Allen-Bradley Kinetix 5700 User manual

Installation Instructions

Kinetix 5700 Capacitor Modules

Catalog Numbers 2198-CAPMOD-2240, 2198-CAPMOD-DCBUS-IO

About the Capacitor Modules

The 2198-CAPMOD-2240 capacitor module and 2198-CAPMOD-DCBUS-IO extension

module are used for energy storage and to extend the DC-bus voltage to another inverter cluster.

The 2198-CAPMOD-2240 capacitor module is used in applications with up to 100 A

maximum external DC-bus current. You can add the 2198-CAPMOD-DCBUS-IO extension

module to the left or right of the capacitor module when the external DC-bus current exceeds

100 A, up to a maximum of 200 A.

See the Kinetix® 5700 Servo Drives User Manual, publication 2198-UM002, for detailed

information on wiring, applying power, troubleshooting, and integration with ControlLogix® or

CompactLogix™ controllers.

Before You Begin

Remove all packing material, wedges, and braces from within and around the components. After

unpacking, check the item nameplate catalog number against the purchase order.

The Kinetix 5700 capacitor modules include the following accessory items.

Topic Page

About the Capacitor Modules 1

Before You Begin 1

Important User Information 2

Install the Capacitor Modules 3

Connector Data 7

Wiring Requirements 9

Additional Resources 12

Item 2198-CAPMOD-2240 2198-CAPMOD-DCBUS-IO

Parts kit containing stud/lug cover with wires (1), lug-cover bottom

plate, hex nuts and spacers for M8 studs, and 55 mm DC-bus link

(1) Stud cover for systems without wires attached is installed on each module.

Wiring plug for the module status (MS) connector X –

Wiring plug for the 24V DC input power (CP) connector X –

Flexible bus bars, 2 each – X

2Kinetix 5700 Capacitor Modules

Publication 2198-IN008B-EN-P - July 2015

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).

Kinetix 5700 Capacitor Modules 3

Publication 2198-IN008B-EN-P - July 2015

Install the Capacitor Modules

These procedures assume that you have prepared your panel, mounted your Kinetix 5700 servo

drives, and understand how to bond your system. For installation instructions regarding

equipment and accessories not included here, refer to the instructions that came with those

products.

Zero-stack Tab and Cutout

Engaging the zero-stack tab and cutout from module-to-module is required for shared-bus drive

systems and includes the Kinetix 5700 capacitor modules. This is done to make sure that the

module connectors are spaced properly to accept the shared-bus connection system.

Zero-stack Tab and Cutout Example

Mount the Capacitor Modules

Clearance requirements below the Kinetix 5700 capacitor and extension modules are identical to

the drive modules, however, additional space is required above for access to the DC-bus studs

and side-to-side for the DC-bus wiring that attaches to the studs. Refer to the Kinetix 5700

Servo Drives User Manual, publication 2198-UM002, for additional mounting information.

SHOCK HAZARD: To avoid the hazard of electrical shock, perform all mounting and wiring of the

Kinetix 5700 drive modules prior to applying power. Once power is applied, connector terminals can

have voltage present even when not in use.

ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling,

tapping, and welding with the system removed from the enclosure. Because the system is of open

type construction, be careful to keep any metal debris from falling into it. Metal debris or other

foreign matter can become lodged in the circuitry, which can result in damage to components.

MOD

NET

MOD

DC BUS

MOD

NET

2198-Pxxx

DC-bus Power Supply

(front view)

Zero-stack Tab

and Cutout Engaged

2198-CAPMOD-2240

Capacitor Module

(front view)

2198-xxxx-ERS3

Inverter

4Kinetix 5700 Capacitor Modules

Publication 2198-IN008B-EN-P - July 2015

You can mount the 2198-CAPMOD-2240 capacitor module on the far right or far left of any

system cluster, depending on the input power configuration. More than one capacitor module

can be used in a cluster, if needed. Each additional module adds to the total system capacitance

and increased energy storage. The 2198-CAPMOD-DCBUS-IO extension module is always

mounted next to a capacitor module and always on the outside of the system cluster (either first

or last). An extension module is needed if the external DC-bus current is greater than 100 A, up

to a maximum of 200 A.

Kinetix 5700 Drive System Example with Extended (200 A) Drive System

For extended 100 A drive systems, remove the 2198-CAPMOD-DCBUS-IO extension

modules.

IMPORTANT

Capacitor modules always mount on the far right or far left of the system cluster, which ever

configuration makes the best use of panel space.

Extension modules always mount next to a capacitor module and on the outside of the cluster,

(first or last) in systems up to a maximum of 200 A.

Inverters with the highest power ratings must be positioned closest to the DC-bus supply (in

decreasing order) and only two clusters are allowed on the same DC-bus.

MOD

NET

I/O-A

510

I/O-B

510

UFB-A UFB-B

D+

D-

MF-A MF-B

MOD

NET

I/O-A

I/O-B

510510

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

MOD

NET

I/O-A

I/O-B

510510

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

MOD

NET

MOD

NET

MOD

NET

I/O

510

I/O-A

510

I/O-B

510

I/O-A

I/O-B

510510

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

I/O

MOD

NET

D+

D-

MODULE

STATUS

MOD

NET

MODULE

STATUS

MOD

NET

I/O-A

I/O-B

510510

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

2198-CAPMOD-DCBUS-IO

Extension Module

2198-CAPMOD-2240

Capacitor Module

2198-CAPMOD-DCBUS-IO

Extension Module

2198-CAPMOD-2240

Capacitor Module

System Cluster 1

Extended System,

Cluster 2

DC-bus

Power Supply

Single-axis

Inverter

Dual-axis

Inverters

Dual-axis Inverters

In this example, the capacitor module

and extension module are positioned on

the far right in both clusters.

However, other configurations are

possible, as long as the inverters with the

highest power ratings (in each cluster)

are positioned closest to the DC-bus

power supply and in decreasing order

leading away from the supply.

High-to-low Power Rating

Kinetix 5700 Capacitor Modules 5

Publication 2198-IN008B-EN-P - July 2015

Kinetix 5700 Drive System Example with RPS Unit (200 A) Drive System

In this example, the 8720MC-RPS unit, capacitor module, and extension module are positioned

on the far left, with the DC-bus supply feeding into the inverter with the highest power rating.

To move the DC-bus input voltage to the far right, you must also reverse the order of the

inverters, so the inverters with the highest power ratings are positioned closest to the DC-bus

supply and in decreasing order leading away from the DC-bus supply.

For an RPS unit in 100 A systems (catalog number 8720MC-RPS065BM), remove the

2198-CAPMOD-DCBUS-IO extension module.

Kinetix 5700 Drive System Example with Multiple Capacitor Modules

Each 2198-CAPMOD-2240 capacitor module adds to the total system capacitance and

increased energy storage.

MOD

NET

I/O-A

510

I/O-B

510

UFB-A UFB-B

D+

D-

MF-A MF-B

MOD

NET

I/O-A

I/O-B

510510

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

MOD

NET

I/O-A

I/O-B

510510

UFB-A UFB-B

D+

D-

MF-A MF-B

D+

D-

MOD

NET

MOD

NET

MOD

NET

MOD

NET

I/O

510

I/O-A

510

I/O-B

510

I/O-A

I/O-B

510510

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

REGENERATIVE POWER SUPPLY

87208720

MCMC

RST PRG ENT

READYREADY

FAULTFAULT

PROGRAMPROGRAM kWkW

D+

D-

MODULE

STATUS

2198-CAPMOD-DCBUS-IO Extension Module

2198-CAPMOD-2240 Capacitor Module

8720MC-RPS190BM

Regenerative Power Supply Single-axis

Inverter Dual-axis Inverters

High-to-low Power Rating

MOD

NET

MOD

NET

MOD

NET

I/O

510

I/O-A

510

I/O-B

510

I/O-A

I/O-B

510510

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

I/O

MOD

DC BUS

MOD

DC BUS

MOD

DC BUS

D+

D-

MODULE

STATUS

MODULE

STATUS

MODULE

STATUS

2198-CAPMOD-2240

Capacitor Modules

DC-bus

Power Supply

Single-axis

Inverter

Dual-axis

Inverters

In this example, the bank of three

capacitor modules are positioned

on the far right. However, they

can all be moved to the far left to

optimize panel space.

6Kinetix 5700 Capacitor Modules

Publication 2198-IN008B-EN-P - July 2015

Product Dimensions

Refer to the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002, for system-wide

drill hole specifications.

Capacitor Module Dimensions

Capacitor Module

Cat. No. AB

(1)

(1) The recommended mounting hardware is M5 (#10-32) steel bolts. Apply 4.0 N•m (35.4 lb•in) maximum torque to each fastener.

2198-CAPMOD-2240 300 (11.81) 345 (13.58) 358 (14.09) 253 (10.0)

2198-CAPMOD-DCBUS-IO 131 (5.16) 176 (6.93) 189 (7.44) 248 (9.76)

MODULE

STATUS A

(2.16)

27.5

(1.08)

27.5

(1.08)

MOD

DC BUS

10.0

(0.39)

29.5

(1.16)

56.3

(2.22)

2198-CAPMOD-xxxx-xx Capacitor Modules

(2198-CAPMOD-2240 module is shown)

Dimensions are in mm (in.)

Kinetix 5700 Capacitor Modules 7

Publication 2198-IN008B-EN-P - July 2015

Connector Data

Lug spacers are needed only when wiring both external DC-bus and active shunt connections to

the lug studs. Two types of lug covers are provided, one for systems with external DC-bus or

active shunt wires attached and one without.

Capacitor Module Features and Indicators

Item Description Item Description

1 Ground stud 7 DC-bus (DC) connector

2 Module status (MS) connector 8 24V control input power (CP) connector

3 DC-bus status indicator 9 DC– M8 stud (external DC-bus)

4 Module status indicator 10 DC+ M8 stud (external DC-bus), shown with

wire lug

5 Stud/lug cover with wires (1)

(1) This example shows the lug cover oriented for wires exiting to the left (capacitor module is on the far left of the drive configuration). Rotate lug

cover 180° when wires exit to the right (capacitor module is on the far right of the drive configuration).

11 M8 hex nut

6 Stud cover without wires 12 Lug spacer

MODULE

STATUS

MOD

DC BUS

24V–

24V+

24V–

24V+

12 11

5700

2198-CAPMOD-2240

Capacitor Module

(front view)

2198-CAPMOD-2240

Capacitor Module

(top views)

2198-CAPMOD-2240

Capacitor Module

(side view, lug cover removed)

8Kinetix 5700 Capacitor Modules

Publication 2198-IN008B-EN-P - July 2015

Extension Module Features and Indicators

DC Bus (DC) Connector Pinout

Item Description Item Description

1 Ground lug 5 DC– M8 stud (external DC-bus)

2 Stud/lug cover with wires (1)

(1) This example shows the lug cover oriented for wires exiting to the left (extension module is on the far left of drive configuration). Rotate lug cover

180° when wires exit to the right (extension module is on the far right of drive configuration).

6DC+ M8 stud (external DC-bus), shown with

flexible bus-bar (2x)

3 Stud cover without wires 7 M8 hex nut

4 DC-bus (DC) connector 8 Lug spacer

DC Pin Description Signal

Bus link DC bus connections

DC–

DC+

5700

2198-CAPMOD-DCBUS-IO

Extension Module

(side view, lug cover removed)

2198-CAPMOD-DCBUS-IO

Extension Module

(front view)

2198-CAPMOD-DCBUS-IO

Extension Module

(top views)

Kinetix 5700 Capacitor Modules 9

Publication 2198-IN008B-EN-P - July 2015

Control Input Power (CP) Connector Pinout

Module Status (MS) Connector Pinout

Wiring Requirements

Capacitor Module Wiring Requirements

CP Pin Description Signal

1 24V power supply, customer-supplied 24V+

224Vcommon 24V–

MS Pin Description Signal

1 Module status relay output + RELAY+

2 Module status relay output – RELAY–

IMPORTANT

The National Electrical Code and local electrical codes take precedence over the values and

methods provided.

Connector

Description Pin Signal

Recommended

Wire Size

mm2(AWG)

Strip Length

mm (in.)

Torque Value

N•m (lb•in)

Module Status MS-1

MS-2

RELAY+

RELAY–

0.14…1.5

(28…16) 7.0 (0.28) 0.22…0.25

(1.9…2.2)

PELV/SELV

24V power (plug)

CP-1

CP-2

24V+

24V–

0.5…2.5

(20…14) 7.0 (0.28) 0.22…0.25

(1.9…2.2)

DC-bus power Bus-bar

DC–

DC+

N/A (1) N/A (1)

(1) DC bus connections are always made from drive-to-drive over the shared-bus connection system. These terminals do not receive discrete wires.

N/A (1)

DC-bus studs

Bus-bar N/A N/A

18 (156)

Lugs 53.5 (1/0) 100 A

85.0 (3/0) 200 A N/A (2)

(2) Strip length for the DC-bus studs depend on the customer-supplied lugs.

ATTENTION: To avoid personal injury and/or equipment damage, observe the following:

•Make sure that the 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.

•Use power connectors for connection purposes only. Do not use them to turn the unit on and off.

•Ground shielded power cables to prevent potentially high voltages on the shield.

10 Kinetix 5700 Capacitor Modules

Publication 2198-IN008B-EN-P - July 2015

Wire an External Active Shunt

Active shunts wire to the DC-bus studs. The capacitor 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.

Active Shunt Connections

Active Shunts Compatible with Kinetix 5700 Drive Systems

Connect Modules with Flexible Bus-bars

When the 2198-CAPMOD-DCBUS-IO extension module is used, two flexible bus-bars make

the external DC-bus lug connections to the 2198-CAPMOD-2240 capacitor module. The

DC-bus links must also be installed.

Flexible Bus-bar Example

Rockwell Automation

Encompass Partners Powerohm Cat. No. Power Rating

Current Rating

Amps

Powerohm Resistors, Inc. PWB035 22.7 35

PWB110 71.5 110

2198-CAPMOD-2240 or

2198-CAPMOD-DCBUS-IO

Capacitor Module

(2198-CAPMOD-2240

module is shown)

Active Shunt

Lug Connections

(above spacer)

DC-Bus

Lug Connections

(below spacer)

Spacer

24V–

24V+

SB+/NC

S1A

SCA

S2A

SB-

S1B

SCB

S2B

816

24V–

24V+

2198-CAPMOD-2240

Capacitor Module

Flexible bus-bars

(external DC-bus connections)

2198-CAPMOD-DCBUS-IO

Extension Module

DC-bus Link Connections

2198-xxxx-ERS3

Inverters

ATTENTION: To avoid damage to components on 200 A

systems, the DC-bus links and the flexible bus-bars must

be installed.

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