Rockwell Automation Allen-Bradley Kinetix 5700 Series User guide

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

2Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020
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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc
Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements
for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 3
Table of Contents
Preface
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
DC-bus Wiring Guidelines Drive Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DC-bus Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2
Non-regenerative Common
DC-bus Configurations
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
Non-regenerative Common
DC-bus Configurations
With Passive or Active Shunt
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
Regenerative Bus Supply
Configurations
Supported Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Typical System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020
Table of Contents
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
Regenerative Bus Supply
Configurations With Active
Shunt
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
Appendix A
Kinetix and PowerFlex Drive
Specifications
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 5
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.

6Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020
Preface
Notes:

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 7
Chapter 1
DC-bus Wiring Guidelines
This chapter provides guidelines for wiring DC common-bus drive systems. Common-bus configurations can be regenerative or non-
regenerative. Other variations include active and passive shunt resistors.
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-RPxxx
regenerative bus supply.
Common Bus Configuration Definition
Non-regenerative (diode-front-end)
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 insulated-
gate 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.
Regenerative with active shunt
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-RPxxx regenerative bus supply.

8Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020
Chapter 1 DC-bus Wiring Guidelines
Figure 1 - Extended DC-bus Installation Example
DC-bus Connections
DC-bus cables and bus bars are used to connect drives in common-bus configurations.
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.
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.
MOD
NET
MOD
NET
MOD
NET
2
1
2
1
2
1
UFB UFB-A UFB-B UFB-A UFB-B
D+
D-
D+
D-
D+
D-
MF-A MF-B MF-A MF-B
D+
D-
MBRK
+
-
MOD
NET
D+
D-
MF
MODULE
STATUS
1
I/O-A
6
510
1
I/O-B
6
510
1
I/O
6
510
1
I/O-A
6
510
1
I/O-B
6
510
MOD
NET
2
1
1
I/O
6
510
OK+
OK–
EN–
EN+
MOD
DCBUS
Single-axis
Inverter Dual-axis
Inverters
Bulletin 1321
Line Reactor
AC Line Filter
Circuit
Protection
Magnetic (M1)
Contactor
Line
Disconnect
Device
DC-bus Circuit
Protection
DC-bus Circuit
Protection
2094-BMxx-S
Axis Modules (5)
PowerFlex
750-Series AC Drive
2094-BMxx-Mxx-S
IAM Module
Common Bus Follower
2094-PRSx
Power Rail
DC-bus
Extension
Bonded Cabinet
Ground Bus
Kinetix 7000
Servo Drive
Bulletin 1492 Power Distribution
Terminal Block
Kinetix 6000 Servo Drive System
Kinetix 5700
Servo Drive System
Regenerative
Bus Supply
2198-CAPMOD-2240
Capacitor Module
2198-DCBUSCOND-RP312
DC-bus Conditioner Module
2099-BMxx-S
Servo Drive
DC-bus Circuit
Protection
Accessory
Modules

Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020 9
DC-bus Wiring Guidelines Chapter 1
Figure 2 - DC-bus Cable Length per Cluster
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-BARCON-xxxx200 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.
IMPORTANT Use low-inductance DC cable routing to help reduce the risk of voltage oscillations between clusters.
Table 1 - Recommended DC-bus Cable Gauge
Regenerative Bus Supply
Cat. No.
Recommended DC-bus Cable Gauge
mm2(AWG/MCM)
2198-RP088 53.5 (1/0)
2198-RP200
2198-RP263 152 (300 MCM)
2198-RP312
DC-bus Power Supply
Cat. No.
Recommended DC-bus Cable Gauge
mm2(AWG/MCM)
2198-P031
53.5 (1/0)
2198-P070
2198-P141
2198-P208
2198-P208 x 2 152 (300 MCM)
2198-P208 x 3
750
745
740
735
730
725
720
715
020 40
3010 60
50 70
065.6 131
98.432.8 197
164 230
Maximum Bus Voltage Set Point
(Volts DC)
DC-bus Cable Length per Cluster (ft)
DC-bus Cable Length per Cluster (m)

10 Rockwell Automation Publication MOTION-AT007A-EN-P - May 2020
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
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).
24V_COM
+24V
2
1
DC+
DC-
24V_COM
+24V
DC+
DC-
24V_COM
+24V
DC+
DC-
DC+
DC-
MS
MS
2
1
Kinetix 5700
2198-Pxxx
DC-bus Power Supply
Bonded Cabinet Ground Bus (user-supplied component)
2198-CAPMOD-DCBUS-IO
Extension Module
Kinetix 5700
2198-Sxxx -ERSxor
2198-Dxxx -ERSx
Inverter
2198-CAPMOD-2240
Capacitor Module
Control Power
(CP) Connectors
DC-bus
(DC) Connectors
PE Ground
Flexible Bus-bars User-supplied External DC-bus
Wire Lug Connections
Module Status
(MS) Connector Monitor capacitor module status by wiring to
digital input Bus Capacitor OK on the DC-bus
power supply or to a Logix 5000™ controller.
PE Ground
PE GroundPE Ground
To External
Inverter Drives or
Active Shunt Modules