2198-C1015-ERS — Kinetix 5500 Dual-Axis Converter Module, 15A, 460V

The 2198-C1015-ERS is a converter (rectifier) module for the Kinetix 5500 servo drive system. It doesn't drive a motor directly — it converts three-phase AC mains power to a DC bus voltage that feeds a group of Kinetix 5500 inverter (axis) modules on a shared bus. One converter module can supply multiple axis modules, centralizing the AC input connection and DC bus supply for a multi-axis servo system.

The "ERS" designation indicates this module includes integrated Safe Speed Monitor safety functionality, which monitors motor speed and can trigger a safe state if speed exceeds configured limits. At 15A AC input current, this module is sized for systems with moderate total axis power — typically two to four smaller servo axes sharing the bus, depending on their individual power ratings and duty cycles.

Specifications

Parameter	Value
Part Number	2198-C1015-ERS
Series	Kinetix 5500
Function	AC-to-DC bus converter (rectifier)
AC Input Voltage	400–480V AC, Three-Phase
Rated AC Input Current	15 A
DC Bus Output Voltage	~650V DC (nominal at 480V AC input)
Safety Function	Safe Speed Monitor (ERS — SIL 2 / PLd)
Shared Bus	Yes — feeds multiple 2198 axis modules via DC bus connector
Integrated Pre-charge	Yes
Regenerative Capability	No (passive front end; dynamic braking via axis modules)
Operating Temperature	0°C to 50°C
Enclosure	IP20
Standards	UL 508C, CE, IEC 61800-5-1, IEC 62061 (SIL 2)

What a Converter Module Does in a Multi-Axis System

A conventional multi-axis drive system might have each axis drive with its own AC input, its own fusing, its own inrush current event on power-up, and its own rectifier generating its own DC bus. The Kinetix 5500 shared bus architecture replaces all of that with a single converter module handling the AC-to-DC conversion for the entire group.

The practical benefits are real. A single three-phase input feed to the converter, a single contactor or circuit breaker for the group, and a single point for input line filtering. Inrush current on startup comes from one pre-charge circuit rather than several simultaneous ones — easier to manage from the supply's perspective. And when one axis regenerates (decelerates a load), that energy goes directly onto the shared DC bus where another axis drawing power can consume it, rather than being wasted as heat in a braking resistor.

The 2198-C1015-ERS is a passive (diode) rectifier front end. It does not regenerate energy back to the AC mains — excess bus energy during braking is handled by the axis modules' dynamic braking transistors and external braking resistors. For highly regenerative applications, verify that the braking resistors sized for the axis modules can absorb the total braking energy of the group.

Commissioning and Protection Notes

Input fusing: fit semiconductor-rated fuses on the AC input lines to the converter, sized per the 2198 system installation manual. Standard thermal-magnetic breakers are not suitable for the converter's rectifier protection — they respond too slowly to the fault profiles involved.
Safety wiring: the ERS safety inputs must be wired to the machine's safety relay or safety controller and validated as part of safety system commissioning. Leaving safety inputs floating or jumped out invalidates the SIL 2 rating and may violate the machine's safety certification.
Ground bonding: the converter chassis must be bonded to the panel earth with a low-impedance connection. The DC bus operates at 650V DC — proper earthing is critical for both personnel safety and EMC compliance.
Mounting orientation: mount vertically only. The converter's cooling relies on natural convection through the heatsink; horizontal mounting blocks the airflow path and causes overtemperature under load.

FAQ

Q: Can a single 2198-C1015-ERS support a mix of Kinetix 5500 single-axis and dual-axis inverter modules?

Yes. The converter supplies the shared DC bus regardless of the inverter module types connected to it. Single-axis and dual-axis inverter modules can coexist on the same bus, provided the total continuous current draw stays within the converter's 15A input rating.

Q: What happens if the AC input power is lost while axes are running?

The DC bus voltage decays as the axes continue to draw current. The bus undervoltage threshold triggers a fault on the axis modules, executing their configured fault stop action (typically a controlled deceleration). The bus voltage decay rate depends on the total capacitance on the bus and the load — heavier loads drain the bus faster. Add a capacitor module to the bus if longer ride-through is needed.

Q: Does the ERS safety function require a safety PLC to operate?

No. The ERS hardware safety inputs are hardwired — they can be driven directly from a safety relay without any safety PLC involvement. The safety function monitors speed in hardware and triggers a safe state when the speed limit is exceeded, independently of the controller program.

Q: Can this converter be used with Kinetix 5700 axis modules?

No. The 2198 converter is specific to the Kinetix 5500 system and its bus connector architecture. Kinetix 5700 uses different bus supply modules from the 2198-P series that are not interchangeable with the 5500 converter modules.

Q: How is the total axis group current demand calculated for sizing?

Use the RMS (root-mean-square) current method, not peak current. Each axis's RMS torque over one full motion cycle is converted to RMS current using the motor's Kt (torque constant). Sum the RMS currents of all axes in the group, then compare to the converter's continuous input current rating. Motion Analyzer automates this calculation from the axis motion profiles.

2198-C1015-ERS Servo Drive Brand New 2198C1015ERS