Rockwell Automation Allen-Bradley 2198-P031 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

2 Rockwell 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

4 Rockwell 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

.

6 Rockwell 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.

8 Rockwell 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

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

5

10

1

I/O-A

6

510

1

I/O-B

6

510

MOD

NET

2

1

I/O

6

5

10

OK+

OK–

EN–

EN+

MOD

DC BUS

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

mm

2

(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

mm

2

(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

0

20

40

3010

60

50

70

0

65.6

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

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 -ERSx or

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

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

DC-bus Wiring Guidelines Chapter 1

Figure 4 - DC Bus-bar Application

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.

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.

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.

MOD

NET

MODULE

STATUS

MOD

NET

2

1

I/O

6

5

10

OK+

OK–

EN–

EN+

MOD

NET

2

1

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

MODULE

STATUS

MOD

DC BUS

1

I/O-A

6

510

1

I/O-B

6

510

MOD

NET

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

I/O-A

6

10

1

I/O-B

6

510

MOD

NET

2

1

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

1

I/O-A

6

510

1

I/O-B

6

510

MOD

NET

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

I/O-A

6

10

1

I/O-B

6

510

MODULE

STATUS

MOD

DC BUS

MOD

DC BUS

2198-CAPMOD-2240

Capacitor Module

DC-bus Circuit

Protection

DC-bus

Extension

DC-bus Bar

Kinetix 5700

Servo Drive System

(power supply cluster #1)

Regenerative Bus Supply

2094-BMxx-S

Axis Modules (5)

2094-BMxx-Mxx-S

IAM Module

Common Bus Follower

2094-PRSx

Power Rail

Kinetix 6000 Servo Drive System

DC-bus Circuit

Protection

Kinetix 5700

Servo Drive System

(cluster #2)

Dual-axis Inverters

2198-CAPMOD-2240

Capacitor Module

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

2198-DCBUSCOND-RP312

DC-bus Conditioner Module

Accessory

Modules

Accessory

Modules

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

Chapter 1 DC-bus Wiring Guidelines

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

If Precharge Enable is selected as a digital input, it must be energized to let the initial bus precharge complete. If Precharge Enable is de-

energized, 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

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.

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.

M1

M2

L1

L2

L3

DC+

DC–

DC –

BR2

L1

L2

L3

U

V

W

DC+

BR1

+

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

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.

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

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.

DC –

BR2

L1

L2

L3

U

V

W

DC+

BR1

+

Optional for PowerFlex Frame 6 Drives

Voltage Rating

Catalog Codes 1 and A

+

DC –

1RB+ CD

BR2

U

V

W

Optional for PowerFlex Frame 6 Drives

Input Type Catalog Number

Position 5, Code 4

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

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

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 –

DC+

L1

L2

L3

U

V

W

+

DC –

DC +

L1

L2

L3

U

V

W

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

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.

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

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

+

DC –

DC+

L1

L2

L3

U

V

W

U

V

W

2094-BCxx-BMxx-S

or

2094-BCxx-BMxx-M

2094-BMxx-S

or

2094-BMxx-M

(up to 7 additional axes)

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

Chapter 1 DC-bus Wiring Guidelines

Notes:

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

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)

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

Kinetix 7000: All power ratings

Kinetix 6000: All 460V configurations

(2)

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

Kinetix 6200/6500: All configurations

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

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 6x00 Drives, and Kinetix 7000 Drives

(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 Supported Drives Special Bus Requirements

AC drives

PowerFlex 750-Series: Frames 1…6

NoneKinetix 7000: 2099-BM06-S…2099-BM08-S

Kinetix 7000: 2099-BM09-S…2099-BM12-S

Kinetix 6000 and

Kinetix 6200/6500 drives

Kinetix 6000: All 460V configurations

(1)

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

None

Kinetix 6200/6500: All 460V configurations

(1)

2198-P208

2198-CAPMOD-2240

2198-CAPMOD-DCBUS-IO

2198-P208

Three-phase

Source

DC+

DC-

M

DC+

DC-

M

AC Drive AC Drive

M

Kinetix 6000 or

Kinetix 6200/6500 Drives

DC+ DC-

Contactor

Three-phase

Capacitor

Module

DC-Bus

Power Supply

Extension

Module

DC Bus

DC-Bus

Power Supply

DC-Bus

Power Supply

Reactor

Line

Reactor

Line

Reactor

Line

AC Line Filter

Three-phase

Circuit

Protection

Circuit

Protection

Circuit

Protection

M

Circuit

Protection

Integrated

Axis Module

Axis

Modules

(1)

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

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.

• 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).

•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-Pxxx DC-bus power supply and 2198-RPxxx 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.

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

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

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

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

.

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 4 - PowerFlex 750-Series Drive Precharge Parameters

Parameter

Digital Input

Number Setting

189 [DI Precharge] 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.

Table 5 - General Purpose Relay Connections

Signal Terminal Description

Recommended Wire Size

mm

2

(AWG)

Strip Length

mm (in.)

Torque Value

N•m (lb•in)

DRIVE OK+ 5 Programmable N.O. Relay 2 output 0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

7.0 (0.275) 0.235 (2.0)

DRIVE OK- 6 Programmable Relay 2 common

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.

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