Fuse and Line Filter sizing for the Kinetix 5500 drive

530800 | Date Created: 03/03/2013 | Last Updated: 01/11/2018

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How do I size my fusing and line filter for the Kinetix 5500 drive?

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:

The recommended fusing, circuit breaker (TBD), and line filter can be found in the Kinetix 5500 User Manual

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.

Shown are quantity 5, 2198-H008-ERS modules all with AC Sharing from the same AC power source. The 2198-

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/).

Sharing, you could not use 3, 2198-H008-ERS and 2, 2198-H015-ERS. This is due to different AC line

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

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.

3. SHARED AC/DC

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

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.

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

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.

AC line is fed to the first 2198 drive. In this example chose 2198-H040-ERS for the example leader drive. It will

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

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.

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

If the original selected leader drive was used with further evaluation, , the 2198-H040-ERS is 13. 4 Amps

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.

Going back to example 4, if we assume the inverter power requirement never changed, we had requirements of

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

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.

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.

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.

transmission and cycle profile.

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