Allen-Bradley 2198-D057-ERS3 — Dual-Axis Servo Inverter | Kinetix 5700 Platform
Engineering Background
The Kinetix 5700 servo drive family was engineered by Rockwell Automation to address the growing demand for high-density, multi-axis motion control in advanced manufacturing. The 2198-D057-ERS3 is a dual-axis inverter module within this platform, designed to share a common DC bus with other Kinetix 5700 modules, dramatically reducing panel footprint and wiring complexity in multi-axis machine architectures.
Product Positioning
This inverter targets OEMs and system integrators building high-performance servo systems on the Logix 5000 control platform. It is particularly suited for applications requiring coordinated multi-axis motion, high dynamic response, and seamless integration with Studio 5000 Logix Designer. The ERS3 firmware revision ensures compatibility with the latest iTRAK and MagnaView linear transport systems.
Complete Technical Specifications
| Parameter | Value |
|---|---|
| Catalog Number | 2198-D057-ERS3 |
| Series / Platform | Kinetix 5700 |
| Module Type | Dual-Axis Inverter |
| Firmware Revision | ERS3 |
| Continuous Output Current (per axis) | 22 A RMS |
| Peak Output Current (per axis) | 57 A peak (3 s) |
| DC Bus Input Voltage | 264–678 V DC (nominal 650 V DC) |
| Output Voltage | 0–480 V AC (3-phase) |
| Switching Frequency | 4 / 8 kHz selectable |
| Communication Interface | EtherNet/IP (dual-port, DLR capable) |
| Motion Feedback | Hiperface DSL, EnDat 2.2, Resolver, Incremental TTL |
| Safety Function | STO (Safe Torque Off), SS1, SLS — SIL 2 / PLd |
| Enclosure Rating | IP20 (panel mount) |
| Operating Temperature | 0 °C to +50 °C (derating above 40 °C) |
| Storage Temperature | −40 °C to +70 °C |
| Relative Humidity | 5–95% non-condensing |
| Vibration Resistance | 2 g, 10–500 Hz |
| Dimensions (H × W × D) | Approx. 380 × 90 × 260 mm |
| Weight | Approx. 5.5 kg |
| Certifications | UL, CE, RCM, cUL |
Proven Application Environments
- Automotive Assembly Lines — Multi-axis coordinated motion for welding robots, transfer lines, and press-feed systems requiring deterministic EtherNet/IP cycle times.
- Packaging Machinery — High-speed pick-and-place, form-fill-seal, and cartoning machines where dual-axis density reduces cabinet size.
- Semiconductor & Electronics Manufacturing — Precision positioning stages with sub-micron repeatability using Hiperface DSL feedback.
- iTRAK Linear Transport Systems — Native ERS3 firmware support for Rockwell’s intelligent track system, enabling independent mover control on a shared bus.
- Material Handling & Conveying — Synchronised multi-axis gantry and conveyor systems with integrated STO safety.
- Printing & Converting — Register control and tension management in web-handling lines demanding high bandwidth torque loops.
Engineering Advantages
- Shared DC Bus Architecture — Regenerative energy from decelerating axes is redistributed to accelerating axes on the same bus, reducing net energy consumption by up to 30%.
- Dual-Axis Density — Two independent servo axes in a single module width, halving the panel space versus single-axis alternatives.
- Integrated Functional Safety — On-board STO/SS1/SLS eliminates external safety relays, simplifying SIL 2 / PLd machine certification.
- Deterministic EtherNet/IP — DLR (Device Level Ring) topology provides network redundancy; CIP Motion ensures ≤1 ms update rates for tight axis synchronisation.
- Universal Feedback Compatibility — Supports all major servo motor feedback protocols without external converter modules.
- Studio 5000 Native Integration — Auto-configuration via Add-On Profiles (AOPs) eliminates manual parameter entry and reduces commissioning time.
System Architecture & Signal Flow
The 2198-D057-ERS3 connects to a Kinetix 5700 DC-bus power supply (e.g., 2198-P070 or 2198-P141) via the shared DC bus connector. The EtherNet/IP dual-port interface daisy-chains to a CompactLogix or ControlLogix controller running Studio 5000. Each axis independently controls a compatible Kinetix VP or MP-Series servo motor through a dedicated power and feedback connector. The integrated safety core communicates over the CIP Safety protocol, allowing the Logix safety controller to command STO without breaking the EtherNet/IP motion network.
Typical signal flow: Logix Controller → EtherNet/IP (CIP Motion) → 2198-D057-ERS3 → Servo Motor (power + Hiperface DSL feedback loop)
Sourcing & Quality Verification
- All units sourced from authorised distributors, OEM decommissions, or verified surplus channels with full traceability documentation.
- Pre-shipment inspection includes visual examination, label authenticity check, firmware revision verification, and functional power-on test where applicable.
- Counterfeit-risk mitigation: holographic labels, date codes, and PCB markings are cross-referenced against Rockwell Automation factory standards.
- Units shipped in anti-static packaging with desiccant; temperature-controlled storage maintained at our warehouse.
- Certificate of conformance and inspection report available upon request.
Procurement Process
- Step 1 — Inquiry: Submit your RFQ via the product page or email support@konmask.com with quantity, required delivery date, and destination country.
- Step 2 — Quotation: Receive a formal quotation within 1 business day including unit price, lead time, and shipping options (DHL / FedEx / sea freight).
- Step 3 — Order Confirmation: Issue a purchase order or pay via T/T bank transfer, PayPal, or credit card. Pro-forma invoice provided.
- Step 4 — Inspection & Dispatch: Unit inspected, photographed, and dispatched with tracking number within 1–3 business days of payment clearance.
- Step 5 — After-Sales Support: 12-month warranty on verified new units; 90-day warranty on tested surplus. Technical support available via email or WhatsApp.
Technical FAQ
Q: Is the 2198-D057-ERS3 compatible with older Kinetix 5700 firmware revisions (ERS1/ERS2)?
A: The ERS3 firmware is backward-compatible with ERS1/ERS2 hardware configurations in most cases, but certain iTRAK and advanced safety features require ERS3 on both the drive and the Logix controller AOP. Verify your Studio 5000 version (v32+ recommended).
Q: Can this module operate as a single-axis drive if only one axis is used?
A: Yes. Axis 2 can remain unconfigured. The module will operate normally on Axis 1 with no performance penalty, though the dual-axis licensing must still be present in the controller project.
Q: What is the maximum cable length between the drive and servo motor?
A: Rockwell Automation specifies a maximum of 50 m (164 ft) for standard motor power cables. For Hiperface DSL feedback, the limit is also 50 m. Shielded, low-capacitance cable is mandatory.
Q: Does this drive support regenerative braking without an external braking resistor?
A: Yes — the shared DC bus inherently handles regenerative energy. An external shunt resistor module (2198-R004 or similar) is only required if total regenerative energy exceeds the bus capacitance during emergency stops with no other accelerating axes present.
Q: What Logix controller families are compatible?
A: CompactLogix 5380/5480, ControlLogix 5580, and GuardLogix 5580 controllers with EtherNet/IP motion capability. A CIP Motion license is required in the controller.
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