Allen-Bradley 2198-D057-ERS3 Industrial AC Servo Driver for Packaging Material Handling and Converting

Allen-Bradley Kinetix® 5700 Series Servo Drive:

Model 2198-D057-ERS3

1. Product Overview

The Allen-Bradley Kinetix® 5700 series servo drives, renowned for their advanced performance and seamless integration capabilities, represent a cornerstone in Rockwell Automation's industrial automation portfolio. Among these, the 2198-D057-ERS3 stands out as a high-power, high-performance servo drive tailored for the most demanding industrial applications. This drive combines cutting-edge technology with robust design, offering exceptional torque, speed, and control precision, making it an ideal choice for OEMs and machine builders worldwide.

2. Product Appearance & Design

The 2198-D057-ERS3 servo drive features a sleek, industrial-grade enclosure designed to withstand harsh operating environments. Its compact yet rugged design ensures optimal space utilization within control cabinets, while its modular construction allows for easy installation and maintenance. The drive is equipped with dual Ethernet ports, facilitating seamless integration into EtherNet/IP networks, and supports a variety of feedback types, including single cable technology, which simplifies wiring and enhances system reliability.

3. Key Features & Performance

• High Power Output: The 2198-D057-ERS3 delivers an impressive continuous output power of 2 x 8.0 kW at 240V AC and 2 x 15.9 kW at 480V AC, with a peak output current of 2 x 162.6 A. This high power capability makes it suitable for driving large motors and handling heavy loads in applications such as metal forming, automotive manufacturing, and material handling.

• Integrated Safety: The drive incorporates integrated Safe Torque-Off (STO) functionality, certified to SIL3 PLe, which ensures safety without the need for separate wiring. This feature reduces installation complexity, saves time and money, and helps minimize potential points of failure, resulting in less downtime and easier troubleshooting.

• Tuning-less Commissioning: Utilizing Load Observer real-time tuning technology, the 2198-D057-ERS3 automatically adjusts to varying load conditions, eliminating the need for manual tuning. This feature significantly reduces commissioning time and enhances machine performance by ensuring optimal control parameters are set from the outset.

• Advanced Control Algorithms: The drive supports both servo and induction motor control, providing high-precision motion control across a wide range of applications. Its virtual torque sensor functionality detects anomalies and provides analytics, while adaptive tuning with multiple tracking notch filters mitigates resonances, ensuring smooth and stable operation.

• Energy Efficiency: The 2198-D057-ERS3 supports CIP Energy, allowing for monitoring of energy consumption and providing opportunities for energy savings through regenerative capabilities. By returning excess energy to the power grid or for plant-wide use, the drive contributes to reduced operating costs and a smaller carbon footprint.

4. Technical Specifications

• Input Voltage: 240V AC or 480V AC (selectable)
• Continuous Output Power: 2 x 8.0 kW (at 240V) / 2 x 15.9 kW (at 480V)
• Peak Output Current: 2 x 162.6 A
• Feedback Support: Wide range of feedback types, including single cable technology
• Networking: Dual Ethernet ports, supporting linear and device level ring topologies
• Safety Certifications: SIL3 PLe certified Safe Torque-Off

5. Application Scenarios

The 2198-D057-ERS3 servo drive is ideally suited for a wide range of high-power, high-performance applications, including:

• Heavy Machinery: In metal forming, stamping, and cutting machines, where high torque and precise control are essential.
• Automotive Manufacturing: For tire building, engine assembly, and body shop applications, where the drive's high power and advanced control capabilities are critical.
• Material Handling: In conveyors, robots, and automated guided vehicles (AGVs), where reliable and efficient motion control is required to handle heavy loads and maintain high throughput.
• Energy & Utilities: In wind turbines, pumps, and compressors, where the drive's energy efficiency and regenerative capabilities contribute to reduced operating costs.

6. Advantages & Benefits

• Increased Productivity: The drive's high power output and advanced control algorithms enable faster cycle times and higher throughput, increasing overall productivity.
• Reduced Downtime: Integrated safety features and tuning-less commissioning reduce the risk of accidents and downtime, ensuring continuous operation.
• Cost Savings: Energy efficiency and regenerative capabilities contribute to lower operating costs, while simplified wiring and reduced installation complexity save time and money.
• Scalability & Flexibility: The drive's modular design and wide range of feedback support make it easy to integrate into existing systems and adapt to changing application requirements.

7. Conclusion

The Allen-Bradley Kinetix® 5700 series servo drive, model 2198-D057-ERS3, represents a significant advancement in industrial automation technology. Its high power output, integrated safety features, tuning-less commissioning, and energy efficiency make it an ideal choice for a wide range of demanding industrial applications. By choosing the 2198-D057-ERS3, OEMs and machine builders can expect increased productivity, reduced downtime, and significant cost savings over the product's lifecycle. Whether in heavy machinery, automotive manufacturing, material handling, or energy & utilities, the 2198-D057-ERS3 servo drive delivers the performance, reliability, and flexibility needed to meet the challenges of modern manufacturing.

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