Allen-Bradley 2198-D020-ERS3 Dual Axis Inverter | Kinetix 5700 Series
Engineering Background
The Kinetix 5700 platform represents Rockwell Automation’s flagship multi-axis servo drive architecture, engineered for high-throughput manufacturing lines where synchronization precision, cabinet space efficiency, and integrated safety are non-negotiable. The 2198-D020-ERS3 is the dual-axis inverter node within this shared DC-bus ecosystem, enabling two independent servo axes to share a single power conversion stage — reducing panel footprint and simplifying wiring topology without sacrificing per-axis performance.
Product Positioning
Designed for procurement engineers and system integrators sourcing replacement or expansion hardware for existing Kinetix 5700 installations. This inverter is the preferred choice for OEM machine builders and end-users operating in automotive, packaging, material handling, and precision assembly environments where axis count density and EtherNet/IP native integration are critical selection criteria.
Complete Technical Specifications
- Catalog Number: 2198-D020-ERS3
- Series: Kinetix 5700
- Drive Type: Dual Axis Inverter
- Continuous Output Current (per axis): 20 A RMS
- Peak Output Current (per axis): 40 A RMS (2 s)
- DC Bus Input Voltage: 264–678 VDC
- Output Voltage: 0–480 VAC (3-phase)
- Output Frequency Range: 0–599 Hz
- Communication Interface: EtherNet/IP (dual-port, embedded switch)
- Motion Control Protocol: CIP Motion (integrated axis module)
- Safety Function: Safe Torque-Off (STO) — SIL 2 / PLd, Cat. 3 (IEC 62061 / ISO 13849-1)
- Safety Rating: -ERS3 (Safe Speed Monitoring, Safe Stop 1, Safe Direction)
- Feedback Supported: Multi-turn absolute encoder, single-turn, incremental (via motor feedback connector)
- Ambient Operating Temperature: 0–50 °C (derating above 40 °C)
- Storage Temperature: −40 to +70 °C
- Humidity: 5–95% RH, non-condensing
- Pollution Degree: 2
- Enclosure Rating: IP20 (panel-mount)
- Cooling Method: Forced air (shared with Kinetix 5700 DC-bus system)
- Certifications: UL, CE, RCM, RoHS compliant
- Weight: Approx. 4.0 kg
- Mounting: DIN rail / panel mount, shared bus bar connection
Proven Application Environments
- Automotive Assembly: Robotic welding positioners, transfer lines, and press-feed systems requiring tight multi-axis synchronization
- Packaging Machinery: High-speed pick-and-place, form-fill-seal, and cartoning lines with coordinated motion profiles
- Material Handling: Conveyor indexing, palletizing, and sortation systems with variable load profiles
- Precision Assembly: Electronics manufacturing, semiconductor handling, and medical device assembly requiring sub-millimeter repeatability
- Printing & Converting: Web tension control and register correction on multi-station presses
Engineering Advantages
- Dual-Axis Density: Two fully independent servo axes in a single inverter module — halves the inverter count versus single-axis alternatives, reducing panel width and wiring complexity
- Shared DC Bus Architecture: Energy regenerated by decelerating axes is immediately available to accelerating axes on the same bus, improving overall system energy efficiency by up to 30%
- Integrated EtherNet/IP: Native CIP Motion eliminates external motion controllers for many applications; dual-port switch enables linear or ring topology without external switches
- -ERS3 Integrated Safety: On-board Safe Speed Monitoring (SSM), Safe Stop 1 (SS1), and Safe Direction (SDI) functions reduce external safety relay hardware and simplify SIL 2 / PLd machine safety compliance
- Studio 5000 Native: Full integration with Logix Designer — axis configuration, tuning, and diagnostics within a single programming environment; no third-party motion software required
- Predictive Diagnostics: Drive-level fault logging and health monitoring accessible via FactoryTalk Diagnostics and standard EtherNet/IP explicit messaging
System Architecture & Signal Flow
The 2198-D020-ERS3 operates as a node on the Kinetix 5700 shared DC-bus rail. AC mains power is rectified by a 2198-Pxxx DC-bus power supply module; the resulting DC bus is distributed via a low-impedance bus bar to all inverter modules in the system. Each inverter independently modulates its two output phases using IGBT-based PWM switching, driven by CIP Motion commands from a CompactLogix or ControlLogix controller over EtherNet/IP. Motor feedback signals (encoder, resolver, or Hiperface DSL) return to the inverter’s feedback ports, closing the position/velocity/torque control loops locally within the drive. Safety I/O for STO and -ERS3 functions connects directly to the inverter’s safety terminals, with safety status reported back to the safety controller over the same EtherNet/IP network.
Sourcing & Quality Verification
- Source: Konmask.com sources 2198-D020-ERS3 units from authorized distribution channels and verified industrial surplus with full traceability documentation
- Inspection Protocol: Each unit undergoes visual inspection, label authenticity verification, and functional power-on testing prior to shipment
- Counterfeit Mitigation: Holographic label verification, date code cross-reference, and Rockwell Automation catalog number validation are applied to every unit
- Condition: New (factory-sealed) and Refurbished (tested, warranted) options available — specify at inquiry
- Documentation: Certificate of conformance and inspection report available upon request
Procurement Process
- Step 1 — Confirm Compatibility: Verify your DC-bus power supply (2198-Pxxx) capacity covers the combined peak current demand of all inverter axes on the shared bus
- Step 2 — Specify Condition: Indicate New or Refurbished preference and required lead time in your inquiry
- Step 3 — Request Quote: Submit your PO number, shipping address, and Incoterms preference to support@konmask.com
- Step 4 — Order Confirmation: Receive proforma invoice with inspection report reference within 1 business day
- Step 5 — Shipment: Units ship with ESD packaging, shock indicators, and full documentation within agreed lead time
Technical FAQ
Q: Can the 2198-D020-ERS3 operate as a single-axis drive if only one axis is used?
A: Yes. One axis port can remain unconnected; the active axis operates normally. The unused axis simply remains unconfigured in Studio 5000.
Q: What DC-bus power supply is required?
A: A 2198-Pxxx series DC-bus power supply sized to the total continuous and peak current demand of all inverters on the shared bus. Rockwell’s Kinetix 5700 sizing tool (available in Studio 5000) calculates the required supply rating.
Q: Is the -ERS3 safety rating backward compatible with -ERS1 or -ERS2 installations?
A: The -ERS3 variant adds Safe Direction (SDI) and Safe Speed Monitoring (SSM) functions not present in earlier suffix variants. Firmware and safety configuration must be updated in Studio 5000 Safety when replacing an earlier suffix unit.
Q: What controller platforms are compatible?
A: CompactLogix 5380/5480 and ControlLogix 5580 controllers running Logix Designer v32 or later with CIP Motion licensing. Verify firmware compatibility with Rockwell’s Product Compatibility and Download Center (PCDC).
Q: What is the warranty on units sourced from Konmask?
A: New units carry the manufacturer’s standard warranty. Refurbished units carry a 12-month Konmask warranty covering functional defects. Contact support@konmask.com for warranty terms.
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