energized DC-bus.

Under this condition, the drives must have an internal or externally supplied precharge. Precharge handshaking is required before inverter operation.

Table 25 - PowerFlex 750-Series Drive Precharge Parameter

Number

189 [DI Precharge]

Parameter

Digital Input

Setting

See PowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001 .

ATTENTION: To avoid personal injury and/or equipment damage, 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.

ATTENTION: The Kinetix 6000 (400V-class), Kinetix 6200/6500, Kinetix 7000, and PowerFlex 750-Series (Frames 5 and 6) AC input drives have no method for you to control the precharge sequence. To avoid sever drive and/or equipment damage due to uncontrolled precharge, do not connect these drives to an energized bus. If a disconnect switch is used between the inputs of the drives and the common DC-bus, an external precharge device must be used.

When an external precharge device is required, a fuse combination switch can be used. These switches provide precharge of capacitive loads, have integrated fuse protection, and perform automatic pre-load type functions with an internal coil.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 39

Chapter 4 Regenerative Bus Supply Configurations

Input and Output Signals

For the Kinetix 7000 drives, wire the control and interface signals on the General Purpose Relay (GPR) and General Purpose I/O (GPIO) connectors as described in the following tables. See the Kinetix 7000 Servo Drives User Manual, publication 2099-UM001 , for more information on the terminal block connections.

Table 26 - General Purpose Relay Connections

Signal

DRIVE OK+

DRIVE OK-

Terminal

5

6

Description

Programmable N.O. Relay 2 output

Programmable Relay 2 common

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

Table 27 - General Purpose I/O Connections

Signal

Regen_OK+

Regen_OK-

Terminal

7

8

Description

Regenerative power supply status

Regenerative power supply status common

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

ATTENTION: For the Kinetix 7000 drives, wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your control string.

In common bus configurations, a REGEN connection on the General Purpose I/O connector is also required for the drives. This connection must be wired in series to the control string, and also wired from the regenerative bus supply to the Kinetix 7000 drive to indicate bus voltage is present.

Drive Ground Jumper Settings

Set the ground jumpers for the Kinetix 6000 (400V-class), Kinetix 6200/6500, and Kinetix 7000 drives according to the following tables. Refer

to Additional Resources on page 81 for the user manual with instructions on how to set the ground jumpers/screws for your servo drive.

Table 28 - Ground Jumper Settings for Kinetix 6000 (400V-class) and Kinetix 6200/6500 Drives

Ground Configuration

Grounded (wye)

Ground Jumper Setting

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

(1) When powered by 2198-RP xxx regenerative bus supply.

Set for ungrounded power

(1)

Table 29 - Ground Jumper Settings for Kinetix 7000 Drives

Ground Configuration Ground Jumper Setting

(1)

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

(1) When powered by 2198-RP xxx regenerative bus supply.

Removed

40 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations Chapter 4

PowerFlex 750-Series drives contain protective metal-oxide varistors (MOV) and common mode capacitors referenced to ground. To guard against unstable operation and/or damage, the drive must be properly configured as shown in the following table.

Table 30 - Power Jumper Settings for PowerFlex 750-Series Drives (Frames 1…6)

Ground Configuration Ground Jumper Setting

(1)

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

(1) When powered by 2198-RP xxx regenerative bus supply.

• Jumper PE-A disconnected (MOV/input filter caps)

• Jumper PE-B disconnected (DC-bus common mode caps)

For instructions on how to disconnect the PE jumpers, refer to PowerFlex 750-Series Power Jumpers Installation Instructions, publication

750-IN011 .

Kinetix 5700 Regenerative Bus Supply Considerations

When extending the DC-bus from the power supply cluster, a capacitor module must be used to extend the bus. Refer to

Kinetix 5700

Accessory Modules on page 71 for more information on when accessory modules are required.

IMPORTANT Regenerative bus supplies do not require an isolation transformer for three-phase input power unless they are connected to corner-grounded or ungrounded facility power.

Bus Supply Ground Jumper Setting

The 2198-RP xxx

regenerative bus supply has a factory-installed ground screw for grounded-wye power distribution. The following table summarizes the ground screw/jumper settings for the 2198-RP xxx

regenerative bus supply.

Table 31 - Ground Jumper Settings for the Regenerative Bus Supply

Ground Configuration

2198-RP xxx

Regenerative Bus Supply

• Grounded (wye)

• Corner-grounded with isolation transformer

• Ungrounded with isolation transformer

Ground jumper installed (default setting)

Impedance grounded 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 corner-grounded 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.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 41

Chapter 4 Regenerative Bus Supply Configurations

Converter OK Signal

The converter OK circuitry of the Kinetix 5700 regenerative bus supply is a relay-driven contact that provides a 24V signal to non-

Kinetix 5700 inverters that they can draw power from the regenerative power supply and that the power supply is not faulted.

Figure 24 - Converter OK Relay Circuit

Regenerative

Bus Supply

Internally

Controlled

Relay

24V PWR

Resettable

Fuse

24V COM

OK+

OK–

The CONV OK signal of the Kinetix 5700 regenerative bus supply (contactor enable connector) can be connected/interlocked to the following

Kinetix and PowerFlex drive inputs to indicate that they can pull power from the bus:

• Regen OK input of Kinetix 7000 drives

• Regeneration OK input of Kinetix 6200/6500 drives

• Enable input of Kinetix 6000 drives

• Regeneration OK input of PowerFlex 750-series drives

Figure 25 - Converter OK Connected/Interlocked to Drive Input

Di C

Di 0

PowerFlex 750-Series Drives

(1)

24VCOM

Regeneration OK

IOD-3

IOD-2

Kinetix 6000 Drives

24VCOM

Enable

IOD-40

IOD-41

Kinetix 6200/6500 Drives

24VCOM

Regeneration OK

GPIO-7

GPIO-8

Kinetix 7000 Drives

Regen_OK+

Regen_OK–

2198-RP xxx

Regenerative Bus Supply

OK+

OK–

CONV OK+

CONV OK–

CONT EN+

CONT EN–

Contactor Enable

(CED) Connector

(1) A 20-750-2262C-2R, or equivalent, option module is required to use the Regeneration OK input. The Regeneration OK input is available only if the Integrated Motion feature of the PowerFlex

750-Series drive is being used. If Integrated Motion is not being used, the Precharge digital input can be used instead.

For PowerFlex drives, the Regeneration OK Input functionality is available for PowerFlex 755 drives only with Integrated Motion applications.

When in motion and the drive detects the Regeneration OK Input transition to an inactive state, the drive generates the Regeneration Powersupply Failure exception and coasts to a stop. The exception cannot be configured and is assigned Stop drive only.

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on the Converter OK circuitry.

42 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations Chapter 4

Contactor Enable Relay

The contactor-enable circuitry includes a relay-driven contact within the 2198-RP xxx

DC-bus power supply. The relay protects the

Kinetix 5700 drive system in the event of overloads or other fault conditions.

Figure 26 - Contactor-enable Control String

Kinetix 5700

2198-RP xxx

Regenerative Bus Supply

Kinetix 6 x 00

2094-BC xx -M xx -S

Integrated Axis Module

* Indicates User Supplied Component

Kinetix 7000

2099-BM xx -S

Servo Drive

24V AC/DC

50/60 Hz

CR1 *

CR1 *

M1 *

STOP *

START *

CR1 *

CONT EN+ CONT EN– CONT EN+ CONT EN–

GPR2+ GPR2–

An AC three-phase mains contactor must be wired in series between the branch circuit protection and the power supply. In addition, the AC three-phase contactor control string must be wired in series with the contactor-enable relay at the contactor-enable terminals.

PowerFlex 750-Series drives are not required to include a contactor-enable control string and they do not have a dedicated contactor enable relay. Although not required, if leveraging Integrated Motion with a PowerFlex 755 drive, we recommend that you configure a digital output from the drive as Contactor Enable and include it in the contactor enable control string.

A Contactor Enable output can be configured in the PowerFlex 755 drive in integrated motion only. The operation of this output is tied to fault processing in the drive. The drive de-energizes the Contactor Enable output when an exception causes the axis to go to the Shutdown state.

This configuration is only valid when an auxiliary power supply is used for control power with frames 1…7 drives.

ATTENTION: Wiring the contactor enable relay is required for Kinetix 5700, Kinetix 6 x

00, and Kinetix 7000 drive systems to help prevent personal injury or damage to Kinetix drive modules. Wire the contactor enable relay into your control string so that:

• three-phase power is removed and the 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 27 - Contactor-enable Relay Circuit

CONT EN+

Normally

Open

Relay

CONT EN-

Power Supply

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on the contactor-enable circuitry.

ATTENTION: For Kinetix 6000 (400V-class) and Kinetix 6200/6500 drive in common-bus configurations, the contactor enable connections for leader and follower drives must be wired in series to the control string.

A contactor or other device that routinely disconnects and reapplies the AC line to the bus supply can cause drive hardware damage. If an input device is used, operation must not exceed two cycles per minute (maximum) or damage can occur to the precharge circuit.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 43

Chapter 4 Regenerative Bus Supply Configurations

System Sizing

These limitations apply to systems supplied by 2198-RP xxx

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 IEC 61800-3 (category C3) requirements when used with 2198-DBR xx

-F line filters. 2198-DB xx

-F line filters have a total motor cable length limit of 400 m (1312 ft). See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , 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

Kinetix and PowerFlex Drive Specifications on page 59

.

• If using the 24V DC shared-bus connection system, add another 24V power supply when control input power to a cluster of drive modules exceeds 40 A.

• The Kinetix 5700 system can have multiple drive clusters in a single DC-bus group. See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on extended clusters.

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on system sizing guidelines.

The motor required for a particular application determines the drive required for full motor performance. For best results, use the Motion

Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com/ .

Capacitance Sizing

Total system capacitance is the sum of all internal capacitance values from each of the drive modules (AC drives, single-axis inverters, dualaxis 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 (refer to

Kinetix and

PowerFlex Drive Specifications on page 59

).

IMPORTANT If your total system capacitance value exceeds the maximum supported capacitance value of the regenerative bus supply, perform one of the following:

• Increase the size of the 2198-RP xxx

regenerative bus supply

• Decrease the total system capacitance by removing inverters or capacitor modules from the DC-bus group

• Separate clusters into multiple DC-bus groups

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.

All drives have a DC-bus capacitance that is proportional to their power ratings. When used in a common DC-bus configuration, these capacitors are directly connected in parallel. This connection results in the DC-bus ripple being shared proportional to the power rating of the drive. When the ratio of the capacitance to the drive-rated current is consistent, it provides the best DC-bus ripple sharing.

For 400/480V AC, the target ratio is 40 µF/A ±10% or greater. For all drives supported in this publication, the target ratio is met when a capacitor module is used to extend the DC-bus, proper DC-bus cable length guidelines are followed, and low-inductance DC cable is used.

See DC-bus Connections

on

page 8 for more information.

Circuit Protection

Do not daisy chain drives to share DC-bus fusing. Configure the shared DC-bus in a star configuration to enable proper fusing. Use fast semiconductor fuses in the DC links to minimize destructive energy in the event of a part or control malfunction. Size fuses to handle large peak currents at the end of precharge.

• See

Kinetix and PowerFlex Drive Specifications on page 59

for the recommended common DC-bus circuit protection devices.

• See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for recommended AC input circuit protection for the Bulletin

2198 power supply.

44 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Chapter

5

Regenerative Bus Supply Configurations With Active Shunt

This system also uses a PWM-controlled IGBT converter for regeneration of power to the AC line. However, in this configuration some regenerative DC-bus energy flows to the incoming AC line, but DC-bus energy that is not regenerated is dissipated to an external shunt resistor (braking) unit. This configuration provides low AC-line harmonics and can be used to meet IEEE-519. Contact our Encompass™

Partners for these shunt resistor (braking) products.

Supported Products

At the time of publication, the following products are supported.

Table 32 - Kinetix 5700 Regenerative Bus Supply Modules

Regenerative Bus Supply

Cat. No.

• 2198-RP088

• 2198-RP200

• 2198-RP263

• 2198-RP312

Supported Drives

PowerFlex® 750-Series: Frames 1…6

(1)

Kinetix® 7000: 2099-BM06-S…2099-BM12-S

Kinetix 6000 and Kinetix 6200/6500: All 460V configurations

(2)

(1) PowerFlex 750-Series (Frames 5 and 6) DC input version drives with precharge must be selected.

(2) Kinetix 6000 configurations require firmware revision 1.92 or later.

When applicable, the drive's internal IGBT can be used with a passive shunt.

Drive Family

PowerFlex 750-Series

Internal Brake IGBT

Standard on Frames 1…5, optional on Frame 6.

Kinetix 7000 No internal brake IGBT.

Kinetix 6000 (400V-class) and Kinetix 6200/6500 Internal bus regulation cannot be used.

IMPORTANT The internal IGBT in Kinetix 6000 (460V) drives and Kinetix 6200/6500 drives are disabled in Common Bus Follower mode.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 45

Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

Typical System Configuration

In this example, standalone AC drives with an external passive shunt, Kinetix 6 x

00 drives, and Kinetix 7000 drives receive DC-bus power from the 2198-RP200 regenerative bus supply.

Figure 28 - Regenerative Bus Supply with Standalone AC Drives, Kinetix 6 x 00 Drives, Kinetix 7000 Drives, and External Passive Shunt

Three-phase

Source

(2)

Three-phase

Contactor

Line

Reactor

(1)

Regenerative

Bus Supply

Capacitor

Module

DC-bus Conditioner

(3)

Module

DC Bus

DC+

(4) (5)

BR

DCDC+ DCDC+ DC-

AC Drive 1 AC Drive 2

M M

M

Integrated

Axis Module

M M M

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

(1) A line reactor can be required. For line reactor selection, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(2) Kinetix 5700 regenerative bus supplies require an isolation transformer when connected to corner-grounded or ungrounded facility power.

(3) Kinetix 5700 regenerative bus supplies in mixed common-bus systems require a DC-bus conditioner module in the power supply cluster.

(4) External passive shunt resistor. For minimum ohms with PowerFlex 750-Series drives, see PowerFlex Dynamic Braking Resistor Calculator Application Technique, publication PFLEX-AT001 .

(5) Connect the shunt resistor (braking IGBT) to the largest frame size drive.

Table 33 - Special Bus Requirements

Drawing Designation

AC Drive 1

AC Drive 2

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000: All 460V configurations

(1)

Kinetix 6200/6500: All 460V configurations

(1)

(1) No internal precharge. Drives must be placed in common-bus follower configuration.

Special Bus Requirements

None

None

46 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations With Active Shunt Chapter 5

In this example, standalone AC drives, Kinetix 6 x

00 drives, and Kinetix 7000 drives receive DC-bus power from the 2198-RP200 regenerative bus supply. An external active shunt is connected to the regenerative bus supply active-shunt (RC) connector.

Figure 29 - Regenerative Bus Supply with Standalone AC Drives, Kinetix 6 x 00 Drives, Kinetix 7000 Drives, and External Active Shunt

Three-phase

Source

(2)

Three-phase

Contactor

Line

Reactor

(1)

(3) (4)

Regenerative

Bus Supply

Capacitor

Module

DC-bus Conditioner

(5)

Module

DC Bus

DC+ DCDC+ DCDC+ DC-

AC Drive 1 AC Drive 2

M M

M M M M

Integrated

Axis Module

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

(1) A line reactor can be required. For line reactor selection, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(2) Kinetix 5700 regenerative bus supplies require an isolation transformer when connected to corner-grounded or ungrounded facility power.

(3) Due to the 10 A connector current rating, connections to the 2198-RP xxx

(RC connector) are limited to only Powerohm PKB xxx

active shunts rated at 7 kW or less.

(4) External active shunt module. For active shunt mounting and wiring considerations, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(5) Kinetix 5700 regenerative bus supplies in mixed common-bus systems require a DC-bus conditioner module in the power supply cluster.

Table 34 - Special Bus Requirements

Drawing Designation

AC Drive

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000: All 460V configurations

(1)

Kinetix 6200/6500: All 460V configurations

(1)

(1) No internal precharge. Drives must be placed in common-bus follower configuration.

Special Bus Requirements

None

None

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 47

Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

In this example, standalone AC drives, Kinetix 6 x

00 drives, and Kinetix 7000 drives receive DC-bus power from the 2198-RP200 regenerative bus supply. An external active shunt is connected to the DC-bus studs of an accessory module.

Figure 30 - Regenerative Bus Supply with Standalone AC Drives, Kinetix 6 x 00 Drives, Kinetix 7000 Drives, and External Active Shunt

Three-phase

Source

(2)

Three-phase

Contactor

Line

Reactor

(1)

Regenerative

Bus Supply

Capacitor

Module

DC-bus Conditioner

(3)

Module

DC Bus

DC+ DCDC+ DCDC+ DCDC+ DC-

External Active

Shunt

(4)

BR1 BR2

AC Drive 1 AC Drive 2

BR

M M

(1) A line reactor can be required. For line reactor selection, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

(2) Kinetix 5700 regenerative bus supplies require an isolation transformer when connected to corner-grounded or ungrounded facility power.

(3) Kinetix 5700 regenerative bus supplies in mixed common-bus systems require a DC-bus conditioner module in the power supply cluster.

(4) External active shunt module. For active shunt mounting and wiring considerations, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

M

Integrated

Axis Module

M M M

Axis

Modules

Kinetix 6000 or

Kinetix 6200/6500 Drives

Table 35 - Special Bus Requirements

Drawing Designation

AC Drive

Kinetix 6000 and

Kinetix 6200/6500 drives

Supported Drives

PowerFlex 750-Series: Frames 1…6

Kinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000: All 460V configurations

(1)

Kinetix 6200/6500: All 460V configurations

(1)

(1) No internal precharge. Drives must be placed in common-bus follower configuration.

Special Bus Requirements

None

None

General Considerations

This section includes information on AC line impedance, disconnect switch connections, and ground screw/jumper settings, depending on the drive family.

ATTENTION: The incorrect use or configuration of third party assemblies can result in reduced system reliability and drive damage.

• All system components (bus supply and PowerFlex or Kinetix drives) must be selected for the same AC-line voltage.

• Low-inductance type DC-bus must be used. See

DC-bus Connections

on

page 8

for details.

• To be used in a common-bus system with a Kinetix 5700 bus supply, the Kinetix 6000 or Kinetix 6200/6500 drive systems must be configured as common-bus follower (internal IGBT for shunting is disabled).

IMPORTANT Do not include the 2094-BSP2 shunt module on the 2094 power rail.

• The Kinetix 7000 drive internal dynamic brake IGBT is not used by the drive main control for bus regulation, therefore any type of regulation must come from an external source.

• Refer to

Additional Resources

on

page 81 for user documentation with the maximum motor cable length requirements of the drives

specific to your application.

48 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations With Active Shunt Chapter 5

AC Line Impedance Considerations

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 input power 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 faults.

• 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-P xxx

DC-bus power supply and 2198-RP xxx

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.

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional AC line impedance considerations.

Disconnect Switch Considerations

If a disconnect switch is used between the common DC-bus and a PowerFlex 750-Series drive input, connect an auxiliary contact on the disconnect switch to a digital input of the drive. The corresponding digital input must be set to Precharge Enable. This setting provides the proper precharge interlocking, which guards against possible damage to the drive when reconnecting the drive to an energized DC-bus.

Under this condition, the drives must have an internal or externally supplied precharge. Precharge handshaking is required before inverter operation.

Table 36 - PowerFlex 750-Series Drive Precharge Parameter

Parameter

Number

189 [DI Precharge]

Digital Input

Setting

See PowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001 .

ATTENTION: To avoid personal injury and/or equipment damage, 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.

If DC input is supplied to 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, or 2099-BM12-S drives, the precharge capability must be provided at the system level. Disconnect switches must not be used between the input of the drive and a common DC-bus without the use of an external precharge device.

ATTENTION: The Kinetix 6000 (400V-class), Kinetix 6200/6500, Kinetix 7000, and PowerFlex 750-Series (Frames 5 and 6) AC input drives have no method for you to control the precharge sequence. To avoid sever drive and/or equipment damage due to uncontrolled precharge, do not connect these drives to an energized bus. If a disconnect switch is used between the inputs of the drives and the common DC-bus, an external precharge device must be used.

When an external precharge device is required, a fuse combination switch can be used. These switches provide precharge of capacitive loads, have integrated fuse protection, and perform automatic pre-load type functions with an internal coil.

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Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

Input and Output Signals

For the Kinetix 7000 drives, wire the control and interface signals on the General Purpose Relay (GPR) and General Purpose I/O (GPIO) connectors as described in the following tables. See the Kinetix 7000 Servo Drives User Manual, publication 2099-UM001 , for more information on the terminal block connections.

Table 37 - General Purpose Relay Connections

Signal

DRIVE OK+

DRIVE OK-

Terminal

5

6

Description

Programmable N.O. Relay 2 output

Programmable Relay 2 common

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

Table 38 - General Purpose I/O Connections

Signal

Regen_OK+

Regen_OK-

Terminal

7

8

Description

Regenerative power supply status

Regenerative power supply status common

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

ATTENTION: For the Kinetix 7000 drives, wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your control string.

In common bus configurations, a REGEN connection on the General Purpose I/O connector is also required for the drives. This connection must be wired in series to the control string, and also wired from the regenerative bus supply to the Kinetix 7000 drive to indicate bus voltage is present.

50 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations With Active Shunt Chapter 5

Drive Ground Jumper Settings

Set the ground jumpers for the Kinetix 6000 (400V-class), Kinetix 6200/6500, and Kinetix 7000 drives according to the following tables. Refer

to Additional Resources on page 81 for the user manual with instructions on how to set the ground jumpers/screws for your servo drive.

Table 39 - Ground Jumper Settings for Kinetix 6000 (400V-class) and Kinetix 6200/6500 Drives

Ground Configuration

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

(1) When powered by 2198-RP xxx regenerative bus supply.

Ground Jumper Setting

(1)

Set for ungrounded power

Table 40 - Ground Jumper Settings for Kinetix 7000 Drives

Ground Jumper Setting

(1) Ground Configuration

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

(1) When powered by 2198-RP xxx regenerative bus supply.

Removed

PowerFlex 750-Series drives contain protective metal-oxide varistors (MOV) and common mode capacitors referenced to ground. To guard against unstable operation and/or damage, the drive must be properly configured as shown in the following table.

Table 41 - Power Jumper Settings for PowerFlex 750-Series Drives (Frames 1…6)

Ground Jumper Setting

(1) Ground Configuration

Grounded (wye)

• AC-fed ungrounded

• Corner grounded

• Impedance grounded

• DC-bus from active converter

(1) When powered by 2198-RP xxx regenerative bus supply.

• Jumper PE-A disconnected (MOV/input filter caps)

• Jumper PE-B disconnected (DC-bus common mode caps)

For instructions on how to disconnect the PE jumpers, refer to PowerFlex 750-Series Power Jumpers Installation Instructions, publication

750-IN011 .

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Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

Active Shunt Considerations

External active shunts are required in the following use cases:

• The 2198-RP xxx 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 Kinetix 5700 Servo Drives User Manual, publication

2198-UM002 , information on the Field Weakening Mode 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-RP xxx

regenerative bus supply capacity. For example, consider a peak-power stopping condition.

• The 2198-RP xxx

regenerative bus supply is operating with DC-bus regulation enabled and the regenerative bus supply loses threephase 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 Encompass partner Powerohm Resistors, Inc. See http://www.powerohm.com

for more information on Powerohm active shunts.

IMPORTANT Powerohm Bulletin PKB xxx

active shunt modules use built-in internal brake resistors. Bulletin PWB xxx

active shunt modules require appropriately sized external brake resistors.

Table 42 - Compatible Active Shunt Specifications (internal brake resistor)

Kinetix 5700 Power Supply

Powerohm

Resistors

Cat. No.

(1)

2198-RP xxx regenerative bus supply when DC-bus regulation is not enabled.

PKB005

PKB010

PKB050

PKB005-800

2198-RP xxx regenerative bus supply when DC-bus regulation is enabled.

PKB010-800

PKB050-800

Input Voltage, nom

480V AC

Turn -on

Bus Voltage

750V DC

800V DC

Continuous

Power kW

1.50

2.06

7.00

1.50

2.06

7.00

Resistance

(internal)

Ω

108

52.7

10.5

108

52.7

10.5

Resistance

(minimum)

Ω

–

–

–

–

–

–

Continuous

Current

Amps

2.00

2.75

9.30

1.88

2.58

8.72

Peak

Current

Amps

6.9

14.2

71.4

7.4

15.2

76.2

(1) How the Powerohm PKB xxx

shunts connect to the 2198-RP xxx regenerative bus supply is explained in

2198-RPxxx Bus Supply with External Active Shunt (built-in brake resistor) on page 54 .

Table 43 - Compatible Active Shunt Specifications (no internal brake resistor)

Kinetix 5700 Power Supply

2198-RP xxx regenerative bus supply when DC-bus regulation is not enabled.

2198-RP xxx regenerative bus supply when DC-bus regulation is enabled.

Powerohm

Resistors

Cat. No.

(1)

PWB035

PWB110

PWB035-800

PWB110-800

Input Voltage, nom

480V AC

Turn -on

Bus Voltage

750V DC

800V DC

Continuous

Power kW

26.25

82.5

26.25

82.5

Resistance

(internal)

Ω

–

–

–

–

Resistance

(minimum)

Ω

7.5

2.5

8.0

2.7

Continuous

Current

Amps

35

110

35

110

Peak

Current

Amps

100

300

100

300

(1) How the Powerohm PWB xxx

shunts connect to the 2198-RP xxx regenerative bus supply is explained in

2198-RPxxx Bus Supply with External Active Shunt (external brake resistor) on page 55

52

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.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations With Active Shunt Chapter 5

Kinetix 5700 Regenerative Bus Supply Considerations

When extending the DC-bus from the power supply cluster, a capacitor module must be used to extend the bus. Refer to

Kinetix 5700

Accessory Modules on page 71 for more information on when accessory modules are required.

IMPORTANT Regenerative bus supplies do not require an isolation transformer for three-phase input power unless they are connected to corner-grounded or ungrounded facility power.

Shunt Connections

IMPORTANT 2198-RP xxx shunt type.

regenerative bus supplies do not support passive shunts. Make active shunt connections to the 2198-RP xxx regenerative bus supply at the active shunt (RC) connector or the external DC-bus studs on accessory modules, depending on the

Figure 31 - RC Connector Wiring

2198-RP xxx

Regenerative Bus Supply

Top View

Active Shunt

(RC) Connector Plug

1

2

Table 44 - Active Shunt (RC) Connector Specifications

Regenerative Bus Supply

Cat. No.

Pin Signal

Continuous

(1) max

Current,

2198-RP xxx

RC-1

RC-2

DC–

DC+

10 A

(1) This connector applies to only Powerohm PKB xxx

xxx

active shunts rated at 7 kW or less.

Recommended Wire Size mm

2

(AWG)

2.5…6

(14…10)

Strip Length mm (in.)

12.0 (0.47)

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 PKB rated at 7 kW or less. All other PKB capacitor module.

and PWB xxx

xxx

active shunts

active shunt connections must be made to the 2198-CAPMOD-2240

You can make active shunt connections in drive systems that include the regenerative bus supply and Powerohm PKB xxx

-800 or

PWB xxx

-800 active shunts at the external DC-bus studs on accessory modules.

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Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

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.

Figure 32 - Active Shunt Connections

Spacer

Active Shunt

Lug Connections

(above spacer)

DC-bus

Lug Connections and

Flexible Bus-bars

(2)

(below 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 Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , 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.

For compatible Powerohm active shunts paired with the 2198-RP xxx

regenerative bus supply, refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

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 33 - 2198-RP xxx Bus Supply with External Active Shunt (built-in brake resistor)

2198-RP xxx

Regenerative Bus Supply

2198xxxx

-ERS

Inverter x

2198-CAPMOD-2240

Capacitor Module

4.6 m (15 ft) Maximum Cable Length

DC+

External DC-bus

DC+

DC–

Powerohm

Bulletin PKB xxx-xxx

Active Shunt Module

Resistor

DC–

3

4

Fault Contact

Digital Input

(IOD) Connector

IN x

COM

(1)

24V DC

9

10

(2)

120V AC

(1) Configure any available digital input as Shunt Thermal Switch OK. See the Kinetix 5700 Servo Drives User Manual, publication

2198-UM002 , for more information on configuring digital inputs.

(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 PKB xxx

active shunts.

54 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations With Active Shunt Chapter 5

Figure 34 - 2198-RP xxx Bus Supply with External Active Shunt (external brake resistor)

2198-RP xxx

Regenerative

Bus Supply

2198xxxx

-ERS x

Inverter

2198-CAPMOD-2240

Capacitor Module

Powerohm

Bulletin PWB xxx-xxx

Active Shunt Module

Powerohm

External Passive

Shunt Module

DC+

External DC-bus

DC+

DC–

DC+

DC–

R1

R2

Resistor

DC–

4.6 m (15 ft)

Maximum Cable Length

9.1 m (30 ft)

Maximum Cable Length

3

4

Fault Contact

9

10

(2)

120V AC

TS

TS

Thermal

Switch Digital Input

(IOD) Connector

IN x

COM

(1)

24V DC

(1) Configure any available digital input as Shunt Thermal Switch OK. See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on configuring digital inputs.

(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 PWB xxx

active shunts.

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).

Bus Supply Ground Jumper Setting

The 2198-RP xxx

regenerative bus supply has a factory-installed ground screw for grounded-wye power distribution. The following table summarizes the ground screw/jumper settings for the 2198-RP xxx

regenerative bus supply.

Table 45 - Ground Jumper Settings for the Regenerative Bus Supply

Ground Configuration

2198-RP xxx

Regenerative Bus Supply

• Grounded (wye)

• Corner-grounded with isolation transformer

• Ungrounded with isolation transformer

Impedance grounded

Ground jumper 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 corner-grounded 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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Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

Converter OK Signal

The converter OK circuitry of the Kinetix 5700 regenerative bus supply is a relay-driven contact that provides a 24V signal to non-

Kinetix 5700 inverters that they can draw power from the regenerative power supply and that the power supply is not faulted.

Figure 35 - Converter OK Relay Circuit

24V PWR

Regenerative

Bus Supply

Internally

Controlled

Relay

Resettable Fuse

24V COM

OK+

OK–

The CONV OK signal of the Kinetix 5700 regenerative bus supply (contactor enable connector) can be connected/interlocked to the following

Kinetix and PowerFlex drive inputs to indicate that they can pull power from the bus:

• Regen OK input of Kinetix 7000 drives

• Regeneration OK input of Kinetix 6200/6500 drives

• Enable input of Kinetix 6000 drives

• Regeneration OK of PowerFlex 750-series drives

Figure 36 - Converter OK Connected/Interlocked to Drive Input

Di C

Di 0

PowerFlex 750-Series Drives

(1)

24VCOM

Regeneration OK

IOD-3

IOD-2

Kinetix 6000 Drives

24VCOM

Enable

IOD-40

IOD-41

Kinetix 6200/6500 Drives

24VCOM

Regeneration OK

GPIO-7

GPIO-8

Kinetix 7000 Drives

Regen_OK+

Regen_OK–

2198-RP xxx

Regenerative Bus Supply

OK+

OK–

CONV OK+

CONV OK–

CONT EN+

CONT EN–

Contactor Enable

(CED) Connector

(1) The Regeneration OK input is available only if the Integrated Motion feature of the PowerFlex 750-Series drive is being used. If Integrated Motion is not being used, the Precharge digital input can be used instead.

For PowerFlex drives, the Regeneration OK Input functionality is available for PowerFlex 755 drives only with Integrated Motion applications.

When in motion and the drive detects the Regeneration OK Input transition to an inactive state, the drive generates the Regeneration Powersupply Failure exception and coasts to a stop. The exception cannot be configured and is assigned Stop drive only.

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on the Converter OK circuitry.

56 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Regenerative Bus Supply Configurations With Active Shunt Chapter 5

Contactor Enable Relay

The contactor-enable circuitry includes a relay-driven contact within the 2198-RP xxx

DC-bus power supply. The relay protects the

Kinetix 5700 drive system in the event of overloads or other fault conditions.

Figure 37 - Contactor-enable Control String

Kinetix 5700

2198-RP xxx

Regenerative Bus Supply

Kinetix 6 x 00

2094-BC xx -M xx -S

Integrated Axis Module

* Indicates User Supplied Component

Kinetix 7000

2099-BM xx -S

Servo Drive

24V AC/DC

50/60 Hz

CR1 *

CR1 *

M1 *

STOP *

START *

CR1 *

CONT EN+ CONT EN– CONT EN+ CONT EN–

GPR2+ GPR2–

An AC three-phase mains contactor must be wired in series between the branch circuit protection and the power supply. In addition, the AC three-phase contactor control string must be wired in series with the contactor-enable relay at the contactor-enable terminals.

PowerFlex 750-Series drives are not required to include a contactor-enable control string and they do not have a dedicated contactor enable relay. Although not required, if leveraging Integrated Motion with a PowerFlex 755 drive, we recommend that you configure a digital output from the drive as Contactor Enable and include it in the contactor enable control string.

A Contactor Enable output can be configured in the PowerFlex 755 drive in integrated motion only. The operation of this output is tied to fault processing in the drive. The drive de-energizes the Contactor Enable output when an exception causes the axis to go to the Shutdown state.

This configuration is only valid when an auxiliary power supply is used for control power with frames 1…7 drives.

ATTENTION: Wiring the contactor enable relay is required for Kinetix 5700, Kinetix 6 x

00, and Kinetix 7000 drive systems to help prevent personal injury or damage to Kinetix drive modules. Wire the contactor enable relay into your control string so that:

• three-phase power is removed and the 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 38 - Contactor-enable Relay Circuit

CONT EN+

Normally

Open

Relay

CONT EN-

Power Supply

Refer to Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on the contactor-enable circuitry.

ATTENTION: For Kinetix 6000 (400V-class) and Kinetix 6200/6500 drive in common-bus configurations, the contactor enable connections for leader and follower drives must be wired in series to the control string.

A contactor or other device that routinely disconnects and reapplies the AC line to the bus supply can cause drive hardware damage. If an input device is used, operation must not exceed two cycles per minute (maximum) or damage can occur to the precharge circuit.

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Chapter 5 Regenerative Bus Supply Configurations With Active Shunt

System Sizing

These limitations apply to systems supplied by 2198-RP xxx

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 IEC 61800-3 (category C3) requirements when used with 2198-DBR xx

-F line filters. 2198-DB xx

-F line filters have a total motor cable length limit of 400 m (1312 ft). See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , 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

Kinetix and PowerFlex Drive Specifications on page 59

.

• If using the 24V DC shared-bus connection system, add another 24V power supply when control input power to a cluster of drive modules exceeds 40 A.

• The Kinetix 5700 system can have multiple drive clusters in a single DC-bus group. See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on extended clusters.

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for additional information on system sizing guidelines.

The motor required for a particular application determines the drive required for full motor performance. For best results, use Motion

Analyzer system sizing and selection tool, available at https://motionanalyzer.rockwellautomation.com/ .

Capacitance Sizing

Total system capacitance is the sum of all internal capacitance values from each of the drive modules (AC drives, single-axis inverters, dualaxis 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 (refer to

Kinetix and

PowerFlex Drive Specifications on page 59

).

IMPORTANT If your total system capacitance value exceeds the maximum supported capacitance value of the regenerative bus supply, perform one of the following:

• Increase the size of the 2198-RP xxx

regenerative bus supply

• Decrease the total system capacitance by removing inverters or capacitor modules from the DC-bus group

• Separate clusters into multiple DC-bus groups

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.

All drives have a DC-bus capacitance that is proportional to their power ratings. When used in a common DC-bus configuration, these capacitors are directly connected in parallel. This connection results in the DC-bus ripple being shared proportional to the power rating of the drive. When the ratio of the capacitance to the drive-rated current is consistent, it provides the best DC-bus ripple sharing.

For 400/480V AC, the target ratio is 40 µF/A ±10% or greater. For all drives supported in this publication, the target ratio is met when a capacitor module is used to extend the DC-bus, proper DC-bus cable length guidelines are followed, and low-inductance DC cable is used.

See DC-bus Connections

on

page 8 for more information.

Circuit Protection

Do not daisy chain drives to share DC-bus fusing. Configure the shared DC-bus in a star configuration to enable proper fusing. Use fast semiconductor fuses in the DC links to minimize destructive energy in the event of a part or control malfunction. Size fuses to handle large peak currents at the end of precharge.

• See

Kinetix and PowerFlex Drive Specifications on page 59

for the recommended common DC-bus circuit protection devices.

• See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for recommended AC input circuit protection for the Bulletin

2198 power supply.

58 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Appendix

A

Kinetix and PowerFlex Drive Specifications

This appendix provides Kinetix® and PowerFlex® drive specifications and includes DC input currents, recommended DC input fuses

(manufacturer catalog numbers), and internal drive DC-bus capacitance.

Kinetix 5700 Drive Specifications

The total system capacitance must be less than the maximum supported DC-bus capacitance value of the power supply.

Table 46 - Kinetix 5700 Power Supply Capacitance

Power Supply

Single DC-bus Power Supply

Multiple DC-bus Power Supplies

Regenerative Bus Supplies

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

Supported Capacitance, max

µF

8,000

13,000

26,000

39,000

9,000

15,000

25,000

Internal Capacitance

µF

585

780

1640

2050

4100

6150

940

2460

4510

5740

207

542

994

1265

Capacitive Energy Absorption

J

129

172

362

453

906

1359

Table 47 - Kinetix 5700 Single-axis Inverter Power Specifications

Attribute

DC input current @ 458…747V DC

2198-S086-ERS3

2198-S086-ERS4

45.7 A

DC

560 µF Internal Capacitance

(1) UL tested to 175.0 A

DC

.

Table 48 - Kinetix 5700 Dual-axis Inverter Power Specifications

2198-S130-ERS3

2198-S130-ERS4

69.0 A

DC

840 µF

2198-S160-ERS3

2198-S160-ERS4

92.3 A

DC

1120 µF

Attribute

DC input current @ 458…747V DC

Internal Capacitance

Per Axis

(1)

X

(1) These attributes apply to both of the axes in each dual-axis inverter.

Table 49 - DC-bus Power Supply Specifications

2198-D006-ERS3

2198-D006-ERS4

2.7 A

DC

165 µF

Attribute

AC input voltage

AC input frequency

Main AC input current

(1)

324…528V (rms) three-phase

Max inrush (0-pk)

11.2A

33.0 A

27.0 A

33.0 A

2198-D012-ERS3

2198-D012-ERS4

5.3 A

DC

2198-P031 2198-P070

324…528V rms, three-phase (480V nom)

47…63 Hz

2198-D020-ERS3

2198-D020-ERS4

8.5 A

DC

330 µF

2198-P141

49.6 A

33.0 A

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

2198-S263-ERS3

2198-S263-ERS4

164.0 A

DC

2050 µF

2198-D032-ERS3

2198-D032-ERS4

13.7 A

DC

390 µF

73.1 A

33.0 A

2198-S312-ERS3

2198-S312-ERS4

207.0 A

DC

(1)

2050 µF

2198-D057-ERS3

2198-D057-ERS4

24.5 A

DC

705 µF

2198-P208

59

Appendix A Kinetix and PowerFlex Drive Specifications

Table 49 - DC-bus Power Supply Specifications

Attribute

Peak AC input current

324…528V (rms) three-phase

Line loss ride through

Control power DC input voltage

Control power DC input current

(1)

(2)

Nominal bus output voltage

Continuous output current to bus

Three-phase

Peak output current to bus

Three-phase

Peak output current duration

(3)

Continuous output power to bus

Nom (480V rms, three-phase)

Peak output power to bus

Nom (480V rms, three-phase)

Bus overvoltage - 480V, nom AC input

Internal shunt resistance

Internal shunt power

Shunt on

Shunt off

Efficiency

Internal Capacitance

Capacitive energy absorption

Short-circuit current rating

2198-P031

33.4 A

20 ms

24V DC ±10%

0.8 A

DC

458…747V DC

10.5 A

31.6 A

1.0 s

7.0 kW

21.0 kW

832V DC

37.5 Ω

75 W

775V plus 30V x bus regulator capacity/utilization

(4)

765V plus 30V x bus regulator capacity/utilization

(4)

99%

585 µF

129 J

DC

DC

200,000 A (rms) symmetrical

2198-P070

74.3 A

25.5 A

70.3 A

1.0 s

17.0 kW

46.0 kW

780 µF

172 J

DC

DC

2198-P141

148.7 A

1.9 A

1.0 s

DC

46.9 A

93.0 kW

13.5 Ω

200 W

1640 µF

362 J

DC

140.8 A

31.0 kW

DC

2198-P208

219.2 A

69.2 A

207.6 A

0.1 s

DC

46.0 kW

DC

138.0 kW

2050 µF

453 J

(1) All modules are limited to 1 power cycle per minute.

(2) For current values when motors include a holding brake and additional information, refer to Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003 .

(3) Peak output current duration with 10% duty cycle.

(4) The shunt on and shunt off voltages increase during periods of shunting activity to promote sharing of shunt power in multi-axis configurations. Shunt utilization is equivalent to the

BusRegulatorCapacity tag in the Logix Designer application.

60 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Kinetix and PowerFlex Drive Specifications Appendix A

Table 50 - Regenerative Bus Supply Specifications

Attribute

AC input voltage

(1)

AC input frequency

Main AC input current

(2)

324…506V (rms) three-phase

Max inrush (0-pk)

Peak AC input current

324…506V (rms) three-phase

Line loss ride through

Control power DC input voltage

Control power DC input current

(2)

(3)

Nominal bus output voltage

Continuous output current to bus

Peak output current to bus

Peak output current duration

(4)

Continuous output power to bus

Nom (480V rms, three-phase)

Peak output power to bus

Nom (480V rms, three-phase)

Bus overvoltage - 480V, nom AC input

Internal shunt resistance

Efficiency

Internal Capacitance

(5)

Capacitive energy absorption

Short-circuit current rating

2198-RP088

47…63 Hz

30.0 A

76.0 A

75.0 A

20 ms

24V DC ±10%

4.3 A

DC

458…747V DC

35.3 A

DC

88.0 A

DC

1.0 s/3.0 s

24.0 kW

2198-RP200

324…506V rms, three-phase (480V nom)

85.0 A

176.0 A

170.0 A

5.4 A

DC

100.0 A

200.0 A

67.0 kW

DC

DC

60.0 kW

832V DC

–

98%

940 µF

207 J

200,000 A (rms) symmetrical

135.8 kW

2460 µF

542 J

2198-RP263

150.0 A

362.0 A

225.0 A

9.1 A

DC

176.4 A

263.0 A

DC

119.0 kW

179.7 kW

–

4510 µF

994 J

DC

2198-RP312

192.0 A

362.0 A

288.9 A

207.0 A

312.0 A

DC

DC

140.0 kW

211.4 kW

5740 µF

1265 J

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

(2) All modules are limited to 1 power cycle per minute.

(3) For current values when motors include a holding brake and additional information, refer to Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003 .

(4) 1.0 second peak output current duration with 10% duty cycle.

3.0 second peak output current duration with 5% duty cycle.

(5) The 2198-RP xxx

regenerative bus supply has no internal shunt resistor.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 61

Appendix A Kinetix and PowerFlex Drive Specifications

Kinetix 6000 Drive Specifications

When using a non-Bulletin 2094 common-bus leader drive, DC-bus fuses are required in both lines of the DC-bus. For example, between the common-bus leader drive and follower IAM module. Base these fuse ratings on the DC output current of the common-bus leader drive. When using more than one follower IAM module, install fuses in both lines of the DC-bus. For example, between the non-Bulletin 2094 common-bus leader and the terminal block, and between the DC-bus terminal block and each follower IAM module.

The 2094-BC xx

-M xx

-S and 2094-BM xx

-S drive modules 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).

Table 51 - DC-bus Circuit-protection Specifications

DC-bus Power

Mersen Fuse

(1)

IAM Module

Cat. No.

Bussmann Fuse

2094-BC01-MP5-S

2094-BC01-M01-S

2094-BC02-M02-S

2094-BC04-M03-S

2094-BC07-M05-S

FWJ-20A14F

FWJ-40A

FWJ-70A

FWJ-125A

(1) Mersen fuses were formerly known as Ferraz Shawmut.

DCT20-2

A70QS40-4

A70QS70-4

A70QS125-4

Table 52 - IAM Module (converter, 400V-class) Power Specifications (series A, B, and C)

2094-BC02-M02-S Attribute

AC input voltage

DC input voltage (common bus follower)

DC input current (common-bus follower)

Continuous power output to bus

Converter capacitance

2094-BC01-MP5-S 2094-BC01-M01-S

324…528V rms three-phase (360…480V nom)

458…747V DC

9.0 A

6 kW

110



F

22.6 A

15 kW

220



F

2094-BC04-M03-S

41.5 A

27.6 kW

940



F

2094-BC07-M05-S

67.7 A

45 kW

1410



F

Table 53 - AM Module (inverter, 400V-class) Power Specifications (series A, B, and C)

Attribute

Capacitance

2094-BMP5-M

(2094-BC01-MP5-M)

75



F

2094-BM01-M

(2094-BC01-M01-M)

150



F

2094-BM02-M

(2094-BC02-M02-M)

270



F

2094-BM03-M

(2094-BC04-M03-M)

840



F

2094-BM05-M

(2094-BC07-M05-M)

1175



F

62 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Kinetix and PowerFlex Drive Specifications Appendix A

Kinetix 6200 and Kinetix 6500 Drive Specifications

When using a non-Bulletin 2094 common-bus leader drive, DC-bus fuses are required in both lines of the DC-bus. For example, between the common-bus leader drive and follower IAM module. Base these fuse ratings on the DC output current of the common-bus leader drive. When using more than one follower IAM module, install fuses in both lines of the DC-bus. For example, between the non-Bulletin 2094 common-bus leader and the terminal block, and between the DC-bus terminal block and each follower IAM module.

The 2094-BC xx

-M xx

-M and 2094-BM xx

-M drive modules 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).

Table 54 - DC-bus Circuit-protection Specifications

DC-bus Power

Mersen Fuse

(1)

IAM Power Module

Cat. No.

Bussmann Fuse

2094-BC01-MP5-M

2094-BC01-M01-M

2094-BC02-M02-M

2094-BC04-M03-M

2094-BC07-M05-M

FWJ-20A14F

FWJ-40A

FWJ-70A

FWJ-125A

(1) Mersen fuses were formerly known as Ferraz Shawmut.

DCT20-2

A70QS40-4

A70QS70-4

A70QS125-4

Table 55 - IAM Module (converter, 400V-class) Power Specifications

Attribute

AC input voltage

2094-BC01-MP5-M 2094-BC01-M01-M

324…528V rms three-phase (360…480V nom)

DC input voltage (common bus follower) 458…747V DC

DC input current (common-bus follower) 9.0 A

Continuous power output to bus

Converter capacitance

6 kW

110



F

Table 56 - AM Module (inverter, 400V-class) Power Specifications

Attribute

Capacitance

2094-BMP5-M

(2094-BC01-MP5-M)

75



F

2094-BM01-M

(2094-BC01-M01-M)

150



F

2094-BC02-M02-M

22.6 A

15 kW

220



F

2094-BM02-M

(2094-BC02-M02-M)

270



F

2094-BC04-M03-M

41.5 A

27.6 kW

940



F

2094-BM03-M

(2094-BC04-M03-M)

840



F

2094-BC07-M05-M

67.7 A

45 kW

1410



F

2094-BM05-M

(2094-BC07-M05-M)

1175



F

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 63

Appendix A Kinetix and PowerFlex Drive Specifications

Kinetix 7000 Drive Specifications

The following fuse examples and short-circuit current ratings are recommended for use with the 2099-BM xx

-S drives when the line interface module (LIM) is not used.

Table 57 - Ferraz Shawmut Fuse Recommendations

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Drive Current

Rating (ADC)

42.9

55.7

69.7

105

137

204

281

Recommended Fuse

Fuse Current

Rating

HSJ80

HSJ90

HSJ100

HSJ175

HSJ200

HSJ400

HSJ400

80

90

100

175

200

400

400 i²t (A²sec)

Pre-arc

1600

2300

2700

8000

14000

63000

63000

Clearing @ 600V AC, max

15000

21000

23000

60000

92000

450000

450000

Peak Let-through Current

@ 100 kA rms

7000 A

7400 A

7700 A

12000 A

13000 A

21000 A

21000 A

Table 58 - Bussmann Fuse Recommendations

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Drive Current

Rating (ADC)

42.9

55.7

69.7

105

137

204

281 i²t (A²sec)

Recommended Fuse Fuse Current Rating

Pre-arc

FWJ-80A

FWJ-100A

FWJ-125A

FWJ-175A

FWJ-200A

FWJ-500A

FWJ-500A

80

100

125

175

200

500

500

1550

2800

4800

7500

11700

39500

39500

Clearing @ 600V AC, max

9700

Peak Let-through Current

@ 100 kA rms

6300 A

17500

35000

65000

80000

8000 A

10000 A

12000 A

13000 A

329000

329000

21000 A

21000 A

Table 59 - Kinetix 7000 Drive Power Specifications

Attribute

AC input voltage

DC input voltage

DC input current

Continuous power output, nom

Total capacitance

(1)

Short-circuit current rating

2099-BM06-S 2099-BM07-S 2099-BM08-S 2099-BM09-S 2099-BM10-S 2099-BM11-S 2099-BM12-S

342…528V AC rms three-phase (380…480V nom)

450…750V DC

42.9 A

22 kW

1800



F

55.7 A

30 kW

2400



F

200,000 A (rms) symmetrical

69.7 A

37 kW

3000



F

105 A

56 kW

4500



F

137 A

75 kW

6000



F

204 A

112 kW

8400



F

281 A

149 kW

8400



F

(1) If DC input is supplied to 2099-BM09-S, 2099-BM10-S, or 2099-BM11-S drives, the precharge capability must be provided at the system level. Disconnect switches must not be used between the input of the drive and a common DC-bus without the use of an external precharge device.

64 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Kinetix and PowerFlex Drive Specifications Appendix A

PowerFlex 750-Series Drive Specifications

The following fuse examples are recommended for use with the 540V DC and 650V DC input PowerFlex 20F and 20G AC drives,

Frame sizes 1…6.

Table 60 - 540V DC Input Fuses, Frames 1…6

Non-time Delay Fuse

Drive Cat. No.

20F and 20G

(1) kW Rating DC Input Rating

Drive DC Bus

Capacitance

µF DC+

Quantity

DC–

Amps Fuse Cat. No.

C2P1

C2P1

C3P5

C3P5

C5P0

C5P0

C8P7

C8P7

C011

C011

C015

C015

C022

C030

C037

C043

C060

C072

C072

C085

–

22

–

30

–

15

–

11

–

18.5

30

–

37

–

5.5

–

7.5

–

4

–

5.5

–

5.5

–

4

–

2.2

–

1.5

–

1.5

–

2.2

HD

–

0.37

–

0.75

–

0.75

–

67.1

48.1

82.4

67.1

82.4

24.6

41.4

33.6

48.1

41.4

17.0

12.6

24.6

17.0

33.6

9.3

12.6

12.6

17.0

12.6

67.1

97.3

82.4

9.3

5.3

9.3

9.3

12.6

3.7

5.3

3.7

5.3

5.3

2.1

2.1

3.7

2.1

3.7

Amps

2.1

1.3

36.2

26.0

44.5

36.2

44.5

13.3

22.3

18.1

26.0

22.3

9.2

6.8

13.3

9.2

18.1

5.0

6.8

6.8

9.2

6.8

36.2

52.5

44.5

5.0

2.9

5.0

5.0

6.8

2.0

2.9

2.0

2.9

2.9

1.1

1.1

2.0

1.1

2.0

kW

1.1

0.7

2

2

3

3

3

4

4

5

5

–

45

–

37

–

30

–

37

–

18.5

–

22

–

11

–

7.5

–

15

1

1

1

2

2

–

5.5

–

7.5

–

4

–

4

–

5.5

1

1

1

Frame

Size

ND

0.75

–

2

0.75

–

1.5

–

1.5

2

2

–

2.2

–

2.2

–

110

705

165

705

280

705

470

705

560

705

680

705

1020

1200

1500

1800

2400

3000

3600

3600 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Bussman JKS-6

(2)

Bussman JKS-4

(2)

Bussman JKS-6

(2)

Bussman JKS-6

(2)

Bussman JKS-8

(2)

Bussman JKS-6

(2)

Bussman JKS-8

(2)

Bussman JKS-8

(2)

Bussman JKS-10

(2)

Bussman JKS-8

(2)

Bussman JKS-10

(2)

Bussman JKS-10

(2)

Mersen HSJ15

(3)

Mersen HSJ10

(3)

Mersen HSJ15

(3)

Mersen HSJ15

(3)

Mersen HSJ20

(3)

Mersen HSJ15

(3)

Mersen HSJ20

(3)

Mersen HSJ20

(3)

Mersen HSJ25

(3)

Mersen HSJ20

(3)

Mersen HSJ25

(3)

Mersen HSJ20

(3)

Mersen HSJ40

(3)

Mersen HSJ25

(3)

Mersen HSJ50

(3)

Mersen HSJ40

(3)

Mersen HSJ70

(3)

Mersen HSJ50

(3)

Mersen HSJ90

(3)

Mersen HSJ70

(3)

Mersen HSJ100

(3)

Mersen HSJ90

(3)

Mersen HSJ125

(3)

Mersen HSJ100

(3)

Mersen HSJ125

(3)

Mersen HSJ100

(3)

Mersen HSJ150

(3)

Mersen HSJ125

(3)

100

90

125

100

125

40

70

50

90

70

100

150

125

25

20

40

25

50

15

20

20

25

20

15

15

15

10

20

8

10

8

10

10

8

6

6

6

8

6

4

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 65

Appendix A Kinetix and PowerFlex Drive Specifications

Table 60 - 540V DC Input Fuses, Frames 1…6 (continued)

Drive Cat. No.

20F and 20G

C104

C104

C140

C170

C205

C260

(1)

Frame

Size

ND

55

5

6

6

6

6

6

–

55

–

75

–

90

–

110

–

132

– kW Rating

HD

–

45

–

45

–

55

–

75

–

90

–

110

DC Input Rating

Amps

120.2

97.3

120.2

97.3

160.3

120.2

194.6

160.3

234.7

194.6

297.7

234.7

kW

64.9

52.5

64.9

52.5

86.5

64.9

105.1

86.5

126.7

105.1

160.7

126.7

Drive DC Bus

Capacitance

µF

4500

4600

4600

9200

9200

9200 1

1

1

1

1

1

DC+

Quantity

1

1

1

1

1

1

DC–

Non-time Delay Fuse

Amps

175

150

175

150

250

175

350

250

350

350

450

350

Fuse Cat. No.

Mersen HSJ175

(3)

Mersen HSJ150

(3)

Mersen HSJ175

(3)

Mersen HSJ150

(3)

Mersen HSJ250

(3)

Mersen HSJ175

(3)

Mersen HSJ350

(3)

Mersen HSJ250

(3)

Mersen HSJ350

(3)

Mersen HSJ350

(3)

Mersen HSJ450

(3)

Mersen HSJ350

(3)

(1) Drive input type (position 5 of catalog number) = 1 (AC input with precharge, includes DC terminals) or 4 (DC input with precharge).

(2) See

Fuse Certification and Test Data on page 68

for fuse self-certification and test data for Bussmann 170M and JKS fuses that are recommended for the DC-bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses meet or exceed the requirements set forth by Rockwell Automation for the fuses on the common DC-bus for all

Allen-Bradley® architecture, component, and legacy drives. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let-through must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Table 61 - 650V DC Input Fuses, Frames 1…6

HP Rating DC Input Rating Non-time Delay Fuse

Drive Cat. No.

20F and 20G

(1)

Frame

Size

ND HD Amps kW

Drive DC Bus

Capacitance

µF

Amps Fuse Cat. No.

DC+

Quantity

DC–

D2P1

D2P1

D3P4

D3P4

D5P0

D5P0

D8P0

D011

D011

D014

D014

1

1

1

1

1

1

2

2

2

2

2

5

–

3

–

7.5

–

3

–

2

–

–

7.5

–

7.5

1

–

1

–

2

–

0.5

–

–

7.5

–

7.5

–

3

–

3

–

5

10

–

10

–

–

2

–

2

–

1

1

–

2.9

7.2

5.3

7.2

7.2

2.9

2.0

2.9

2.9

5.3

9.6

7.2

9.5

7.2

1.2

2.0

1.2

2.0

2.0

1.2

0.72

1.2

4.5

11.1

8.1

11.1

11.1

4.5

3.0

4.5

4.5

8.1

14.7

11.1

14.7

11.1

1.9

3.0

1.9

3.0

3.0

1.9

1.1

1.9

110

705

165

705

280

705

470

560

705

680

705

10

20

15

20

20

10

10

10

6

15

30

20

30

20

6

6

6

6

6

6

4

6

Bussman JKS-6

(2)

Bussman JKS-4

(2)

Bussman JKS-6

(2)

Bussman JKS-6

(2)

Bussman JKS-6

(2)

Bussman JKS-6

(2)

Bussman JKS-6

(2)

Bussman JKS-6

(2)

Bussman JKS-10

(2)

Bussman JKS-6

(2)

Bussman JKS-10

(2)

Bussman JKS-10

(2)

Mersen HSJ15

(3)

Bussman JKS-10

(2)

Mersen HSJ20

(3)

Mersen HSJ15

(3)

Mersen HSJ20

(3)

Mersen HSJ20

(3)

Mersen HSJ30

(3)

Mersen HSJ20

(3)

Mersen HSJ30

(3)

Mersen HSJ20

(3)

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

66 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Kinetix and PowerFlex Drive Specifications Appendix A

Table 61 - 650V DC Input Fuses, Frames 1…6 (continued)

Drive Cat. No.

20F and 20G

(1)

Frame

Size

ND

HP Rating

HD Amps

DC Input Rating kW

Drive DC Bus

Capacitance

µF

Amps

Non-time Delay Fuse

Fuse Cat. No.

DC+

Quantity

DC–

D022

D027

D034

D040

D052

D065

D065

D077

D096

D096

D125

D156

D186

D248

2

3

3

3

4

4

5

5

5

6

6

6

6

6

15

–

20

–

25

–

30

–

40

–

50

–

50

–

60

–

75

–

75

–

100

–

125

–

150

–

200

–

–

10

–

15

–

20

–

25

–

30

–

40

–

40

–

50

–

60

–

60

–

75

–

100

–

125

–

150

23.3

14.7

28.9

23.3

36.4

28.9

42.9

36.4

55.7

42.9

69.7

55.7

69.7

55.7

84.5

69.7

105.3

84.5

105.3

84.5

137.1

105.3

171.2

137.1

204.1

171.2

272.1

204.1

15.1

9.5

18.8

15.1

23.6

18.8

27.8

23.6

36.1

27.8

45.1

36.1

45.3

36.2

54.7

45.1

68.3

54.7

68.4

54.9

88.9

68.3

110.9

88.9

132.2

110.9

176.3

132.2

1020

1200

1500

1800

2400

3000

3600

3600

4500

4600

4600

9200

9200

9200

40

30

50

40

60

50

80

60

90

80

100

90

100

90

150

100

175

150

175

150

200

175

300

200

400

300

400

400

Mersen HSJ40

(3)

Mersen HSJ30

(3)

Mersen HSJ50

(3)

Mersen HSJ40

(3)

Mersen HSJ60

(3)

Mersen HSJ50

(3)

Mersen HSJ80

(3)

Mersen HSJ60

(3)

Mersen HSJ90

(3)

Mersen HSJ80

(3)

Mersen HSJ100

(3)

Mersen HSJ90

(3)

Mersen HSJ100

(3)

Mersen HSJ90

(3)

Mersen HSJ150

(3)

Mersen HSJ100

(3)

Mersen HSJ175

(3)

Mersen HSJ150

(3)

Mersen HSJ175

(3)

Mersen HSJ150

(3)

Mersen HSJ200

(3)

Mersen HSJ175

(3)

Mersen HSJ300

(3)

Mersen HSJ200

(3)

Mersen HSJ400

(3)

Mersen HSJ300

(3)

Mersen HSJ400

(3)

Mersen HSJ400

(3)

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

(1) Drive input type (position 5 of catalog number) = 1 (AC input with precharge, includes DC terminals) or 4 (DC input with precharge).

(2) See

Fuse Certification and Test Data on page 68

for fuse self-certification and test data for Bussmann 170M and JKS fuses that are recommended for the DC-bus fusing.

(3) A test program was developed to confirm that the HSJ (High Speed J) fuses meet or exceed the requirements set forth by Rockwell Automation for the fuses on the common DC-bus for all

Allen-Bradley architecture, component, and legacy drives. The criteria for acceptance was:

• 600V AC rectified, 810V DC average, fuses located at (+) and (-) leg. Short circuit test at 65 kA.

• Time constant minimum 3 milliseconds (maximum 15 milliseconds).

• No over-load protection required.

• Let-through must be less than rating of the conductors.

This testing is listed in UL file E2137 Vol2 Sec 31 page 1 and in CSA report 1662646.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 67

Appendix A Kinetix and PowerFlex Drive Specifications

Fuse Certification and Test Data

The following are copies of self-certification letters and test data for JKS and 170M fuses that are recommended in the previous tables for

PowerFlex 750-Series drives (Frames 1…6). Configuration A indicates one fuse in the (+) leg and one fuse in the (–) leg of the DC-bus.

JKS Fuses

Cooper Bussmann

P. O. Box 14460

St. Louis, MO 63178-4460

January 25, 2002

Sr. Project Engineer, Rockwell Automation

6400 West Enterprise Drive

P.O. Box 760

Mequon, WI 53092

Subject: DC Testing for JKS Fuses

Dear Mr.

At the request of Rockwell Automation, Bussmann has completed the DC testing for the JKS fuses and is pleased to present the attached information indicating successful 'Self-Certification DC Rating' on all subject fuses. Bussmann tested fuses to the following parameters specified by Rockwell Automation:

• Short Circuit Current = 65 kA

• Voltage = 810V DC

• Time Constant ≥0.4 ms

Additional tests were performed for acceptability:

• Short Circuit Current = 30 times fuse amperage

• Voltage = 810V DC

• Time Constant ≥0.4 ms

The attached table identifies the fuses tested, the actual circuit parameters and the circuit configuration. In the attached table, the

Interrupting Amps column specifies the fuses minimum and maximum amps that the fuse will safely clear at 810V DC.

Circuit Configuration A

Fuse Fuse

By way of this correspondence, Cooper Bussmann self-certifies the preceding fuses in end-user applications to the preceding parameters and the attached data sheet.

Should you have any questions regarding this correspondence, please contact me at the listed address and numbers.

Regards,

Strategic OEM Accounts Manager

Cooper Bussmann

68 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Kinetix and PowerFlex Drive Specifications Appendix A

Table 62 - Cooper Bussmann JKS, DC Fuse Test for Rockwell Automation

Fuse

JKS-(3A…15A)

JKS-(3A…15A)

JKS-(20A…30A)

JKS-(20A…30A)

JKS-(35A…60A)

JKS-(35A…60A)

JKS-(70A…100A)

JKS-(70A…100A)

JKS-(110A…200A)

JKS-(110A…200A)

JKS-(225A…400A)

JKS-(225A…400A)

JKS-(450A…600A)

JKS-(450A…600A)

Results

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

–

2950 A

–

5960 A

–

11.5 kA

–

15.5 kA

Min

–

375 A

–

920 A

–

1820 A

Interrupting Amps

Max

69.6 kA

–

69.6 kA

–

69.6 kA

–

69.6 kA

–

69.6 kA

–

69.6 kA

–

69.6 kA

–

Circuit Parameters

Volts DC

816

812

816

812

816

810

810

816

812

810

816

812

816

810

Time Constant

2.78 ms

0.55 ms

2.78 ms

0.4 ms

2.78 ms

0.5 ms

2.78 ms

0.86 ms

2.78 ms

3.34 ms

2.78 ms

2.92 ms

2.78 ms

0.4 ms

Circuit Configuration

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

Configuration A

170M Fuses

Cooper Bussmann

P. O. Box 14460

St. Louis, MO 63178-4460

May 15, 2002

Sr. Project Engineer, Rockwell Automation

6400 West Enterprise Drive

P.O. Box 760

Mequon, WI 53092

Subject: DC Testing for 170M Fuses

Dear Mr.

At the request of Rockwell Automation, Bussmann has completed the DC testing for the 170M fuses and is pleased to present the attached information indicating successful 'Self-Certification DC Rating' on all subject fuses.

Bussmann tested fuses to the following parameters specified by Rockwell Automation:

• Short Circuit Current = 65 kA and 100 kA

• Voltage = 810V DC

• Time Constant ≥0.4 ms

Additional tests were performed for acceptability:

• Short Circuit Current = 30 times fuse amperage as minimum current interrupting rating or as tested

• Voltage = 810V DC

• Time Constant ≥0.4 ms

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 69

Appendix A Kinetix and PowerFlex Drive Specifications

The attached table identifies the fuses tested, the actual circuit parameters and the circuit configuration. In the attached table, the

Interrupting Amps column specifies the fuses minimum and maximum amps that the fuse will safely clear at 810V DC.

Circuit Configuration A

Fuse Fuse

By way of this correspondence, Cooper Bussmann self-certifies the preceding fuses in end-user applications to the preceding parameters and the attached data sheet.

Should you have any questions regarding this correspondence, please contact me at the listed address and numbers.

Regards,

Strategic OEM Accounts Manager

Cooper Bussmann

Table 63 - Cooper Bussmann 170M, DC Fuse Test for Rockwell Automation

Fuse

170M6646

170M6646

170M6650

170M6650

170M7510

170M7510

170M6792

170M6792

170M6793

170M6793

170M6794

170M6794

170M6828

170M6828

170M6934

170M6934

170M7560

170M7560

Results

–

–

–

Acceptable

Acceptable

Acceptable

Acceptable

–

–

–

–

–

–

–

Acceptable

Acceptable

–

–

23 kA

–

27.5 kA

–

–

37 kA

Circuit Parameters

Interrupting Amps

Min

–

Max

69.8 kA

10.2 kA

–

–

69.6 kA

21.1 kA

–

20 kA

–

19 kA

–

–

65 kA

–

65 kA

–

65 kA

45.2 kA

–

60 kA

–

65 kA

–

65 kA

–

105.4 kA

–

100 kA

–

Volts DC

810

810

810

810

810

810

810

810

810

812

810

810

812

812

812

810

810

810

Time Constant

2 ms

2 ms

2 ms

2 ms

2 ms

1.8 ms

2 ms

1.66 ms

2 ms

1.2 ms

2 ms

2 ms

2 ms

2 ms

2 ms

1.12 ms

2 ms

2 ms

Circuit Configuration

–

–

–

Configuration A

Configuration A

Configuration A

Configuration A

–

–

–

–

–

–

–

Configuration A

Configuration A

–

–

70 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Appendix

B

Kinetix 5700 Accessory Modules

The requirements for when to use accessory modules vary depending on whether your system is powered by the 2198-P xxx

DC-bus power supply or 2198-RP xxx

regenerative bus supply.

Accessory Module

Cat. No.

2198-CAPMOD-2240

2198-CAPMOD-DCBUS-IO

Accessory Module

Capacitor Module

Extension Module

2198-DCBUSCOND-RP312 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.

Accessory Flow Chart

In this flowchart, a 2198-P xxx

DC-bus power supply or 2198-RP xxx

regenerative bus supply supplies DC-bus power to a mixed-architecture common-bus drive system.

The power supply cluster includes the 2198-P xxx

DC-bus power supply or 2198-RP xxx

regenerative bus supply.

System variables that you need to know include the following:

• The type of AC to DC converter used

• The external DC-bus current

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 71

Appendix B Kinetix 5700 Accessory Modules

Figure 39 - Mixed Architecture Common-bus System

Start

What type of AC to DC converter is used?

Kinetix 5700

Regenerative Bus Supply

Kinetix 5700

DC-bus Power Supply

Power Supply Cluster:

• Capacitor Module

• DC-bus Conditioner Module

Yes

Is there an external active shunt in the system?

Power Supply Cluster:

• Capacitor Module

• DC-bus Conditioner Module

No

<104 A

Power Supply Cluster:

• Capacitor Module

What is the external DC-bus current?

≥104 A up to 208 A, max

Power Supply Cluster:

• Capacitor Module

• Extension Module

Capacitor Module

The capacitor module is used 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. The module can be paralleled with itself or with another accessory module for up to 208 A.

Observe the following capacitor module guidelines:

• Required in each cluster of a multi-cluster system

• More than one capacitor module can be used in a cluster, if needed

• Flexible bus-bars are included with only the 2198-CAPMOD-DCBUS-IO extension module. So, if you have two capacitor modules, two DCbus 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.

72 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Figure 40 - Capacitor Module Block Diagram

DC-bus Output

Lug Connector

DC+

DC–

Kinetix 5700 Accessory Modules Appendix B

Fuse Detection

Module Status

Status Indicator

MS

MS

Module Status

(MS) Connector

DC-bus Detection

DC-bus Status

Status Indicator

Capacitor Bank

DC-bus Input

Link Connector

DC+

DC–

Fuse

DC+

Bleeder

Resistor

DC– DC–

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 the Kinetix® 5700 Servo Drives User Manual, publication 2198-UM002 , to see how the DC-bus power supply

Digital Inputs category is configured.

Figure 41 - DC-bus Power Supply with Capacitor Module

2198-P xxx

DC-bus Power Supply

2198-CAPMOD-2240

Capacitor Module

MS

MS

Module Status (MS)

Connector

Digital Input

(IOD) Connector

IN x

COM

(1)

24V DC

(1) Configure either of two digital inputs as Bus Capacitor OK. For DC-bus power supply configurable functions, see Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , for more information on accessory module installation.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 73

Appendix B Kinetix 5700 Accessory Modules

DC-Bus Conditioner Module

The DC-bus conditioner module decreases the voltage stress on insulation components in an inverter system with long cable lengths and can be 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. The module can be paralleled with itself or with another accessory module for applications up to 208 A.

Observe the following DC-bus conditioner module guidelines:

• A DC-bus conditioner module is required on all Kinetix 5700 extended clusters

• A DC-bus conditioner module is required on the power supply cluster if a regenerative bus supply or external active shunt is included in the system.

• When a DC-bus conditioner module is installed and there is no use-case for installation, the module does not provide any benefit

• 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 42 - DC-bus Conditioner Module Block Diagram

Fuse Detection and

Over Temperature

Protection

Module Status

Status Indicator

MS

MS

Module Status

(MS) Connector

DC-bus Output

Lug Connector

DC+

DC–

DC-bus Detection

DC-bus Status

Status Indicator

DC-bus Input

Link Connector

DC+

DC–

Chassis

Fuse

Conditioning Circuit

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 Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 , to see how the regenerative bus supply Digital

Inputs category is configured.

74 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Figure 43 - Regenerative Bus Supply with DC-bus Conditioner Module

2198-RP xxx

Regenerative Bus Supply

MS

MS

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

Module Status (MS)

Connector

Kinetix 5700 Accessory Modules Appendix B

Digital Input

(IOD) Connector

IN x

COM

(1)

24V DC

(1) Configure any one of four digital inputs as Bus Conditioner OK. For regenerative bus supply configurable functions, see Kinetix 5700 Servo Drives User Manual, publication 2198-UM002 .

Refer to the Kinetix 5700 DC-bus Conditioner Module Installation Instructions, publication 2198-IN016 , for additional installation information.

Extension Module

The extension module, when paired with a capacitor module, is used to extend the DC-bus voltage to another inverter cluster in systems with

≥104 A current and up to 208 A.

Observe the following extension module guidelines:

• The 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).

• Flexible bus-bars are included with the 2198-CAPMOD-DCBUS-IO extension module. So, if you have a 2198-CAPMOD-DCBUS-IO extension module with a capacitor module or a DC-bus conditioner module, you do not need to order the 2198-KITCON-CAPMOD2240 or 2198-

KITCON-DCBUSCOND connector set separately.

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 75

Appendix B Kinetix 5700 Accessory Modules

Notes:

76 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Index

Numerics

2094 shunt module

2094-BSP2

19 ,

28 ,

38

,

48

2198-CAPMOD-2240

8 ,

10 ,

11

, 71

2198-CAPMOD-DCBUS-IO

10

,

71

2198-DCBUSCOND-RP312

8

,

11 ,

71

A

AC line impedance

19

,

28

,

39

,

49

accessory modules

33

,

54

capacitor module

71 ,

72

DC-bus conditioner module

71

, 74

extension module 71 ,

75

flow chart

71

active shunt

interconnect diagram 33

,

54

lug connections

33

, 54

Shunt Thermal Switch OK 31

, 52 specifications

31 ,

52

use cases

31

,

52

active-front-end

7

D

DC bus bar

10

cable length

10

example

11

DC-bus

cable gauge

9

cables

8

cable length

8

low inductance

9

capacitance

24

, 36

, 44 ,

58 ,

59

conditioner module

71

, 74

connections

8

,

10

Bus Capacitor OK 10

DC bus bar

10

DC-bus cable gauge

9

DC-bus cables

8

wiring

9 ,

10

current

10

filter

11

link

9

lug connections

33

, 54

wiring example

10

digital input

precharge enable

12

diode-front-end

7 ,

17 ,

25

disconnect switch

20

, 29

,

39

,

49

drive system

DC-bus connections

8

extended bus example

8

mounting order

7

B block diagrams capacitor module

73

DC-bus conditioner module

74

braking chopper

15 ,

25

Bus Capacitor OK

10

bus overvoltage faults

8

Bus Voltage Reference Source

8

Bus Voltage Set Point

8

C cable length

8 ,

10

capacitance

59

capacitance sizing

24 ,

36 ,

44 ,

58

capacitor module

71 ,

72

, 73

circuit protection

24 ,

36 ,

44

,

58

Kinetix 6000

62

Kinetix 6200/6500

63

Kinetix 7000

64

PowerFlex 750-Series

65

cluster example

11

common bus

8

contactor enable

35

, 43

, 57

contactor enable control string

23

,

35

,

43

,

57

contactor-enable relay circuit

23

, 35

converter OK

42 ,

56

Kinetix 6000

42

,

56

Kinetix 6200/6500 42

,

56

Kinetix 7000

42

, 56

PowerFlex 750-Series

42

, 56

E

Enable

42 ,

56

extension module

71

,

75

external active shunt

47 ,

48

external passive shunt

46

F flexible bus-bars

33 ,

54

flow chart

71

full regeneration

37

fuse certification and test data

68

G ground jumper settings

21 ,

30

, 40

,

51 ,

55

ground screw settings

22

,

34

,

41

I

IEEE-519

37

, 45

interconnect diagrams active shunt

33

, 54

module status

73

,

75

internal

IGBT

19

, 28

, 38 ,

48

shunt

15

,

25

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 77

Index

K

Kinetix 5700

10

cluster example

11

DC-bus connections

10

DC-bus link

9

DC-bus supply

17 ,

25

DC-bus wiring example

10

regenerative bus supply

37

, 45

specifications

59

Kinetix 6000

circuit protection specifications

62

drives

8

,

15

ground jumper settings

21

, 30 ,

40

, 51

power specifications, AM 460V

62 power specifications, IAM 460V 62

specifications

62

Kinetix 6200/6500

63

circuit protection specifications

63

drives

15

specifications power, AM 460V

63

power, IAM 460V

63

Kinetix 7000

circuit protection specifications

64

drives

8

,

14

ground jumper settings

21

, 30 ,

40

, 51

I/O connections

20 ,

29 ,

40

, 50

Relay connections

20 ,

29 ,

40

, 50

specifications

64

L line reactor

18 ,

26 ,

27

,

38

, 39

, 46

, 47 ,

48

, 49

M maximum cable lengths

24

, 36

, 44 ,

58

module status

10

DC-bus power supply

73

regenerative bus supply

75

Motion Analyzer website

81

mounting order

7

N non-regenerative definition

7

non-regenerative bus supply

AC line impedance

19 ,

28

active shunt specifications

31

capacitance sizing 24

, 36

circuit protection

24 ,

36

configurations

18 ,

26

contactor enable

23 ,

35

contactor-enable relay circuit

23

, 35

DC-bus capacitance

24 ,

36

disconnect switch

20 ,

29

ground jumper settings

21

,

30

ground screw settings

22 ,

34

Kinetix 5700 DC-bus supply

17

, 25

Kinetix 7000 I/O connections

20

,

29

line reactor

18

,

26

,

27

maximum cable lengths

24 ,

36

passive shunt connections

32

passive shunt specifications

32

Precharge Enable

20 ,

29

system sizing

24 ,

36

total system capacitance

24 ,

36

P passive shunt connections

32

specifications

32

PowerFlex 750-Series

AC Drive

8

circuit protection specifications

65

frames 1…4

12

frames 5 and 6

13

ground jumper settings

21

,

30 ,

41

, 51

precharge parameters

20

, 29

,

39

,

49

precharge

42 ,

56

DC-bus filter

11

enable

12

Kinetix 6000 drives

15

Kinetix 6200/6500 drives

15

Kinetix 7000 drives

14

parameters

20

,

29 ,

39 ,

49

PowerFlex 750-Series, frames 1…4

12

PowerFlex 750-Series, frames 5 and 6

13

Precharge Enable

20 ,

29

, 39

, 49

R

Regen OK

42 ,

56

Regeneration OK

42 ,

56

regeneration plus shunt

45

regenerative definition

7

78 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Index regenerative bus supply

AC line impedance

39

, 49

active shunt specifications

52

bus overvoltage fault

8

bus voltage set point

8

capacitance sizing 44 ,

58

circuit protection

44 ,

58

configurations

38

, 46

contactor enable

43

,

57

converter OK

42 ,

56

DC-bus capacitance

44

, 58

disconnect switch

39

, 49

external active shunt

47 ,

48

external passive shunt

46

full regeneration

37

ground jumper settings

40

, 51

,

55

ground screw settings

41

Kinetix 5700 regenerative bus supply

37

, 45

Kinetix 7000 I/O connections

40 ,

50

line reactor

38 ,

39 ,

46 ,

47

,

48 ,

49

maximum cable lengths

44

, 58

meets IEEE-519

37 ,

45

Precharge Enable

39

, 49

regeneration plus shunt

45

shunt connections

53

system sizing

44

, 58

total system capacitance

44

, 58

S shunt active

31 ,

52

connections

53

resister

15 ,

25

Shunt Thermal Switch OK

31 ,

33 ,

52 ,

54

sizing

24 ,

36 ,

44 ,

58

specifications

DC-bus capacitance

59 fuse certification and test data

68

Kinetix 5700

59

capacitance

59

DC-bus power supply

59

regenerative bus supply

61

Kinetix 6000

62

circuit protection

62

Kinetix 6000 power specifications

AM 460V

62

IAM 460V

62

Kinetix 6200/6500

63 circuit protection 63

power, AM 460V

63

power, IAM 460V

63

Kinetix 7000

circuit protection 64

specifications

64

PowerFlex 750-Series circuit protection

65

system sizing

24 ,

36 ,

44 ,

58

system block diagrams capacitor module

73

DC-bus conditioner module

74

T total system capacitance

24 ,

36 ,

44

,

58

U use cases active shunt

31

,

52

W website

Motion Analyzer

81

wiring external DC-bus

9 ,

10

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 79

Index

Notes:

80 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020

Drives in Common Bus Configurations with Kinetix 5700 Bus Supplies Application Technique

Additional Resources

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

Resource

Kinetix Rotary Motion Specifications Technical Data, publication

Kinetix Linear Motion Specifications Technical Data, publication

Kinetix Servo Drives Specifications Technical Data, publication

KNX-TD001

KNX-TD002

KNX-TD003

Description

Provides product specifications for Kinetix VPL, VPC, VPF, VPH, and VPS motors, Kinetix

MPL, MPM, MPF, and MPS motors, and Kinetix HPK rotary motors.

Provides product specifications for Kinetix MPAS and MPMA linear stages,

Kinetix VPAR, MPAR, and MPAI electric cylinders, LDAT-Series linear thrusters, and

LDC-Series™ linear motors.

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

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

Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004

Kinetix 5700 Servo Drives User Manual, publication 2198-UM002

Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001

Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-UM002

Kinetix 7000 High Power Servo Drives User Manual, publication 2099-UM001

Provides information on installing, configuring, startup, troubleshooting, and applications for your Kinetix servo drive system.

Kinetix Motion Control Selection Guide, publication KNX-SG001

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

Kinetix 5700 Drive Systems Design Guide, publication KNX-RM010

Kinetix 6000 and Kinetix 6200/6500 Drive Systems Design Guide, publication KNX-RM003

Kinetix 7000 Drive Systems Design Guide, publication GMC-RM007

PowerFlex 750-Series Drive Technical Data, publication

PowerFlex 750-Series Products with TotalFORCE® Control Technical Data, publication 750-TD100

750-TD001

1321 Power Conditioning Products Technical Data, publication 1321-TD001

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

Provides technical data on PowerFlex 750-Series drives.

Provides detailed information on, kit selection, kit ratings and specifications, and option specifications.

Information on line reactors and isolation transformers.

Drives in Common Bus Configurations Application Technique, publication DRIVES-AT002

Drives in Common Bus Configurations with PowerFlex 755TM Bus Supplies

Application Technique, publication DRIVES-AT005

Industry Installation Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-AT003

Provides the necessary guidelines, considerations, and limitations for the proper application of PowerFlex drives used in common bus configurations.

Provides the necessary guidelines, considerations, and limitations for the proper application of Allen-Bradley drives used in common bus configurations.

Provides basic information for different enclosure systems, environmental/location considerations, and power and grounding considerations needed to properly install a

Pulse Width Modulated (PWM) AC drive.

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

Provides basic information to install, protect, wire, and ground pulse width modulated

(PWM) AC drives.

PowerFlex 750-Series AC Drives Installation Instructions, publication 750-IN001 Provides the basic steps to install PowerFlex 750-Series drives.

PowerFlex 750-Series Power Jumpers Installation Instructions, publication 750-IN011

Provides jumper settings for PowerFlex 750-Series AC drives.

PowerFlex 750-Series EMC Plate and Cores - Frames 1…7 Installation Instructions, publication 750-IN006

Provides installation information for PowerFlex 750-Series EMC plate and cores.

PowerFlex 755 AC Drives EMC Cores Installation Instructions, publication 750-IN024

PowerFlex 750-Series Drive Programming Manual, publication 750-PM001

Provides installation information for PowerFlex 755 AC drives EMC cores.

Provides information on programming PowerFlex 750-Series drives.

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

EtherNet/IP Network Devices User Manual, ENET-UM006

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

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 and infrastructure components and features.

Safety Guidelines for the Application, Installation, and Maintenance of Solid-State

Control, publication SGI-1.1

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 solidstate components.

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Product Certifications website, rok.auto/certifications .

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 MOTION-AT007A-EN-P - May 2020 81

Rockwell Automation Support

Use these resources to access support information.

Technical Support Center

Knowledgebase

Local Technical Support Phone Numbers

Literature Library

Product Compatibility and Download Center

(PCDC)

Find help with how-to videos, FAQs, chat, user forums, and product notification updates.

rok.auto/support

Access Knowledgebase articles.

rok.auto/knowledgebase

Locate the telephone number for your country.

Find installation instructions, manuals, brochures, and technical data publications.

Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes.

rok.auto/phonesupport rok.auto/literature rok.auto/pcdc

Documentation Feedback

Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our content, complete the form at rok.auto/docfeedback .

Allen-Bradley, Encompass, expanding human possibility, Kinetix, LDC-Series, PowerFlex, Rockwell Automation, Rockwell Software, Studio 5000 Logix Designer, and TotalFORCE are trademarks of

Rockwell Automation, Inc.

EtherNet/IP is a trademark of ODVA, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec .

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Publication MOTION-AT007A-EN-P - May 2020

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