Allen-Bradley Kinetix 5700 Repair
When your Allen-Bradley Kinetix 5700 servo drive fails, downtime costs add up fast. Flexa Systems offers component-level repair with a 2-year warranty, free diagnostics, and no-fix no-charge guarantee—saving you 30-60% compared to buying new while restoring full motion performance.
Allen-Bradley Kinetix 5700 — Overview
The Allen-Bradley Kinetix 5700 (2198-Dxxx inverter modules, 2198-Pxxx power supplies) is Allen-Bradley's DC-bus-shared servo architecture designed for multi-axis industrial machines. With power ratings from 1.7 to 112 kW and single- and dual-axis inverters on a common DC bus, the Kinetix 5700 is deployed in CNC machining centers, robotic cells, packaging lines, and material handling systems where synchronized motion and regenerative energy sharing are critical. Each inverter module connects to a shared power supply, reducing cabinet footprint and electrical infrastructure costs.
Component-level repair makes strong economic sense for Kinetix 5700 systems. New inverter modules range from $4,000 to over $15,000 depending on power rating, while our repairs typically cost $900–$2,800. Because the Kinetix 5700 uses modular inverter cards with discrete IGBT modules, gate drivers, and feedback circuits, most failures can be traced to specific semiconductor or power stage components. Our technicians repair at the board level, test under load, and verify EtherNet/IP communication and motion profile execution before return.
| Catalog | 2198-Dxxx/-Sxxx (inverter), 2198-Pxxx/-RPxxx (supply) |
| Voltage | 195–528V AC three-phase input, 276–747V DC bus |
| Power Range | 1.7–112 kW (2.5–192A continuous) |
| Axes | Single- and dual-axis inverters on a shared DC bus |
| Feedback | Hiperface DSL, Hiperface, EnDat, incremental TTL, sin/cos |
| Communication | EtherNet/IP, Integrated Motion on EtherNet/IP, CIP Sync |
| Control Modes | Position, Velocity, Torque |
| STO Safety | Hardwired and integrated STO, PL e / SIL 3 |
Common Kinetix 5700 Failures We Repair
Every failure repaired at component level — root cause fixed, not just the fault code cleared.
IGBT / IPM Power Module Failure
High-frequency switching stress, inductive load spikes, or DC bus overvoltage events cause IGBT junction failure or IPM thermal shutdown. Symptoms include FLT S10 (Inverter Overcurrent) or FLT S16 (Ground Current) faults that return with the motor and cable proven good. We replace failed IGBT modules, gate driver ICs, and test under rated load with back-EMF simulation to verify thermal performance and switching integrity.
DC Bus Capacitor Degradation
Electrolytic capacitors in the DC link lose capacitance over time due to ripple current and ambient heat, which can show up as DC-bus faults such as FLT S33 (Bus Undervoltage) or FLT S25 (Precharge Failure), or as erratic torque output. We measure ESR and capacitance, replace aged capacitors with high-ripple-rated equivalents, and verify DC bus stability under regenerative braking conditions.
Encoder Feedback Interface Failure
Hiperface DSL or EnDat transceiver ICs fail due to electrical noise, ground loops, or cable faults, triggering FLT S45 (Feedback Comm) or FLT S47 (Feedback Device Failure). We diagnose differential signal integrity, replace failed transceivers or opto-isolators, and validate bidirectional encoder communication at full speed to ensure sub-arc-second position accuracy.
Gate Driver Circuit Failure
Gate driver ICs (often IR2110, 2ED020I12, or similar) fail from shoot-through events or dV/dt-induced latch-up, preventing IGBT switching. This causes no motor response or immediate FLT S10 (Inverter Overcurrent) faults. We replace gate driver ICs, bootstrap diodes, and gate resistors, then perform safe short-circuit testing to confirm deadtime and desaturation protection.
Control Board / DSP Processor Failure
The main control board houses the TI TMS320 DSP and EtherNet/IP ASIC; failures here cause loss of network communication, parameter corruption, or failure to initialize. We diagnose power rail sequencing, replace failed processors or memory ICs, reflash firmware, and verify motion profile execution and CIP Sync timing.
Power Supply (2198-P) Rectifier / Inrush Failure
Three-phase bridge rectifiers and NTC inrush limiters in the 2198-P power supply fail from repetitive start cycles or supply transients, causing no DC bus voltage or FLT S25 (Precharge Failure). We replace bridge modules, inrush thermistors, and pre-charge relays, then load-test at full rated current to verify bus regulation and ripple.
Kinetix 5700 Fault Codes Reference
Fault codes as printed in Allen-Bradley fault-code reference 2198-RD003, for the 2198-Dxxx / 2198-Sxxx inverters and 2198-Pxxx power supplies. For the complete list, see our Kinetix 5700 fault codes guide.
| Code | Name | Cause & Fix |
| FLT S10 | INV OVERCURRENT | Inverter current exceeded the hardware instantaneous limit. Check the motor power cable and windings for shorts, verify wire gauge, operate within the continuous rating and lengthen acceleration. If it returns with motor and cable proven good, the inverter power stage needs repair. |
| FLT S16 | GROUND CURRENT FL | Excessive ground current sensed in the power stage. Check motor power wiring and cable for shorts, replace the motor if the fault persists, and check DC-bus wiring when a capacitor module is used. |
| FLT S35 | BUS OVERVOLT FL | DC-bus voltage above the factory limit, typically from excessive regeneration. Change the deceleration profile, measure the shunt resistance, add an external shunt; replace the DC-bus power supply if its shunt resistor is open. |
| FLT S33 | BUS UNDERVOLT FL | DC-bus voltage below the factory limit. Verify the incoming AC voltage, monitor the AC source for glitches or line droop, and consider a UPS on the AC input. |
| FLT S25 | CONV PRECHARGE FAILURE | The DC bus did not reach its precharge level in time, or is too high. Check AC input voltage on all phases and input wiring, check for an inverter or motor shorted to ground; replace the power supply or drive module if it persists. |
| FLT S29 | BUS REG OVERLOAD FL | The shunt (bus regulator) thermal model exceeded its limit. Modify the application duty cycle, add an external shunt or a capacitor module. |
| FLT S31 | BUS REG FAILURE | The shunt circuit detected a shorted shunt resistor. Check the shunt connector for shorts and measure the resistor; replace the power supply if the internal shunt is shorted. |
| FLT S38 | FUSE BLOWN | The internal DC-bus fuse is blown. It is not user-replaceable — the module must be returned for repair if the fault continues. |
| FLT S07 | MTR OVERLOAD FL | The motor thermal model exceeded its factory limit. Modify the command profile to reduce speed or increase time. |
| FLT S11 | INV OVERTEMP FL | Inverter temperature exceeded the factory limit. Reduce ambient temperature, verify airflow through the drive is not obstructed, and modify the command profile. |
| FLT S45 | FDBK COMM FL | Missed or corrupted serial data from the motor feedback device (DSL / Hiperface). Check feedback cable and connector, shield terminations and motor frame grounding; reduce shock and vibration at the motor. |
| NODE FLT 03 | HARDWARE 00 | Communication with the power board could not be established. Cycle control power and update firmware; return the drive for repair if the fault continues. |
| FLT M26 | RUNTIME ERROR | The drive firmware hit an unrecoverable runtime error. Cycle control power, check the feedback device, reset the module; return it for repair if the fault continues. |
How Kinetix 5700 Repair Works
4-step process — ship us the drive, get it back repaired with a 2-year warranty
Free Diagnostic
Ship your servo drive. Component-level diagnostic within 24–48hrs. No charge, no obligation.
Written Quote
Detailed repair quote: what failed, what we replace, exact cost. Approve before any work.
Component Repair
Service engineers perform circuit board and component-level repair. Root cause fixed.
Load Test & Ship
Full load test under operating conditions. Ships back with 2-year warranty.
Kinetix 5700 Drives In Stock
Tested, refurbished Kinetix 5700 units available for immediate purchase or exchange. All units carry our 2-year warranty.
Kinetix 5700 Repair — FAQ
Answers to the most common questions about our Allen-Bradley Kinetix 5700 (2198-Dxxx / 2198-Pxxx series) servo drive repair service
How much does Kinetix 5700 repair cost?
Kinetix 5700 repair at Flexa Systems typically costs between $900 and $2,800 depending on the fault and power rating, compared to $4,000–$15,000+ for new OEM replacement. We offer free diagnostics, and every repair is backed by our 2-year warranty with a no-fix no-charge guarantee.
What is the most common Kinetix 5700 failure?
The most common failure is IGBT or IPM power module degradation, often triggered by repetitive inductive load switching, DC bus overvoltage events during regenerative braking, or thermal cycling. This typically presents as FLT S10 (Inverter Overcurrent) or FLT S16 (Ground Current) that returns after the motor and cable check out. We replace the power stage, gate driver circuit, and load-test under full rated current.
How long does Kinetix 5700 repair take?
Most Kinetix 5700 repairs ship in 5–30 business days from receipt, including diagnostics, component-level repair, firmware validation, and full motion profile testing. Rush service is available with 24–72 hour turnaround for critical production downtime situations.
Do you repair discontinued Kinetix 5700 drives?
Yes, we repair discontinued and obsolete Kinetix 5700 models. Because we work at the component level—replacing IGBTs, gate drivers, capacitors, and control ICs—we are not dependent on OEM part availability. We maintain an inventory of equivalent semiconductors and have circuit-level documentation for legacy inverter modules.
Will my Kinetix 5700 parameter and motion settings be preserved?
Yes. Component-level repair preserves your drive's firmware and stored parameters in non-volatile memory. We do not reflash or reset configuration unless the control board memory IC has failed. Your motion profiles, tuning gains, and EtherNet/IP node address remain intact, minimizing recommissioning time.
What is your warranty on Kinetix 5700 repairs?
Every Kinetix 5700 repair from Flexa Systems is backed by a comprehensive 2-year warranty covering parts and labor. If we cannot successfully repair your drive, there is no charge—our no-fix no-charge guarantee ensures you only pay for verified, functional repairs.
Ready to Get Your Kinetix 5700 Repaired?
Free diagnostic evaluation, no obligation. Most repairs returned in 5–30 business days. Rush service available in 24–72 hours for critical equipment.