Rockwell Automation Allen-Bradley Kinetix 5500 Instruction Manual

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Fuse and Line Filter sizing for the Kinetix 5500 drive
530800 | Date Created: 03/03/2013 | Last Updated: 01/11/2018
Access Level: Everyone Print
Question
How do I size my fusing and line filter for the Kinetix 5500 drive?
Answer
Refer to documents in this tech note:
The Kinetix 5500 User Manual
(http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf)
Publication 2198-UM001 appendix C for tutorial of sizing main and control power for various application
configurations.
The Kinetix 5500 Design Guide
(http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/gmc-rm009_-en-p.pdf)
Publication GMC-RM009
The Kinetix Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/), Publication gmc-td003
Use the Motion Analyzer Software to evaluate your machine load inertia, transmission and cycle profile
characteristics.
Refer to other ancillary device documentation such as VPL motor, line filter installation and other as required.
To size your Kinetix 5500 fusing, circuit breaker and line filter, you will be required to know the exact configuration
of converter/inverter power modules based on the application requirement.
The Kinetix 5500 supports multiple configurations:
1. STAND-ALONE
In this example, AC line power is transferred solely to the 2198-H040-ERS module and converter for use for motor
inverter output.

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The recommended fusing, circuit breaker (TBD), and line filter can be found in the Kinetix 5500 User Manual
(http://literature.rckwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf) Chapter 2,
Planning the Kinetix 5500 Drive System Installation, and the Kinetix Servo Drive Technical Documentation
(http://gmc-td003_-en-p.pdf/).
Recommended Components for the Stand-Alone system are:
KTK-R-25 Fuse
2198-DB20-F Line Filter
There are no integration limitations here as this is a standalone drive system.
2. AC SHARING
In this example, AC Sharing is using the same AC power supply to each of the converter modules. This MUST be
accomplished with the use of the 2198 AC bus bars and control power bus bars.

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Shown are quantity 5, 2198-H008-ERS modules all with AC Sharing from the same AC power source. The 2198-
H008-ERS continuous AC line Amps are 2.60 Amps RMS continuous.
Recommended Components for the AC Sharing system are:
For the above example using 5 2198-H008-ERS use KTK-R-15 fuses. Other recommended fusing can be
found in the Kinetix Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/).
With AC sharing, ALL converters must be of the same power therefore all axis must be the same. In AC
Sharing, you could not use 3, 2198-H008-ERS and 2, 2198-H015-ERS. This is due to different AC line
characteristics such as inrush in order to have a symmetrical AC power up.
AC Sharing configuration does not support use of the 2198 capacitor module for similar reasons as item 2
above.
For a line filter use, the total AC amps is approximately 13 Amps RMS for this configuration. A 2198-DB08-F
is 7.5 Amps continuous and cannot be used. Therefore, use 2198-DB20-F as that can handle the current
requirements of the AC Sharing configuration shown above.
AC Sharing MUST be used with both AC sharing bus bar and DC control power bus bars.
Three phase power MUST be used for AC/DC Sharing. Single Phase operation is not supported in AC/DC
Sharing.
AC Bus bar and DC control power bus bars MUST be used in this configuration.
The 2198-H008-ERS is a frame 1 Kinetix 5500, as referenced in the Kinetix 5500 User Manual
(http://literature.rckwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf) & Kinetix

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Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/)
Use Qty 1, 2198-H040-ADP-IN for the first 2198-H008-ERS which will allow you to bring in both AC L1-
L3(and ground) and DC control power.
Use Qty 4, 2198-H040-AP-T for each of the next 4, 2198-H008-ERS to allow AC sharing and DC control
power sharing
3. SHARED AC/DC
Shared AC/DC is similar to Shared AC except now the DC bus are tied together to take advantage of bus
capacitive absorption and more ability to handle regenerative energy on the entire DC bus. This configuration
MUST be used with the available AC bus bars, DC bus bars and DC control power bus bars.
Shown are quantity 4, 2198-H015-ERS modules and a 2198-CAPMOD-1300. The 2198-H015-ERS continuous AC
line Amps are 5.20 Amps RMS continuous.
Recommended Components for the shared AC / DC system are:
For the above example using 5 2198-H008-ERS use KTK-R-25 fuses. Other recommended fusing can be
found in the Kinetix Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/).
With AC/DC sharing, ALL converters must be of the same power therefore all axis must be the same. In AC
Sharing, you could not use 2, 2198-H015-ERS and 2, 2198-H015-ERS. This is due to different AC line

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characteristics such as inrush in order to have a symmetrical AC power up.
AC/DC sharing will support the use of the capacitor module WHEN three phase power is utilized. In this
frame 2 drive, 2198-H015-ERS, even though single phase configuration is available, the 2198-CAPMOD-
1300 cannot be used.
For a line filter use, the total AC amps is approximately 20.8 Amps RMS for this configuration. A 2198-
DB20-F is 20 Amps continuous and cannot be used. Therefore, use 2198-DB42-F as that can handle the
current requirements of the AC/D Sharing configuration shown above.
AC Sharing MUST be used with both AC sharing bus bar and DC control power bus bars.
The 2198-H015-ERS is a frame 2 Kinetix 5500, as referenced in the Kinetix 5500 User Manual
(http://literature.rckwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf) & Kinetix
Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/)
Use Qty 1, 2198-H040-ADP-IN for the first 2198-H015-ERS which will allow you to bring in both AC L1-
L3(and ground) DC control power and have a connection for the first DC bus bar to drive 2.
Use Qty 3, 2198-H040-ADP-T for each of the next 4, 2198-H015-ERS to allow AC sharing.,DC control power
sharing and DC bus power sharing
In this configuration, qty 4, 2198-H015-ERS are used. Each converter section can put 1.6 kW (230 Vac) or
3.2 kW(460 Vac) when in a Shared DC bus or standalone inverter use. When used in Shared AC/DC
configuration, the SUM of the converter output must be derated or limited to 70% of continuous power
available. In this instance, 4 x 1.6 kW x .7 = 4.48 kW (230 Vac) or 4 x 3.2 kW x .7 = 8.96 kW (460 Vac). The
2198-HR015-ERS inverter power continuous out in this configuration cannot exceed either of these values.
Three phase power MUST be used for AC/DC Sharing. Single Phase operation is not supported in AC/DC
Sharing.
4. SHARED DC BUS
Shared DC Bus is comparable operation to the Kinetix 6000 series where the DC bus is supplied by the leader
drive to the followers that are on the DC bus.

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AC line is fed to the first 2198 drive. In this example chose 2198-H040-ERS for the example leader drive. It will
supply DC bus not only to it's inverter but 4 other 2198 inverters. For configuration, use Qty 2, 2198-H015-ERS,
Qty 1, 2198-H008-ERS and Qty 1, 2198-H003-ERS. A 2198-CAPMOD-1300 is also specified for adding DC bus
capacitance and ability to assist in DC bus capacitance absorption for regenerative energy applications. The
2198-H040-ERS is 4 kW (230 Vac) and 8.4 kW (460 Vac) power to the DC bus. The 2198-H040-ERS is also 13.4
Amps RMS input.
Recommended Components for the shared DC BUS system are:
For the above example using 1 2198-H040-ERS, use KTK-R-25 fuses. Other recommended fusing can be
found in the Kinetix Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/).
With DC shared, the leader converter power MUST be able to supply all follower drive inverter power
requirements. Here, at full rating, the 2198-H040-ERS is 4 kW (230 Vac) or 8.4 kW(460 Vac), the 2198-
H015-ERS is 1.5. kW(230 Vac) or 3. 2 kW(460 Vac) inverter output, the 2198-H008-ERS is .8 kW (230 Vac)
or 1.6 kW (460 Vac) and the 2198-H003-ERS is .3 kW (230 Vac) or .6 kW (460 Vac) output.
4+ 2 x 1.5 + .8 + .3 kW = 8.1 kW > 2198-H040-ERS (4 kW DC power out to bus) at 230 Vac so you would
need a bigger size converter module. However, frame 3, 2198-H075-ERS is the largest frame power
structure and can deliver 7.2 kW to the bus and would fall short here. The options are changing the follower
drives to lower the possible output, using Motion Analyzer to size based on ACTUAL load and transmission
plus cycle profile use OR use a Shared AC/DC Hybrid System which is discussed last.

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8.3 kW + 2 x 3.2 + 1.6 + .6 kW = 16.9 kW > 2198-H040-ERS at 460 Vac(8.4 kW DC power out to bus) at
460 Vac so you would need a bigger size converter module or 2198-H075-ERS which can deliver 14.9 kW at
460 Vac. The options are changing the follower drives to lower the possible output, using Motion Analyzer to
size based on ACTUAL load and transmission plus cycle profile use OR use a Shared AC/DC Hybrid System
which is discussed last.
Shared DC configuration will support the use of the capacitor module WHEN three phase power is utilized.
If the original selected leader drive was used with further evaluation, , the 2198-H040-ERS is 13. 4 Amps
RMS input.so a 2198-B20-F is recommended. For a 2198-H075-ERS, with 23.7 Amps RMS input, use
2198-B42-F line filter.
Shared DC configuration MUST be used with both DC Shared power and DC control power bus bars.
The 2198-H040-ERS is a frame 3 Kinetix 5500, as referenced in the Kinetix 5500 User Manual
(http://literature.rckwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf) & Kinetix
Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/)
Use Qty 1, 2198-H070-ADP-IN for the 2198-H040-ERS which will allow you to bring in both AC L1-L3(and
ground) DC control power and have a connection for the first DC bus bar to drive 2.
DC Sharing to smaller drives is allowed. Here there are Use Qty 3, 2198-H040-ADP-T for each of the next
4, 2198-H015-ERS to allow AC sharing.,DC control power sharing and DC bus power sharing
Three phase power to the leader module MUST be used for Shared DC configuration. Single Phase
operation is not supported in Shared DC configuration.
In logic/drive's properties/Power, the Bus Configuration for the lead drive needs to be selected with Shared
AC/DC.
5. SHARED AC/DC HYBRID
Shared AC/DC Hybrid may be the most flexible of the above combinations when it comes to supplying more DC
power from multiple converters to the DC bus for inverters to utilize.

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Going back to example 4, if we assume the inverter power requirement never changed, we had requirements of
4+ 2 x 1.5 + .8 + .3 kW = 8.1 kW < Qty 2, 2198-H075-ERS converter power which is 7.2 kW x 2 x .7 = 10.08 kW.
8.3 kW + 2 x 3.2 + 1.6 + .6 kW = 16.9 kW < 14.9kW x 2, x .7 = 20.86 kW at 460 Vac.
In example 4, we stated, AC line is fed to the first 2198 drive. In this example chose 2198-H040-ERS for the
example leader drive. It will supply DC bus not only to it's inverter but 4 other 2198 inverters. For configuration,
use Qty 2, 2198-H015-ERS, Qty 1, 2198-H008-ERS and Qty 1, 2198-H003-ERS. A 2198-CAPMOD-1300 is also
specified for adding DC bus capacitance and ability to assist in DC bus capacitance absorption for regenerative
energy applications.
For example 5 this now changes to Shared AC/DC Hybrid with AC being supplied to Qty 2, 2198-H075-ERS then
DC bus sharing to Qty 1, 2198-H015-ERS, Qty 1, 2198-H008-ERS and Qty 1, 2198-H003-ERS. The addition of
the capacitor module also meets the number of capacitor modules per the 2198 Frame 3 size as defined in the
Kinetix Drives Technical Data.
Recommended Components for the shared AC/DC hybrid system are:
For the above example using 2 Shared AC/DC Hybrid there can be no more than Qty 2, 2198-H075-ERS
therefore this solution is valid and use LPJ-50SP for the fuse sizing.

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Shared DC configuration will support the use of the capacitor module WHEN three phase power is
utilized. Note here frame 3 is used for the converter which ONLY supports three phase power input.
Shared DC configuration MUST be used with both DC Shared power and DC control power bus bars.
The 2198-H075-ERS is a frame 3 Kinetix 5500, as referenced in the Kinetix 5500 User Manual
(http://literature.rckwellautomation.com/idc/groups/literature/documents/um/2198-um001_-en-p.pdf) & Kinetix
Servo Drive Technical Documentation (http://gmc-td003_-en-p.pdf/)
Use Qty 1, 2198-H070-ADP-IN for the 2198-H075-ERS which will allow you to bring in both AC L1-L3(and
ground) DC control power and have a connection for the first DC bus bar to drive 2.
Use Qty 1, 2198-H070-ADP-T for the next 2198-H075-ERS to share the AC but also the DC bus and DC
control power.
Use Qty 3, 2198-H040-DP-T to connect the last 2198-H075-ERS to each of the 2198-H015-ERS, 2198-
H008-ERS and 2198-H003-ERS with DC bus and DC control power sharing.
Three phase power to the leader module MUST be used for Shared DC configuration. Single Phase
operation is not supported in Shared DC configuration.
The largest line filter that can be used is a 2198-DB42-B which is 42 Amp rated. Since the Qty 2, 2198-
H075-ERS AC line rated is 47.4 Amps RMS total, this filter cannot be used.
A shared AC / DC Hybrid system example was done to show that there are multiple evaluations for the
system layout that need to occur.
One option is to use no line filter.
Another option if a line filter is required and the full AC converter power of both 2198-H075-ERS is required,
this Shared AC/DC Hybrid must be broken up into two separate Shared AC/DC Hybrid configurations. This
can now mean the 2198-H075-ERS could go back to a smaller converter power selection.
Motion Analyzer is now a good source to evaluate the entire system power requirement based on load,
transmission and cycle profile.
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