Kinetix 5700 Capacitor Modules

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1 Installation Instructions Kinetix 5700 s Catalog Numbers 98-CAP-40, 98-CAP-DCBUS-IO Topic Page About the s Before You Begin Install the s Connector Data 6 Wiring Requirements 8 Additional Resources Summary of Changes Active shunt catalog numbers were added to the table on page 9. About the s The 98-CAP-40 capacitor module and 98-CAP-DCBUS-IO extension module are used for energy storage and to extend the DC-bus voltage to another inverter cluster. The 98-CAP-40 capacitor module is used in applications with up to 00 A maximum external DC-bus current. You can add the 98-CAP-DCBUS-IO extension module to the left or right of the capacitor module when the external DC-bus current exceeds 00 A, up to a maximum of 00 A. See the Kinetix 5700 Servo Drives User Manual, publication 98-UM00, for detailed information on wiring, applying power, and troubleshooting. 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. Item 98-CAP CAP-DCBUS-IO Parts kit containing stud/lug cover with wires (), lug-cover bottom plate, hex nuts and spacers for M8 studs, and 55 mm DC-bus link X X Wiring plug for the module status (MS) connector X Wiring plug for the 4V DC input power (CP) connector X Flexible bus bars, each X () Stud cover for systems without wires attached is installed on each module.

2 Kinetix 5700 s Install the s 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. 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. 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 Zero-stack Tab and Cutout Engaged 98-xxxx-ERS3 Inverter 98-Pxxx DC-bus Power Supply (front view) DC BUS 98-CAP-40 (front view) Mount the s 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 98-UM00, for additional mounting information. Rockwell Automation Publication 98-IN008C-EN-P - April 07

3 4 I/O 5 0 I/O-A I/O-B I/O-A 6 I/O-B UFB MF ULE I/O-A 6 I/O-B I/O-A I/O-B I/O-A 6 I/O-B I/O-A 6 I/O-B ULE Kinetix 5700 s You can mount the 98-CAP-40 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 98-CAP-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 00 A, up to a maximum of 00 A. 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 00 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. Kinetix 5700 Drive System Example with Extended (00 A) Drive System DC-bus Power Supply High-to-low Power Rating Single-axis Inverter Dual-axis Inverters System Cluster I/O 6 98-CAP-DCBUS-IO Extension Module 98-CAP-40 MBRK + - High-to-low Power Rating Dual-axis Inverters Extended System, Cluster In this example, the capacitor module and extension module are positioned on the far right in both clusters. 98-CAP-DCBUS-IO Extension Module 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. 98-CAP-40 For extended 00 A drive systems, remove the 98-CAP-DCBUS-IO extension modules. Rockwell Automation Publication 98-IN008C-EN-P - April 07 3

4 4 I/O READY FAULT PROGRAM RST PRG REGENERATIVE REGENERATIVE POWER SUPPLY 5 0 ENT A V kw I/O-A I/O-B I/O-A 6 I/O-B UFB MF ULE DC BUS ULE DC BUS ULE ULE DC BUS I/O I/O-A I/O-B I/O-A 6 I/O-B UFB MF I/O-A 6 I/O-B I/O-A I/O-B I/O-A 6 I/O-B Kinetix 5700 s Kinetix 5700 Drive System Example with RPS Unit (00 A) Drive System 870MC-RPS90BM Regenerative Power Supply High-to-low Power Rating Single-axis Inverter Dual-axis Inverters 870 MC MC 98-CAP-DCBUS-IO Extension Module MBRK CAP-40 In this example, the 870MC-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 00 A systems (catalog number 870MC-RPS065BM), remove the 98- CAP-DCBUS-IO extension module. Kinetix 5700 Drive System Example with Multiple s DC-bus Power Supply Single-axis Inverter Dual-axis Inverters 98-CAP-40 s I/O 6 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. MBRK + - Each 98-CAP-40 capacitor module adds to the total system capacitance and increased energy storage. 4 Rockwell Automation Publication 98-IN008C-EN-P - April 07

5 Kinetix 5700 s Product Dimensions Refer to the Kinetix 5700 Servo Drives User Manual, publication 98-UM00, for system-wide drill hole specifications. Dimensions 9.5 (.6) 55 (.6) Dimensions are in mm (in.) 56.3 (.) DC BUS C B ULE A 98-CAP-xxxx-xx s 7.5 (.08) 7.5 (.08) 0.0 (0.39) D Cat. No. A B () C D 98-CAP (.8) 345 (3.58) 358 (4.09) 53 (0.0) 98-CAP-DCBUS-IO 3 (5.6) 76 (6.93) 89 (7.44) 48 (9.76) () The recommended mounting hardware is M5 (#0-3) steel bolts. Apply 4.0 N m (35.4 lb in) maximum torque to each fastener. Rockwell Automation Publication 98-IN008C-EN-P - April 07 5

6 Kinetix 5700 s 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. Features and Indicators DC BUS CAP-40 (side view, lug cover removed) 0 ULE CAP-40 (front view) 7 4V 4V+ 8 4V 4V+ 98-CAP-40 (top views) Item Description Item Description Ground stud 7 DC-bus (DC) connector Module status (MS) connector 8 4V control input power (CP) connector 3 DC-bus status indicator 9 DC M8 stud (external DC-bus) 4 Module status indicator 0 5 Stud/lug cover with wires () DC+ M8 stud (external DC-bus), shown with wire lug M8 hex nut 6 Stud cover without wires Lug spacer () 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 80 when wires exit to the right (capacitor module is on the far right of the drive configuration). 6 Rockwell Automation Publication 98-IN008C-EN-P - April 07

7 Kinetix 5700 s Extension Module Features and Indicators CAP-DCBUS-IO Extension Module (side view, lug cover removed) 6 98-CAP-DCBUS-IO Extension Module (front view) CAP-DCBUS-IO Extension Module (top views) Item Description Item Description Ground lug 5 DC M8 stud (external DC-bus) Stud/lug cover with wires () 3 Stud cover without wires 7 M8 hex nut 4 DC-bus (DC) connector 8 Lug spacer () 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 80 when wires exit to the right (extension module is on the far right of drive configuration). DC Bus (DC) Connector Pinout DC Pin Description Signal 6 DC+ M8 stud (external DC-bus), shown with flexible bus-bar (x) Bus link DC bus connections DC DC+ Rockwell Automation Publication 98-IN008C-EN-P - April 07 7

8 Kinetix 5700 s Control Input Power (CP) Connector Pinout CP Pin Description Signal 4V power supply, customer-supplied 4V+ 4V common 4V Module Status (MS) Connector Pinout MS Pin Description Signal Module status relay output + RELAY+ Module status relay output RELAY Wiring Requirements IMPORTANT The National Electrical Code and local electrical codes take precedence over the values and methods provided. Wiring Requirements Connector Description Module Status PELV/SELV 4V power (plug) DC-bus power DC-bus studs Pin MS- MS- CP- CP- Bus-bar Signal RELAY+ RELAY 4V+ 4V Recommended Wire Size mm (AWG) (8 6) (0 4) Strip Length mm (in.) 7.0 (0.8) 7.0 (0.8) N/A () N/A () Bus-bar DC N/A N/A DC+ Lugs 53.5 (/0) 00 A 85.0 (3/0) 00 A N/A () Torque Value N m (lb in) (.9.) (.9.) N/A () 8 (56) () DC bus connections are always made from drive-to-drive over the shared-bus connection system. These terminals do not receive discrete wires. () 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. 8 Rockwell Automation Publication 98-IN008C-EN-P - April 07

9 Kinetix 5700 s 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 Spacer Active Shunt Lug Connections (above spacer) DC-Bus Lug Connections (below spacer) 98-CAP-40 or 98-CAP-DCBUS-IO (98-CAP-40 module is shown) See Mount the Capacitor Modules on page for mounting information and example configurations. Active Shunts Compatible with Kinetix 5700 Drive Systems Rockwell Automation Encompass Partner Powerohm Resistors, Inc. Active Shunt Cat. No. Power Rating Current Rating kw Amps PKB005.5 N/A PKB00.0 N/A PKB N/A PWB PWB Rockwell Automation Publication 98-IN008C-EN-P - April 07 9

10 Kinetix 5700 s Connect Modules with Flexible Bus-bars When the 98-CAP-DCBUS-IO extension module is used, two flexible bus-bars make the external DC-bus lug connections to the 98-CAP-40 capacitor module. The DC-bus links must also be installed. Flexible Bus-bar Example Flexible bus-bars (external DC-bus connections) DC-bus Link Connections DC-bus Links 98-xxxx-ERS3 Inverters 4V 4V+ 9 SB+/NC SA SCA SA SB- SB SCB SB 8 6 4V 4V+ 98-CAP-DCBUS-IO Extension Module 98-CAP-40 ATTENTION: To avoid damage to components on 00 A systems, the DC-bus links and the flexible bus-bars must be installed. 0 Rockwell Automation Publication 98-IN008C-EN-P - April 07

11 Kinetix 5700 s Apply Stud/Lug Covers Covers ship with the capacitor modules and are used to protect you from the electrical hazard that is present on the DC-bus studs, lugs/wires, and flexible bus-bars that are attached to capacitor modules. Insert the appropriate cover over the external DC-bus connections. You can rotate the covers 80 to accommodate lugs, wires, or flexible bus-bars exiting from either the left or right. ATTENTION: To avoid personal injury, make sure that the appropriate cover is inserted over the DC-bus studs, lugs/wires, or flexible bus-bars when installing 98-CAP-40 and 98-CAP-DCBUS-IO capacitor modules. Covers with wires also require a hinged bottom plate to prevent access from below. Stud/Lug Cover With Wires Remove knockout for external DC-bus and active shunt connections. Remove knockouts for large wires and wire lugs. 98-CAP-40 or 98-CAP-DCBUS-IO Attach Bottom Plate Leave knockouts attached for small wires and wire lugs. Stud Cover With Wires ATTENTION: To avoid unintentional damage to the lug cover, we recommend cutting the knockout to remove it from the cover. Stud Cover With Flexible Bus-bars 98-CAP-40 or 98-CAP-DCBUS-IO Extension Module Remove knockouts when flexible bus-bars are used to connect the capacitor module and extension module. Rockwell Automation Publication 98-IN008C-EN-P - April 07

12 Ground Your to the Subpanel Ground Bulletin 98 drives and 98-CAP-xxxx-xx capacitor modules to a bonded cabinet ground-bus with a braided ground strap. Connecting the Braided Ground Strap 98-CAP-40 or 98-CAP-DCBUS-IO Extension Module (side view) Item Description 4 3 Ground screw (green).0 N m (7.5 lb in), max Braided ground strap (customer supplied) () 3 Ground grid or power distribution ground 4 Bonded cabinet ground-bus (customer supplied) () Make braided ground straps mm (0.5 in.) by 0.8 mm (0.03 in.). Keep straps as short as possible. Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Kinetix 5700 Servo Drives User Manual, publication 98-UM00 Kinetix 5700 Passive Shunt Modules Installation Instructions, publication 98-IN0 Industrial Automation Wiring and Grounding Guidelines, publication Product Certifications website, Description Provides information on installing, configuring, starting, and troubleshooting your Kinetix 5700 servo drive system. Provides information on installing and wiring Kinetix 5700 external shunt modules. Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at Rockwell Automation maintains current product environmental information on its website at Allen-Bradley, Encompass, Kinetix, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat: İçerenköy, İstanbul, Tel: +90 (6) Publication 98-IN008C-EN-P - April 07 Supersedes Publication 98-IN008B-EN-P - July 05 *PN-48798* PN Copyright 07 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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