Kinetix 5700 2198-D006-ERS3 Replacement

Overview

The Rockewell Automation/Allen-Bradley Kinetix 5700 multi-axis servo drive system is designed for large, high-performance machines with high axis counts. The 2198-D006-ERS3 is a dual-axis servo drive module within this family, providing an efficient footprint by controlling two independent servo motors from a single, narrow book-style chassis.

Featuring Integrated Safety with CIP Safety over EtherNet/IP (with Safe Torque Off functionality), the 2198-D006-ERS3 integrates with GuardLogix safety controllers. When a device like the 2198-D006-ERS3 fails, plant engineers must replace it rapidly and safely to minimize production down-time. This guide reviews specifications, upgrade alternatives, physical installation, and logical commissioning of a replacement drive.

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Legacy Product Information

The Kinetix 5700 system utilizes modular common DC bus technology. The 2198-D006-ERS3 is designed to connect to a shared DC bus supplied by a Kinetix 5700 regenerative or non-regenerative power supply.

Technical Specifications

• Catalog Number: 2198-D006-ERS3
• Product Type: Dual-Axis Servo Drive
• Safety Option: Integrated Safety / CIP Safety (Safe Torque Off) and Hardwired Safe Torque Off
• Continuous Output Current (RMS per axis): 2.5 A
• Peak Output Current (RMS per axis): 6.25 A
• Continuous Output Power (nominal): 1.6 kW at 400...480V input
• Input Voltage (DC Bus): 450...740V DC
• Module Width: 55 mm
• Supported Feedback Types: Hiperface DSL (single-cable), EnDat, and multi-element feedback via encoder modules.
• Current Lifecycle Status: Active. However, supply chain constraints often require system integrators to evaluate direct replacements, safety upgrades, or higher-capacity modules to minimize shipping bottlenecks.

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Recommended Replacements

If a direct replacement unit is not immediately available, or if safety requirements have changed, there are several compatible alternatives within the Kinetix 5700 family.

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Compatibility Considerations

Before replacing a 2198-D006-ERS3, consider the following platform dependencies:

• Control Platform: Compatible with ControlLogix 5570/5580 and CompactLogix 5370/5380 controllers supporting Integrated Motion on EtherNet/IP.
• Studio 5000 Logix Designer Version:
  • Version 29.00 or later is recommended for basic -ERS3 functionality.
  • If upgrading to an -ERS4 module, Studio 5000 Version 31.00 or later is required to access advanced safety profiles.
• Cabling System: Direct support for 2090-CSxM1DF-xxAA single-cable systems (Hiperface DSL) which carry power, safety, and feedback signals in one cable jacket. Ensure the connector kit (2198-KITCON-DSL) is preserved or replaced if damaged during disassembly.
• Shared Bus Connection: Uses the 2198-BARCON-x bus bar connector system. Shared bus systems require correct spacing. Intermixing modules of different physical frame sizes requires an appropriate transition connector.

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Upgrade Benefits

Upgrading from the standard -ERS3 series to the -ERS4 series offers enhanced operational security and safety capabilities:

1. Advanced Safe Motion: While the -ERS3 provides ONLY Safe Torque Off (STO), the -ERS4 supports over 10 safe-speed and safe-position monitoring functions via CIP Safety (e.g., Safely-Limited Speed, Safe Stop 1, Safe Stop 2, Safe Operating Stop).
2. Reduced Downtime: Operators can perform maintenance, clear jams, or enter hazard zones under safely monitored reduced speed limits without turning off the entire motor power grid, shortening startup times.
3. Simplified Infrastructure: Eliminates auxiliary safety relay monitoring units, local safe speed cards, and complex multi-point feedback wiring.

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Common Migration Challenges

1. IP Address Configuration: The Kinetix 5700 does not have physical rotary switches. Relying on DHCP/BOOTP server settings can cause network mismatch errors if the new drive is not configured with the precise MAC/IP binding of the failed unit.
2. Firmware Mismatch: A new out-of-box drive may have a newer or older major firmware revision than the database in the Studio 5000 project. Ensure you have the corresponding ControlFLASH or ControlFLASH Plus packages ready.
3. DC Bus Bar Realignment: When installing the module back to the backplane system, misaligning the slide-on bus bar connectors (2198-BARCON-x) can cause terminal arcing or failure to close the DC loop.
4. Safety Network Number (SNN) Reset: Safe CIP networks require a distinct Safety Network Number assigned to the safety device. A brand-new or refurbished drive must have its previously programmed safety signature reset before the GuardLogix controller can apply the new safety parameters.

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Step-by-Step Replacement Procedure

Follow these electrical and configuration steps to replace a failed 2198-D006-ERS3.

Section 1: Physical Removal and Electrical Isolation

   DANGER: HIGH VOLTAGE RISK
   The DC bus of the Kinetix 5700 can retain lethal charge voltages up to 740V DC 
   even after line power input is disconnected. Wait at least 5 minutes for bus 
   capacitors to discharge before touching any electrical terminals. Verify bus 
   voltage is below 50V DC using a properly rated digital multimeter at the DC+/DC- ports.

1. Lock out and tag out (LOTO) all AC power feeds routing to the Kinetix 5700 power supply (e.g., 2198-P070 or 2198-RP088).
2. Wait a minimum of 5 minutes for the DC bus internal capacitance to discharge.
3. Test terminal voltage between the DC+ and DC- points on the bus using a digital multimeter calibrated for 1000V DC. Ensure the read value is below 50V DC.
4. Label and disconnect the feedback/connector kits:
   • Motor feedback and power output plug kits (2198-KITCON-DSL).
   • Ethernet cables (Dual RJ45 ports).
   • Safe Torque Off (STO) connector (if hardwired STO is used on the M1 control port).
   • 24V DC control power port.
5. Locate the shared DC bus bar cover at the top of the system. Pry open the plastic covers.
6. Loosen the bus-bar connection screws on the left and right sides of the failed drive module using a standard hex or flathead screwdriver. Slide the bus bar elements open.
7. Remove the mounting screws securing the 2198-D006-ERS3 drive module to the cabinet panel plate (top and bottom mounting tabs).
8. Carefully pull the module straight out from the DIN-rail/mounting panel.

Section 2: Mounting and Wiring the New Module

1. Hook the replacement 2198-D006-ERS3 drive onto the DIN-rail system and position it flush with the neighboring drive modules.
2. Reinstall and hand-tighten the top and bottom mounting panel screws.
3. Slide the 2198-BARCON-x bus bar connectors across the terminal interfaces of adjacent modules. Conforming to specified torque, tighten the connection clamp screws to 1.77 N•m (15.7 lb•in).
4. Close the protective top-hinged DC bus covers until they click into position.
5. Reconnect the motor cables using the 2198-KITCON-DSL connector kit. Ensure the shield clamp grounding bracket is making robust contact with the cable shield to suppress high-frequency EMI.
6. Connect the 24V supply connector, RJ45 Ethernet patches, and auxiliary control cables.

Section 3: Commissioning & Logix Configuration

1. Apply 24V DC auxiliary control power. Do not apply high-drive line AC voltage to the power supply subsystem yet.
2. Verify that the module display turns on. The drive status indicator will display a transition code or "NO IP."
3. Set the IP Address:
   • Open the BOOTP/DHCP utility on your commissioning laptop or use Rockwell's ControlFLASH Plus interface.
   • Locate the MAC address of the new drive (printed on the side rating plate label).
   • Assign the identical IP Address that was allocated to the failed unit. Set to "Disable BOOTP/DHCP" to lock in static parameters.
4. Firmware Matching:
   • Open Studio 5000 Logix Designer and connect online to the controller.
   • If the drive’s firmware revision does not match the project offline configuration, use ControlFLASH Plus to update or downgrade the drive’s firmware. Flash over the Ethernet network to match the firmware expected by your Logix controller project.
5. Reset Safety Identity:
   • Since this is an -ERS3 unit used in a CIP Safety system, go online with your safety controller in Studio 5000.
   • Open the properties page of the replacement 2198-D006-ERS3.
   • Navigate to the Safety tab.
   • Click Reset Ownership (or Reset Safety Network Number). Confirm the safety signatures match, allowing the safe controller to sign ownership to the new module.
6. Download and Run:
   • Cycle the main AC line power to the power supply module.
   • Clear any outstanding axes fault conditions in the Logix project via Motion Group commands or Direct Command tool.
   • Perform a physical test jog to verify directionality, brake configuration, and position feedback loop closure.

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Frequently Asked Questions

Can I mix a 2198-D006-ERS3 and a 2198-D006-ERS4 on the same Kinetix 5700 DC Bus?

Yes. You can mix -ERS3 (standard CIP safety) and -ERS4 (advanced CIP safety) modules on the same physical power system. However, they must be configured accurately in your Logix Designer project IO tree, matching the exact catalog numbers of each module slot.

Do I need to re-program the safety signature in the GuardLogix controller?

The safety signature in the PLC program does not need modification if you are replacing the module with an identical 2198-D006-ERS3. However, because the hardware serial number and Safety Network Number (SNN) are different on the new drive, you must perform a "SNN Reset" on the newly installed hardware through Studio 5000 to authorize safety ownership.

What is the purpose of the 2198-KITCON-DSL connector kit?

It is a dual-axis, single-cable feedback plug-in connector designed for Hiperface DSL encoders. It integrates motor power, brake, and DSL feedback signals in a clean, shielded clamp block housing to prevent electromagnetic interference (EMI).

Why does my drive show an "E19 Lockout" or "E18" fault code after replacement?

These error codes often represent encoder communication breakdown, cross-talk, or internal feedback failure. Double-check that all ground clamps are tightened according to recommended torque values and that shield terminations have proper metal-to-metal continuity on the chassis base plate.

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Related Products & Families

To complete your system replacement or scaling project, you may require accessories and peripheral hardware standard to Kinetix 5700 layouts:

• Power Supplies: 2198-P070 (non-regenerative, 24 kW), 2198-RP088 (active regenerative, 32 kW).
• Capacitor Modules: 2198-CAPMOD-2240 (used to store energy in high duty-cycle setups).
• Bus Bar Connectors: 2198-BARCON-55DCAC (55mm wide shared-bus linking elements).
• Supported Servo Motors: VP-Series Low Inertia Motors (VPL-A/Bxxxxxx, VPF-A/Bxxxxxx).

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Need Help?

Whether you need a brand-new factory-sealed dynamic replacement, or high-quality remanufactured and certified surplus components to reduce lead times, Palm Parts Solution can assist. All modular series components are thoroughly tested by qualified technicians and backed by a comprehensive warranty.

If you are experiencing commissioning challenges or need assistance sourcing a reliable replacement for your 2198-D006-ERS3 system, contact the technical support team at Palm Parts Solution today.