Table 122 — Fault Code Summary
(1) (2)
Fault Code Type
Description
Standard runtime axis exceptions. The exception can apply to an individual axis or to
FLT Sxx
all axes.
Manufacturer-specific runtime axis exception. The exception can apply to an individual
FLT Mxx
axis or to all axes.
INIT FLT Sxx
Exceptions that prevent normal operation and occur during the initialization process.
INIT FLT Mxx
Exceptions that can prevent normal operation of the drive module and apply to the
NODE FLTxx
entire module and affect all axes.
Exceptions that can prevent normal operation of the drive module, but do not result in
NODE ALARM xx
any action other than reporting the alarm to the controller.
INHIBIT Sxx
Conditions that prevent normal operation and indicate the drive module is prevented
from being enabled.
INHIBIT Mxx
ALARM Sxx
An underlying exception condition that does not result in any action other than
reporting the alarm to the controller.
ALARM Mxx
(3)
SAFE FLTxx
Exception generated by a fault condition detected in the safety function.
(1) Sxx refers to Standard exceptions.
(2) Mxx refers to Manufacturer-specific exceptions.
(3) For troubleshooting 2198-xxxx-ERS3 inverter SAFE FLT fault codes, refer to
page 316
(hardwired safety) or
refer to the Kinetix 5700 Safe Monitor Functions Safety Reference Manual, publication 2198-RM001.
TIP Fault codes triggered by conditions that fall outside factory set limits are identified by
FL at the end of the display message. For example, FLT S07 – MTR OVERLOAD FL.
Fault codes triggered by conditions that fall outside user set limits are identified by UL
at the end of the display message. For example, FLT S08 – MTR OVERLOAD UL.
For fault code descriptions and possible solutions, see the Kinetix 5700 Fault
Codes.xlsx file attached to this publication. For more information about the
file, see
Access the Attachments
SAFE FLT Fault Codes
For troubleshooting 2198-xxxx-ERS4 inverter SAFE FLT fault codes, refer to
the Kinetix 5700 Safe Monitor Functions Safety Reference Manual,
publication 2198-RM001.
Rockwell Automation Publication 2198-UM002G-EN-P — February 2019
Troubleshoot the Kinetix 5700 Drive System
Troubleshoot the Safe Torque-off Function
page 329
(integrated safety). For troubleshooting 2198-xxxx-ERS4 inverter SAFE FLT fault codes,
on
page
13.
Chapter 7
on
277
-
Contents
-
Table of Contents
-
Troubleshooting
-
Bookmarks
Quick Links
This manual links to the Kinetix 5700 Servo Drive Fault Codes, publication
2198-RD003; download the spreadsheet for offline access.
Kinetix 5700 Servo Drives User
Manual
Catalog Numbers 2198-P031, 2198-P070, 2198-P141, 2198-P208, 2198-RP088, 2198-RP200,
2198-RP263, 2198-RP312, 2198-D006-ERS3, 2198-D012-ERS3, 2198-D020-ERS3,
2198-D032-ERS3, 2198-D057-ERS3, 2198-S086-ERS3, 2198-S130-ERS3, 2198-S160-ERS3,
2198-S263-ERS3, 2198-S312-ERS3, 2198-D006-ERS4, 2198-D012-ERS4, 2198-D020-ERS4,
2198-D032-ERS4, 2198-D057-ERS4, 2198-S086-ERS4, 2198-S130-ERS4, 2198-S160-ERS4,
2198-S263-ERS4, 2198-S312-ERS4, 2198T-W25K-ER, 2198-CAPMOD-2240, 2198-CAPMOD-DCBUS-IO,
2198-DCBUSCOND-RP312
User Manual
Original Instructions
Troubleshooting
Summary of Contents for Rockwell Automation Allen-Bradley Kinetix 5700
15 posts in this topic
HI , I would like to ask you for your opinion
THIS IS MY PROBLEM WITH THE kinetix 6500
The equipment was working fine , but now i cant make to servo move with the program, cant run the test or autotuning
Status in front of servo drives say running.
Everything is green, no errors,
when I activate the MSO I can hear a click at servodrive, but the servo is not energized, because i dont hear the usual noise when the servo is energized, I have check the cables and conectors, everythig is fines, I check the servo resistence , no shortcuts or open lines, The wierd part is when the servos are in the running state i can move by hand, they are supossed to be locked.
after that I activate the home MAH, or test or autotuning , or a direct command ,and then it fails When i try to jog . move, test or autotuning the servo it says s55 velocity error or excess positon error, i can not get servo to move at all
I can see the position from the encoder back to the plc. I have turned the servo and i see the position at actualposition
Before the equipment was working , moving , I just swith it off one day, and the next day I couldnt make it move
Best regards
I have added the programm as an attachment
k6500.ACD
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Sounds like you have a problem with the encoder. The drive thinks everything is ok until it tries to command a move, then is doesn’t see the encoder feedback changing. Check the connections, then with the servo off, turn the shaft by hand. You should see the actual position tag changing.
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Hi JRoss
This is part of what I have check
I did, and i can see the encoder readigs at actualposiotion tag changing , The servo was moving before, responding to autotuning, test, MAH, MAJ , MAM instructions and direct comands, I have check lines with encoder and power lines and readings, and they look normal. All lights are green, the bus led is green and steady,
When the servo is activated with MSO instruction, the servo is loose, I can turn it by hand, no alarms. but when I try to move it with MAH or MAJ , for example , then the S55 appears,
I have also check the inputs L1 L2 L3 with the bus + and bus- and i have normal readings, also U V W with bus + and bus — and also normal readings, with my muitimeter to check diode at rectification and BJTs . And when the kinetix is on I get around 640 volts DC ant BUS + and Bus —
I was thinking that it could be the BJTs that are not fireing signal to the servo and the error might be because the dirves tries to move the servo, and it doesnt move , sp there is a difference and gives the s55 error.
I have check the BJT installed, with multimeter, the block of BJT give normal readings UVW with Bus+ and Bus — , I dond see shorts just the normal readings of diodes,
Best Regards
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12 hours ago, JRoss said:
Sounds like you have a problem with the encoder. The drive thinks everything is ok until it tries to command a move, then is doesn’t see the encoder feedback changing. Check the connections, then with the servo off, turn the shaft by hand. You should see the actual position tag changing.
Hi JRoss
This is part of what I have check
I did, and i can see the encoder readigs at actualposiotion tag changing , The servo was moving before, responding to autotuning, test, MAH, MAJ , MAM instructions and direct comands, I have check lines with encoder and power lines and readings, and they look normal. All lights are green, the bus led is green and steady,
When the servo is activated with MSO instruction, the servo is loose, I can turn it by hand, no alarms. but when I try to move it with MAH or MAJ , for example , then the S55 appears,
I have also check the inputs L1 L2 L3 with the bus + and bus- and i have normal readings, also U V W with bus + and bus — and also normal readings, with my muitimeter to check diode at rectification and BJTs . And when the kinetix is on I get around 640 volts DC ant BUS + and Bus —
I was thinking that it could be the BJTs that are not fireing signal to the servo and the error might be because the dirves tries to move the servo, and it doesnt move , sp there is a difference and gives the s55 error.
I have check the BJT installed, with multimeter, the block of BJT give normal readings UVW with Bus+ and Bus — , I dond see shorts just the normal readings of diodes,
Best Regards
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When you are turning the servo by hand does the position change correctly? In both directions? When you use MSO to turn the servo on and can turn it by hand, does it fault out?
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1 hour ago, JRoss said:
When you are turning the servo by hand does the position change correctly? In both directions? When you use MSO to turn the servo on and can turn it by hand, does it fault out?
Yes, I have turned it in both directions, the lecture or readings of encoder at actualposition tag increases and decreases the revolutions normally
Yes , when the MSO is on, I can turn the servo by hand, but no more than 1 rev , after or around 1 revolution the fault appears s55,
I can move it back and forth , but no more than 1 rev, after that it fails and shows s55 velocity error, it doest fell hard
I have check the power rail terminals, the Dc volts lines in power rail takes DC to the output side of the kinetix 6500, I was thinking that there may not be DC 640 volt , but there it is in power rail
Best Regards
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Is this a new install or an exisiting system?
What is the full part number of your servo motor you have connected to the K6500?
Are you using the hardwired enable input on the drive?
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OK, try this…
The control module on the drive is removable. Loosen the screw and rock the module in and out of the connection 5 or 6 times. This will clean up the connections between the control module and the power module. This is a known issue with the 6500 that I have dealt with personally on two occasions. Different symptoms both times, but weird stuff that didn’t make sense.
If that doesn’t work, next step is to start swapping out parts, including the cables.
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Kinetix 6500, Fault S55 => (a) Improperly sized drive or motor, (b) Mechanical system out of specification. The servo controller is telling you that when it tries to move the load to the commands you have given it (i.e., position, velocity, acceleration, etc.), that it detects this cannot be achieved properly.
Have you modeled the load in Motion Works, to verify that the mechanical engineers properly sized the motor and gearbox and servo controller?
A-B/Rockwell servos often typically tune «hot». What allows you to tune and jog the servo without issue may be covering up the inability to command to position.
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19 hours ago, Donovanr said:
Is this a new install or an exisiting system?
What is the full part number of your servo motor you have connected to the K6500?
Are you using the hardwired enable input on the drive?
Is an existing system
MPL-B1530U-EJ72AA
Yes Im using 2 signals from connector DB 44 the the input for enable and the input for home sensor
Best Regards
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19 hours ago, JRoss said:
OK, try this…
The control module on the drive is removable. Loosen the screw and rock the module in and out of the connection 5 or 6 times. This will clean up the connections between the control module and the power module. This is a known issue with the 6500 that I have dealt with personally on two occasions. Different symptoms both times, but weird stuff that didn’t make sense.
If that doesn’t work, next step is to start swapping out parts, including the cables.
Ok I did,
and also cleaned the conectors, they look shiny like new,
I ran a test but no changes , still fails
I have another servomotor with cables , Ill change them and Ill let you now
Best Regards
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8 hours ago, kaiser_will said:
Kinetix 6500, Fault S55 => (a) Improperly sized drive or motor, (b) Mechanical system out of specification. The servo controller is telling you that when it tries to move the load to the commands you have given it (i.e., position, velocity, acceleration, etc.), that it detects this cannot be achieved properly.
Have you modeled the load in Motion Works, to verify that the mechanical engineers properly sized the motor and gearbox and servo controller?
A-B/Rockwell servos often typically tune «hot». What allows you to tune and jog the servo without issue may be covering up the inability to command to position.
The servo in not moving something heavy, is very light the load
You can feell that the servomotor shaft is even harder to turn than the load , the load is very very soft
The servomotor is an MPL-B1530u-EJ72aa
The servo drive is a 6 kw and in the manual Design User, it says that is OK to use this servo with this servodrive, is in the list of useable motors
Right now the servo is not connected to the load, and Is displaying S55 any way, I have tried to do Home to sensor, , MAJ , MAM, Direct commands , with out being connected the servo to the load
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23 hours ago, JRoss said:
OK, try this…
The control module on the drive is removable. Loosen the screw and rock the module in and out of the connection 5 or 6 times. This will clean up the connections between the control module and the power module. This is a known issue with the 6500 that I have dealt with personally on two occasions. Different symptoms both times, but weird stuff that didn’t make sense.
If that doesn’t work, next step is to start swapping out parts, including the cables.
Hi JRoss
I have another 2094 BMP5 but this one is with sercos in another machine, I have taken the servomotor and cables and plug it with this equipment in sercos
And the servo gets really hard to move the servomotor shaft by hand , I just tried a little bit to move it, when the MSO is activated from direct command instructions. Im using the same servomotor with the same cables at the s kinetix 6500 . Is responding very nice to MAH and MAJ, with sercos servodrive
So I think it may be the IBJT s that are not fireing the signal to the servo, but I have check the U V W vs Bus+ Bus- , las time Ive check and the reading of diode were fine, no shortcuts
U V W vs BUS — READINGS diode
0.448 U — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 V — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 W — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
U V W vs BUS + READINGS diode
0.448 U — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 V — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 W — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
I have also check the readings of the IBJT s at kinetix 6000 sercos and the same readings of UVW vs BUS + and BUS-
Best Regards
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U V W vs BUS — READINGS diode
0.448 U — BUS- OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 V — BUS- OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 W — BUS- OL WHEN INVERTED LEADS or wires AT MULTIMETER
U V W vs BUS + READINGS diode
0.448 U — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 V — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
0.448 W — BUS+ OL WHEN INVERTED LEADS or wires AT MULTIMETER
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The alarm you are getting means the encoder feedback doesn’t match the drive command to the motor. I usually see this when there is a problem with the encoder (damage, wiring, polarity). But it sounds like you have a problem with the motor side of the drive, not the encoder.
Since you tested the motor and cables with another drive, then there is something wrong with the 6500, either in the control module or the power module. You’ll have to contact your distributor.
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198
Rockwell Automation Publication 2094-UM002E-EN-P — May 2012
Chapter 8
Troubleshooting the Kinetix 6200 and Kinetix 6500 Drive System
Fault Codes
These fault code tables are designed to help you resolve anomalies. When a fault
is detected, the four-character status indicator scrolls the display message. This is
repeated until the fault code is cleared.
For information on troubleshooting SAFE FLT fault codes, refer to the
Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Safety Reference Manual,
publication
2094-RM001
.
Table 80 — Fault Code Summary
Fault Code Type
Description
FLT Sxx
Standard runtime anomalies.
FLT Mxx
INIT FLT Sxx
Anomalies that prevent normal operation and occur during the initialization process.
INIT FLT Mxx
NODE FLTxx
Anomalies that prevent normal operation of all drives on the power rail.
NODE ALARM xx
Anomalies that prevent normal operation of all drives on the power rail, but do not
result in any action other than reporting the alarm to the controller.
ALARM Sxx
ALARM Mxx
Warnings of conditions that may affect normal operation, but do not result in any
action other than reporting the alarm to the controller.
TIP
Fault codes triggered by conditions that fall outside factory set limits are identified by FL at the end of
the display message. For example, FLT S03…MTR OVERSPEED FL.
Fault codes triggered by conditions that fall outside user set limits are identified by UL at the end of
the display message. For example, FLT S04…MTR OVERSPEED UL.
Table 81 — FLT Sxx Fault Codes
Four-character
Display Message
RSLogix 5000
Fault Message
Problem or Symptom
Potential Cause
Possible Resolution
FLT S02…MTR COMMUTATION
Illegal Hall State
State of Hall feedback inputs is
incorrect.
Improper connections.
• Check Hall wiring at motor
feedback (MF) connector.
• Check 5V power supply to the
encoder.
FLT S03…MTR OVERSPEED FL
Motor Overspeed
Motor speed has exceeded 125% of maximum rated speed.
• Check cables for noise.
• Check tuning.
FLT S04…MTR OVERSPEED UL
(Kinetix 6500 drives only)
Motor Overspeed
Motor speed has exceeded user velocity limits.
FLT S05…MTR OVERTEMP FL nn
Motor Overtemperature
The motor thermostat, motor
thermistor, or encoder temperature
sensor indicates that the motor factory
temperature limit has been exceeded.
The nn sub-code is defined as follows:
High motor ambient
temperature and/or
Excessive Current.
• Operate within (not above)
the continuous torque rating
for the ambient temperature.
• Lower ambient temperature or
increase motor cooling.
01: Motor Thermostat or Thermistor.
Motor wiring error.
Check motor wiring at motor
feedback (MF) connector.
02: Encoder Temperature Sensor.
Incorrect motor selection.
Verify the proper motor has been
selected.
(Ocr-Read Summary of Contents of some pages of the Allen-Bradley Kinetix 5700 Document (Main Content), UPD: 20 March 2023)
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250, 250 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Chapter 6 Configure and Start the Kinetix 5700 Drive System The Motor Device Specification dialog box appears. 7. From the Data Source pull-down menu, choose Nameplate Datasheet. This is the default setting. If you have an Allen-Bradley HPK-Series™ asynchronous rotary motor, refer to page 246 to see how to populate the Nameplate / Datasheet parameters by selecting the m…
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46, 46 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Chapter 2 Plan the Kinetix 5700 Drive System Installation • Powering multiple (two or more) regenerative bus supplies from the same AC input-power source. – Switching ripple from each regenerative bus supply can interfere with other regenerative bus supplies on 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 sou…
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2, 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 s…
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225, Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 225 Configure and Start the Kinetix 5700 Drive System Chapter 6 6. Click the AC Line category. Source Power is the kVA rating of the transformer feeding the regenerative power supply. The default Source Power setting is 10 times the power rating of the regenerative power supply. When the transformer rating is less than the regenerative power supply rating, enter the kVA rating of the transformer. The So…
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275, Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 275 Chapter 7 Troubleshoot the Kinetix 5700 Drive System This chapter provides troubleshooting tables and related information for your Kinetix® 5700 drive system. Safety Precautions Observe the following safety precautions when troubleshooting your Kinetix 5700 drive system. Topic Page Safety Precautions 275 Interpret Status Indicators 276 Axis Troubleshooting 280 Regenerative Bus Supply Troubleshooti…
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216, 216 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Chapter 6 Configure and Start the Kinetix 5700 Drive System ‘Motion Safety’ applies to 2198-Sxxx-ERS4 (single-axis) inverters. ‘Motion Safety 1’ and ‘Motion Safety 2’ applies to 2198-Dxxx-ERS4 (dual-axis) inverters. Motion Safety and Motion Safety 1 align with Axis 1 configured in Associated Axes. Motion Safety 2 aligns with Axis 3 configured in Associat…
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392, Allen-Bradley Kinetix 5700 392 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Appendix C Size Multi-axis Shared-bus Configurations In this example, two drive clusters in the same cabinet are connected by the same 458…747V DC-bus voltage. Kinetix 5700 capacitor modules provide connection points for the DC bus. The extension module is needed only when the DC-bus system current exceeds 104 A, and can support up to 208 A maximum external DC-bu…
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195, Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 195 Configure and Start the Kinetix 5700 Drive System Chapter 6 Table 107 — Navigating the Regenerative Bus Supply Settings Menu Settings Menu Selections Sub Menu Selections Attributes Default Description Protected Mode Reset ENABLED DISABLED ENABLED When Enabled (default), identity object or safety resets are not possible when a controller connection is …
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436, 436 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Appendix E Motor Control Feature Support The speed is increased by updating the speed reference and then re-executing the MDS instruction. Figure 233 — Increase Speed The speed is decreased by updating the speed reference and then re-executing the MDS instruction. Figure 234 — Decrease Speed
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358, Allen-Bradley Kinetix 5700 358 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Appendix A Interconnect Diagrams Contactor Wiring Examples We recommend that you wire an Allen-Bradley® (Bulletin 100) auxiliary contactor to the 2198-RPxxx regenerative-bus supply digital input (IOD connector) and configure AC Line Contactor OK to monitor three-phase input power. Use the Normally Open (N.O.) auxiliary contact, i…
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272, 272 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Chapter 6 Configure and Start the Kinetix 5700 Drive System Tune Induction Motors Follow these steps to tune the induction motor axes. 1. Verify the load is removed from the axis being tuned. 2. Select the Autotune category. 3. Type values for Travel Limit and Speed. In this example, Travel Limit = 50.0 and Speed = 2.0. The actual value of programmed units depend on your appl…
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401, Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 401 Appendix D Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies This appendix provides information on maximum motor cable length limitations for Kinetix® 5700 drive systems. Maximum motor cable lengths for the following configurations are dependent on these configuration variables: • Kinetix 5700 power supply – 2198-Pxxx DC…
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59, Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 59 Plan the Kinetix 5700 Drive System Installation Chapter 2 Accessory Module Selection The requirements for when to use accessory modules vary depending on whether your system is powered by the 2198-Pxxx DC-bus power supply or 2198-RPxxx regenerative bus supply. 8720MC-RPS regenerative power supplies follow the same requirements as 2198-RPxxx regenerative bus supplies for acc…
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404, 404 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Appendix D Maximum Motor Cable Lengths for Kinetix 5700 Power Supplies Regenerative Bus Supply Configurations 2198-RPxxx regenerative bus supplies have limited maximum drive-to-motor cable length when DC-bus regulation is enabled. However, the DC Bus can be extended up to 70 m (230 ft) to remote clusters of Kinetix 5700 inverters.…
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11, Allen-Bradley Kinetix 5700 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 11 Preface This manual provides detailed installation instructions for mounting and wiring your Kinetix® 5700 power supplies, single-axis inverters, dual-axis inverters, and accessory modules. Also included is system configuration with the Studio 5000 Logix Designer® application, integration of your drive modules with a Logix 5000™ controller, system startup, and troubleshooting. Also provided in this …
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352, 352 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 Appendix A Interconnect Diagrams In this example, three-phase AC input power is fed to two 8720MC-RPS065 units in a leader/follower configuration. The DC-bus (TB1) terminals connect to the Kinetix 5700 DC-bus via the DC-bus conditioner module because the system current exceeds 104 A. Figure 175 — 8720MC-RPS065 Leader/Follower Units with Kinetix 5700 Drive System E/N L1 L2…
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141, Allen-Bradley Kinetix 5700 Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 141 Connect the Kinetix 5700 Drive System Chapter 5 Wiring Requirements Wires must be copper with 75 °C (167 °F) minimum rating. Phasing of main AC power is arbitrary and earth ground connection is required for safe and proper operation. Refer to Power Wiring Examples on page 343 for interconnect diagrams. Table 65 — DC-bus Power Supply Wiring Requirements IMPORTANT The National Electrical Code and local electrical codes …
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357, Rockwell Automation Publication 2198-UM002G-EN-P — February 2019 357 Interconnect Diagrams Appendix A Capacitor Module Status Wiring Example You can configure either of the DC-bus power supply digital inputs as Bus Capacitor OK in the Logix Designer application to monitor the Module Status output. Refer to page 205 to see how the DC-bus power supply Digital Inputs category is configured. Figure 178 — DC-bus Power Supply with Capacitor Module …