Allen-Bradley 2099-BM08-S, 2099-BM11-S, 2099-BM12-S User Manual

User Manual

Kinetix 7000 High Power Servo Drive

Catalog Numbers 2099-BM06-S, 2099-BM07-S, 2099-BM08-S, 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, 2099-BM12-S

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety

Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1

available from your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/ ) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING:

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION:

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD:

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD:

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, CompactLogix, ControlFlash, ControlLogix, DriveExplorer, Kinetix, RSLogix 5000, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

New and Updated

Information

Summary of Changes

This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.

This table contains the changes made to this revision.

Topic

Updated the Additional Resources with updated and new publications.

Updated the Typical System Diagrams to include updated catalog numbers for

Bulletin MPL motors, Bulletin MPM motors, and regenerative power supplies.

Added the Using Motion Analyzer to Determine Heat Dissipation information to the

Enclosure Selection section.

Added the mounting information from Chapter 3 - Mount the Kinetix 7000 Drive

System, to Chapter 2 - Install the Kinetix 7000 Drive System and removed Chapter 3.

Updated the Kinetix 7000 Front Panel Connectors and Displays, Kinetix 7000 Top

Panel Connectors and Switches, and Kinetix 7000 Bottom Panel Connectors

illustrations and tables for clarity.

Updated the IOD connector pinouts in the Hardware Enable, Home and Positive and

Negative Overtravel circuit diagrams.

Added information on Reading Analog Input Voltage Values.

Updated information on configuring the General Purpose I/O regenerative power supply OK signal.

Added Figure 41 Safe-Off, Motion-allowed Jumper.

Updated the information in the Setting the Ground Jumper in Ungrounded Power

Configurations section.

Updated the Wire the Kinetix 7000 Drive Connectors section.

Added Flying-lead Feedback Cable Pinouts for the new 2090-XXNFMF-Sxx and 2090-

CFBMxDF-CDAFxx Feedback Cable.

Added illustrations to the Wire Feedback and I/O Connectors section.

Updated the information on External Shunt Module Connections to reflect

availability of certain shunt modules.

Updated the Node Addressing Examples to reflect current topologies.

Updated the steps and images in the Configure the Logix SERCOS interface Module section to reflect the current software release.

Added the Configure Drive Parameters and System Variables section.

Added an explanation for the Drive Overtemperature Fault (E23) to the list of Error

Codes.

Updated the Specifications and Dimensions section to reflect current data and

specifications.

Added Korean Registration of Broadcasting and Communications Equipment

certification to the Certifications table.

Added the new External Shunt Modules section to Appendix A.

Updated the Interconnect Diagrams to reflect new cables and corrected connections

information.

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Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

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Summary of Changes

Notes:

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Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Table of Contents

Preface

Start

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

About the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Typical Drive System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CE Requirements - System without LIM . . . . . . . . . . . . . . . . . . . . . . . 19

CE Requirements - System with LIM . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CE Requirements - System with DC Common Bus through 8720MC-

RPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 2

Install the Kinetix 7000 Drive System

System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Establish Noise Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cable Categories for Kinetix 7000 Systems . . . . . . . . . . . . . . . . . . . . . 35

Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 36

Mount the Kinetix 7000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Kinetix 7000 Connector Data

Chapter 3

Locate and Identify Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . 42

Digital and Analog Input/Output (IOD) Connector Pinout. . . . . 45

General Purpose I/O (GPIO) Terminal Block Connections . . . . . 46

General Purpose Relay (GPR) Terminal Block Connections . . . . . 46

Motor Feedback (MF) Connector Pinouts . . . . . . . . . . . . . . . . . . . . . 47

Auxiliary Feedback (AF) Connector Pinouts . . . . . . . . . . . . . . . . . . . 49

Safe-off (SO) Terminal Block Connections . . . . . . . . . . . . . . . . . . . . . 50

Control Power (CP) Terminal Block Connections . . . . . . . . . . . . . . 51

Power Terminal Block (PTB) Connections. . . . . . . . . . . . . . . . . . . . . 51

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

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6

Table of Contents

Connect the Kinetix 7000 Drive

System

Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Digital Inputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Analog Inputs (IOD Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Analog Outputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

General Purpose I/O (GPIO Connector) . . . . . . . . . . . . . . . . . . . . . . . 63

General Purpose Relay (GPR Connector). . . . . . . . . . . . . . . . . . . . . . . 64

SERCOS Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Safe-off (SO Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Control Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Motor (MF) and Auxiliary Feedback (AF) Connections . . . . . . . . . . . . . 66

Motor and Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . . . . 66

Chapter 4

Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Building Your Own Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Shielded Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Required Cable Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

General Wire Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 75

Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Power Distribution Systems Without a Ground Reference . . . . . . . 77

Setting the Ground Jumper in Ungrounded Power Configurations . . . 78

Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and

2099-BM08-S Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Removing the Ground Wires on 2099-BM09-S and 2099-BM10-S

Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Removing the Ground Wires on 2099-BM11-S and 2099-BM12-S

Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Grounding the Kinetix 7000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 81

Grounding Your System to the Subpanel . . . . . . . . . . . . . . . . . . . . . . . 81

Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Motor Power Cable Shield Termination . . . . . . . . . . . . . . . . . . . . . . . . 82

MP-Series (Bulletin MPL) Motor Connectors . . . . . . . . . . . . . . . . . . 83

Input Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Acceptable Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Shielded/Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Power Wire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Power Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Table of Contents

Configure and Startup the Kinetix

7000 Drive System

Wire the Kinetix 7000 Drive Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Wire the Control Power (CP) Connector . . . . . . . . . . . . . . . . . . . . . . 88

Wire AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Wire DC Input Power (Common Bus Configurations Only) . . . . 89

Wire the Safe-off (SO) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Wire the General Purpose Relay (GPR) and General Purpose I/O

(GPIO) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Wire Motor Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Wire the Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Flying-lead Feedback Cable Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Wire Feedback and I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Connect Premolded Motor Feedback Cables . . . . . . . . . . . . . . . . . . . 95

Wire Panel-mounted Breakout Board Kits. . . . . . . . . . . . . . . . . . . . . . 96

Wire Low-profile Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

SERCOS Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . 101

Chapter 5

Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Node Addressing Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Configure the Logix SERCOS interface Module . . . . . . . . . . . . . . . . . . . 110

Configure the Logix Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Configure the SERCOS Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Configure the Kinetix 7000 Drive Modules. . . . . . . . . . . . . . . . . . . . 117

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Apply Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Configure Drive Parameters and System Variables . . . . . . . . . . . . . . . . . 134

Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Troubleshoot the Kinetix 7000 Drive

System

Chapter 6

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Interpret Error Codes and Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 138

Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

General System Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Logix/Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

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Table of Contents

Specifications and Dimensions

Interconnect Diagrams

Upgrade Firmware

Index

Appendix A

Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Power Dissipation Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Weight Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

AC Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

External Shunt Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Precharge Capacities of the Regenerative Power Supply . . . . . . . . . . . . . 157

Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Appendix B

Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Power Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Kinetix 7000 Drive/Rotary Motor Wiring Examples . . . . . . . . . . . 172

Kinetix Safe-off Feature Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Appendix C

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Upgrade Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

8

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Preface

About This Publication

This manual provides detailed installation instructions for mounting, wiring, and troubleshooting your Kinetix 7000 drive, and system integration for your drive/ motor combination with a Logix controller.

Who Should Use This Manual

This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 7000 drive, and programmers directly involved in the operation, field maintenance, and integration of the Kinetix 7000 drive with a SERCOS interface module.

If you do not have a basic understanding of the Kinetix 7000 drive, contact your local Rockwell Automation sales representative before using this product for the availability of training courses.

Conventions Used in This

Manual

These conventions are used throughout this manual.

•

Bulleted lists such as this one provide information, not procedural steps.

•

Numbered lists provide sequential steps or hierarchical information.

Additional Resources

Resource

Kinetix 7000 DC-DC Converter and Control Board Kits, publication 2099-IN002

Kinetix 7000 Drive Installation Instructions, publication 2099-IN003

Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010

ControlLogix SERCOS interface Module Installation Instructions, publication

1756-IN572

Logix5000 Controllers General Instructions Reference Manual, publication

1756-RM003

ControlLogix System User Manual, publication 1756-UM001

CompactLogix SERCOS interface Module Installation Instructions, publication 1768-IN005

CompactLogix Controllers User Manual, publication 1768-UM001

SoftLogix Motion Card Setup and Configuration Manual, publication 1784-UM003

SoftLogix 5800 User Manual, publication 1789-UM002

8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

The following documents contain additional information concerning related products from Rockwell Automation.

Description

Provides information on removing and replacing the DC-DC converter, DC-DC converter fuse, and the control board assembly in a Kinetix 7000 drive.

Provides information on installing a Kinetix 7000 drive.

Provides information on proper handling, installing, testing, and troubleshooting fiber-optic cables.

Provides details about installing a 3, 8 or 16-Axis ControlLogix SERCOS interface module.

Provides programmers with details about each available instruction for a

Logix5000 controller. You should be familiar with how the Logix5000 controller stores and processes data before consulting this publication.

Provides information about configuring and troubleshooting a ControlLogix system.

Provides information on installing and troubleshooting a CompactLogix SERCOS interface motion module.

Provides information on installing, configuring, programming, and operating a

CompactLogix system.

Provides information on configuring and troubleshooting a SoftLogix PCI card.

Provides information on configuring, programming, and operating a SoftLogix system.

Provides a hardware description and start-up and programming procedures for the 8720MC-RPS Regenerative Power Supply.

Provides information, examples, and techniques designed to minimize system failures caused by electrical noise.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

9

Preface

Resource

Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002

Kinetix Motion Control Selection Guide, publication GMC-SG001

Kinetix 7000 Drive Systems Design Guide, publication GMC-RM007

Kinetix Servo Drives Specifications Technical Data, publication GMC-TD003

Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004

Rockwell Automation Configuration and Selection Tools website http://www.rockwellautomation.com/en/e-tools

Rockwell Automation Product Certification Website: http://www.rockwellautomation.com/products/certification/

Kinetix Accelerator Toolkit Quick Start, publication IASIMP-QS002

Kinetix Accelerator Toolkit Brochure, publication MOTION-BR004

SERCOS and Analog Motion Configuration and Startup, publication

MOTION-UM001

Motion Coordinate System User Manual, publication MOTION-UM002

Logix5000 Controllers Motion Instructions Reference Manual, publication MOTION-RM002

National Electrical Code, published by the National Fire Protection Association of Boston, MA

Safety Products, publication S117-CA001

Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls, publication SGI-IN001

Understanding the Machinery Directive, publication SHB-900

Allen-Bradley Industrial Automation Glossary, publication AG-7.1

Description

Provides detailed installation instructions for wiring and troubleshooting a

Kinetix 7000 safe-off drive.

Provides descriptions and specifications for the 2099 product family including motors and accessories.

The purpose of this publication is to assist you in identifying the drive system components and accessory items you’ll need for your Kinetix 7000 drive/motor combination.

Provides catalog numbers and product specifications, including performance, environmental, certifications, load force, and dimension drawings for Allen-

Bradley® servo drives.

Provides catalog numbers, product specifications, and dimensions for Allen-

Bradley servo drive accessories.

Provides information and access to the Motion Analyzer application analysis software for drive/motor sizing.

Provides online product selection and system configuration tools, including

AutoCAD (DXF) drawings.

Provides online access to declarations of conformity (DoC) currently available from Rockwell Automation.

Provides examples of using a Logix controller to connect to multiple devices

(servo drives, motors, and HMI) over the EtherNet/IP network in a Kinetix

Integrated Motion application.

Provides information about the Kinetix Accelerator Toolkit.

Provides information to create a motion coordinate system with SERCOS or analog motion modules.

Provides, information on configuring and troubleshooting your ControlLogix,

CompactLogix, and SoftLogix SERCOS interface modules.

Provides programmers with details about the motion instructions that are available for a Logix5000 controller.

Provides access to articles on wire sizes and types for grounding electrical equipment.

Provides information on principle standards and implementation of safety products and catalogs available safety products.

Provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solidstate components.

Provides information on the CE marking process, with references to key European requirements and resources, and examples of safety component applications.

A glossary of industrial automation terms and abbreviations.

You can view or download publications at http://literature.rockwellautomation.com

. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell

Automation® sales representative.

10

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Chapter

1

Start

Use this chapter to become familiar with the design and installation requirements for Kinetix 7000 drive systems.

Topic

About the Drive System

Typical Drive System Diagrams

Catalog Number Explanation

Agency Compliance

13

18

Page

12

18

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

11

Chapter 1

Start

About the Drive System

The Kinetix 7000 high-power servo drive is designed to provide a Kinetix

Integrated Motion solution for applications with output power requirements in the range of 22…149 kW (40…248 A).

Table 1 - Kinetix 7000 Drive System Overview

Kinetix 7000

Component

Servo Drive

Catalog Numbers

2099-BM

xx

-S

(1)

Regenerative Power

Supply

Logix Controller

Platform

8720MC-RPS

1756-L60M03SE module

1756-M

xx

SE module

1768-M04SE module

1784-PM16SE PCI card

RSLogix 5000 Software 9324-RLD300ENE

Rotary Servo Motors MP-Series, HPK-Series, and

RDD-Series

Cables Motor Power, Feedback, and

Brake cables

Description

The Kinetix 7000 servo drive with safe-off feature is available with 460V AC input power, or capable of operating with a shared DC bus.

The 8720MC-RPS is a sinusoidal PWM converter that may serve as a regenerative power supply for one or more drives.

The SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix platform and

Kinetix 7000 drive system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (SERCOS) protocol over a fiber-optic cable.

RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of controllers.

Compatible rotary servo motors include MP-Series (Bulletin MPL and MPM) 400V class motors, HPK-Series motors, and

RDD-Series direct-drive motors.

Bulletin 2090 motor power/brake and feedback cables are available with bayonet, threaded, and SpeedTec connectors.

Power/brake cables have flying leads on the drive end and straight connectors that connect to servo motors. Feedback cables have flying leads that wire to low-profile connector kits on the drive end and straight connectors on the motor end.

AC Line Filters

Communication

2090-XXLF-TC

xxxx

Line Interface Module 2094-BL50/75S, or 2094-

XL75S-C

x

External Shunt

Modules

NA

Large power motors may require user power wiring to handle larger current requirements.

Bulletin 2090 SERCOS fiber-optic cables are available as enclosure only, PVC, nylon, and glass with connectors at both ends.

Bulletin 2090-XXLF-TC

xxxx

three-phase AC line filters are required to meet CE and available for use in all Kinetix 7000 drive systems.

The line interface module (LIM) contains the circuit breakers, power supplies, and safety contactor required for Kinetix 7000 operation. Individual components can be purchased separately in place of the LIM.

See External Shunt Modules on page 156

intended for use with Kinetix 7000 drives.

for active shunt solutions from Rockwell Automation Encompass Partners and

(1) See the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 , for more information.

12

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Typical Drive System

Diagrams

460V AC

Three-Phase

Input Power

Start

Chapter 1

Typical Kinetix 7000 system installations include three-phase AC configurations, with and without the line interface module (LIM), and DC common bus configurations.

Figure 1 - Kinetix 7000 System Configuration with LIM and External Resistive Shunt

RSLogix 5000 Software

Input

Logix 5000 Controller

Output

1756-M

xx

SE SERCOS

Interface Module

ControlLogix Chassis

Safe-off,

General Purpose I/O,

General Purpose Relay

Connections

Commissioning

2090-SC

xxx

-

x

SERCOS Fiber-Optic Ring

2099-BM

xx

-S Kinetix 7000 Drive

2094-BL75S

Line Interface Module

(optional component)

MAIN V AC

2090-K6CK-D

xxx

Low Profile Connector Kits for

I/O, Motor Feedback, and Auxiliary Feedback

24V DC

Control Power

2090-XXLF-TC

xxxx

AC Line Filter

External Shunt Module (optional component). See

External Shunt Modules on page 156 for more

information.

Motor Power Cable

HPK-Series Motors, RDD-Series Direct Drive Motors, MPM-

B165

xx

and MPM-B215

xx

, and MPL-B5

xxx

, MPL-B6

xxx

,

MPL-B8

xxx

, and MPL-B9

xxx

(shown) Servo Motors

Encoder

Feedback

Cable

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

13

Chapter 1

Start

Input Fusing

Input

Contactor

Three-Phase

Input Power

Figure 2 - Kinetix 7000 System Configuration without Line Interface Module (LIM)

RSLogix 5000 Software

Input

Logix 5000

Controller

Output

1756-M

xx

SE

SERCOS Interface Module

ControlLogix

Chassis

Safe-off,

General Purpose I/O,

General Purpose Relay connections

Commissioning

2090-SC

xxx

-

x

SERCOS Fiber-Optic Ring

2099-BM

xx

-S Kinetix 7000 Drive

2090-K6CK-D

xxx

Low Profile Connector Kits for

I/O, Motor Feedback, and Auxiliary Feedback.

1606-XL

xxx

24V DC

Control Power

Control Power Supply

Input

Input

Allen-Bradley

1606-XL

P o w e r S u p p l y

2090-XXLF-TC

xxxx

AC Line Filter

External Shunt Module (optional component).

See External Shunt Modules on page 156 for more

information.

Motor Power Cable

HPK-Series Motors, RDD-Series Direct Drive Motors, MPM-

B165

xx

and MPM-B215

xx

, and MPL-B5

xxx

, MPL-B6

xxx

,

MPL-B8

xxx

, and MPL-B9

xxx

(shown) Servo Motors

Encoder

Feedback

Cable

14

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Three-phase

Input Power

Input

Fusing

Start

Chapter 1

The Kinetix 7000 drive system shown in Figure 3

below illustrates a regenerative power only configuration with a 8720MC regenerative power supply (RPS). The harmonic filter and varistor are available separately, but are included with the

RPS unit when ordering the 8720MC-RPS065BM-HV2. In this configuration the Kinetix 7000 drive provides motoring power and the 8720MC-RPS065 provides regenerative power.

8720MC-RFI80

AC Line Filter

(required for CE)

Figure 3 - Kinetix 7000 System Configuration with AC Input and Regenerative Power Supply

RSLogix 5000 Software

Logix Controller

Programming Network

Logix SERCOS interface Module

ControlLogix Chassis

RST PRG ENT

8720

MC

A

V

8720MC-LR

xx

Line Reactor

8720MC-RPS065BM-HV2

Regenerative Power Supply

Magnetic

Contactor

DC Bus

2099-BM

xx

-S

Kinetix 7000 Drive

2090-K6CK-D

xxx

Low Profile Connector

Kits for I/O, Motor and

Auxiliary Feedback

1606-XL

xxx

24V DC

Control Power

Control Power

Supply Input

Input

Allen-Bradley

1606-XL

P o w e r S u p p l y

Regenerative

Power Only

8720MC-HF-B2 Harmonic Filter

Included with

8720MC-RPS065BM-HV2.

8720MC-VA-B Varistor

Included with

8720MC-RPS065BM-HV2.

2090-SC

xxx-x

SERCOS Fiber-optic Ring

Kinetix 7000 High Power

Servo Drive System

Motor

Power

Cable

Encoder

Feedback

Cable

Three-phase

Input Power

HPK-Series Motors, RDD-Series Direct

Drive Motors, MPM-B165

xx

and MPM-

B215

xx

, and MPL-B5

xxx

, MPL-B6

xxx

,

MPL-B8

xxx

, and MPL-B9

xxx

(shown)

Servo Motors

Input

Fusing

Magnetic

Contactor

2090-XXLF-TC

xxxx

AC Line Filter

(required for CE)

1321-3R Type Line Reactor,

3% compatible with

Kinetix 7000 Drive

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

15

Chapter 1

Start

Input

Fusing

Three-phase

Input Power

The Kinetix 7000 drive system shown in

Figure 4 below illustrates a DC

common bus configuration with two follower Kinetix 7000 (2099-BM11-S) drives and an 8720MC regenerative power supply (RPS). In full-line regenerative mode the 8720MC-RPS190 unit provides motoring and regenerative power.

Figure 4 - Kinetix 7000 System Configuration with AC Input and 8720MC-RPS190 with Full-line

Regeneration

RSLogix 5000 Software

Logix SERCOS interface Module

Logix Controller

Programming Network

RST PRG ENT

8720

MC

REGENERATIVE POWER SUPPLY

8720MC-EF190-VB

EMC Line Filter

This unit includes an AC line filter (required for CE), magnetic contactor, harmonic filter, and varistor.

IMPORTANT

The 8720MC-EF190-VB line filter unit and two

8720MC-LR10-100B line reactors are required when using the

8720MC-RPS190 regenerative power supply.

Ground

Fault

Protection

Fusing

RST PRG ENT

8720

MC

A

V

8720MC-LR10-100B

Line Reactor

(two units in parallel)

8720MC-RPS190BM

Regenerative Power Supply

Kinetix 7000 Drive

2099-BM11-S

2090-K6CK-D

xxx

Low Profile Connector

Kits for I/O, Motor and

Auxiliary Feedback

1606-XL

xxx

24V DC

Control Power

Control Power

Supply Input

Input

Allen-Bradley

1606-XL

Power Supply

DC Bus

Fusing

Full Regenerative

Motor

Power Cable

HPK-Series Motors

2090-SC

xxx-x

SERCOS Fiber-optic Ring

2099-BM11-S

Kinetix 7000 Drive

2090-K6CK-D

xxx

Low Profile Connector

Kits for I/O, Motor and

Auxiliary Feedback

1606-XL

xxx

24V DC

Control Power

Allen-Bradley

1606-XL

Power Supply

Input

Control Power

Supply Input

DC Bus

Fusing

DC Bus

Encoder

Feedback Cable

Motor

Power Cable

HPK-Series Motors, RDD-Series Direct

Drive Motors, MPM-B165

xx

and MPM-

B215

xx

, and MPL-B5

xxx

, MPL-B6

xxx

,

MPL-B8

xxx

, and MPL-B9

xxx

(shown)

Servo Motors

Encoder

Feedback

Cable

16

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Start

Chapter 1

Three-Phase

Input Power

Input

Fusing

8720MC-LR

xx

Line Reactor

The Kinetix 7000 drive system shown in Figure 5

below illustrates a DC common bus configuration with two follower Kinetix 7000 drives and an

8720MC regenerative power supply (RPS). The harmonic filter and varistor are available separately, but are included when ordering the 8720MC-RPS065BM-

HV2 RPS unit. In full-line regenerative mode the 8720MC-RPS065BM-HV2 unit provides motoring power and regenerative power. In common bus mode, you must calculate the total bus capacitance of your DC common bus system.

This allows you to plan your panel layout and sufficiently size the 8720MC-RPS to precharge the entire system.

8720MC-RF180

AC Line Filter

Figure 5 - Kinetix 7000 System Configuration with DC Input from 8720MC-RPS065 Providing Fullline Regeneration

Input

Output

Logix 5000

Controller

1756-M

xx

SE SERCOS

Interface Module

ControlLogix

Chassis

RSLogix 5000 Software

Commissioning

Magnetic

Contactor

Harmonic Filter

(included with

8720MC-RPS065BM-HV2

Regenerative Power Supply)

Varistor

(included with

8720MC-RPS065BM-HV2

Regenerative Power Supply)

2090-SC

xxx

-

x

SERCOS Fiber-Optic Ring

8720MC-RPS065BM-HV2

Regenerative Power Supply

2099-BM

xx

-S

Kinetix 7000 Drive

2099-BM

xx

-S

Kinetix 7000 Drive

Ground

Fault

Protection

Fusing

A

V k W

R S T PRG ENT

8720

MC

R E G E N E R A T I W ER UPPLY S U P P LY

2090-K6CK-D

xxx

Low Profile Connector Kits for

I/O, Motor Feedback, and Auxiliary Feedback

1606-XL

xxx

24V DC

Control Power

Control Power

Supply Input

(To retain logic control when main DC power is removed.)

Full Regenerative

Input

Allen-Bradley

1606-XL

P o w e r S u p p l y

DC Bus

Fusing

Motor Power Cable

HPK-Series Motors

2090-K6CK-D

xxx

Low Profile Connector Kits for

I/O, Motor Feedback, and Auxiliary Feedback.

1606-XL

xxx

24V DC

Control Power

Control Power

Supply Input

(To retain logic control when main DC power is removed.)

DC Bus

Input

Allen-Bradley

1606-XL

P o w e r S u p p l y

DC Bus

Fusing

Encoder Feedback Cable

Motor Power Cable

HPK-Series Motors, RDD-Series Direct

Drive Motors, MPM-B165

xx

and MPM-

B215

xx

, and MPL-B5

xxx

, MPL-B6

xxx

,

MPL-B8

xxx

, and MPL-B9

xxx

(shown)

Servo Motors

Encoder

Feedback

Cable

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

17

Chapter 1

Start

Catalog Number Explanation

Kinetix 7000 drive catalog numbers and descriptions are listed in the table below.

Kinetix 7000

Drive

Kinetix 7000, 460V, 22 kW, 40 A continuous output

Kinetix 7000, 460V, 30 kW, 52 A continuous output

Kinetix 7000, 460V, 37 kW, 65 A continuous output

Kinetix 7000, 460V, 56 kW, 96 A continuous output

Kinetix 7000, 460V, 75 kW, 125 A continuous output

Kinetix 7000, 460V, 112 kW, 180 A continuous output

Kinetix 7000, 460V, 149 kW, 248 A continuous output

Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Agency Compliance

If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply.

ATTENTION:

Meeting CE requires a grounded system, and the method of grounding the AC line filter and drive must match. Failure to do this renders the filter ineffective and may cause damage to the filter.

For grounding examples, see

Grounded Power Configurations on page 75

.

For more information on electrical noise reduction, see the System Design for

Control of Electrical Noise Reference Manual, publication GMC-RM001 .

18

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Start

Chapter 1

CE Requirements - System without LIM

To meet CE requirements when your Kinetix 7000 system does not use a 2094 line interface module to supply AC line and dc control power, the following requirements apply:

•

Install an 8720MC-RF180 line filter as close to the 8720MC-RPS unit as possible, and the AC line filter (2090-XXLF-TC

xxxx

) as close to the

Kinetix 7000 drive as possible.

•

For MP

x

motors, use 2090 series motor power cables or use connector kits.

Terminate cable shields at the chassis and the motor terminal block with a

360° connection.

•

For HPK-Series motors, use UL Approved 4 wire, 600V AC, shield, VFD cabling. Terminate cable shields at the chassis and the motor with a 360° connection.

•

Combined motor power/feedback cables must not exceed 90 m (295.3 ft).

•

Use 2090 series motor feedback cables or connector kits and terminate the feedback shield as shown in Chapter 4 for wiring instructions and

Appendix B for motor feedback connector kit catalog numbers. Drive to motor feedback cables must not exceed 90 m (295.3 ft).

•

Install the Kinetix 7000 system inside an enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure.

Separate signal and power cables.

•

Output power, control (I/O), and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation.

•

All shielded cables should terminate with a properly shielded connector.

See the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , for information on electrical noise reduction and grounding practices.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

19

Chapter 1

Start

CE Requirements - System with LIM

To meet CE requirements when your Kinetix 7000 system includes the line

interface module (LIM), follow all the requirements as stated in CE

Requirements - System without LIM on page 19

and these additional requirements that also apply to the AC line filter:

•

Install the LIM, 2094-XL75S-C

x

or 2094-BL50/75S, and line filter

(2090-XXLF-TC

xxx

) as close to the Kinetix 7000 drive as possible.

IMPORTANT

The full rated current on the AC input line should not exceed that of the line interface module.

Catalog numbers 2094-XL75S-C

x

or 2094-BL50S for 2099-BM06-S and

2099-BM07-S Kinetix 7000 drives, or 2094-BL75S for 2099-BM08-S Kinetix

7000 drives.

IMPORTANT

CE requires use of a grounded secondary or source with a 2099-BM

xx

-S drive.

Never use a LIM in an ungrounded input, due to the potential for high lineto-neutral voltages damaging components within the line filter.

CE Requirements - System with DC Common Bus through 8720MC-RPS

To meet CE requirements when your Kinetix 7000 system includes a common

DC bus with an 8720MC-RPS, follow all the requirements as stated in the CE

Requirements - System without LIM on page

19 , the recommended installation and wiring in the 8720MC Regenerative Power Supply Reference Manual, publication 8720MC-RM001 , and these additional requirements:

•

Install a three-phase line filter on the AC input power line of the RPS as

indicated in Interconnect Diagrams beginning on page 161

.

•

Install a single-phase line filter when attaching an AC line input to the

RPS MC1/2 circuit as indicated in the Interconnect Diagrams beginning

on page

161 .

20

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Chapter

2

Install the Kinetix 7000 Drive System

This chapter describes system installation guidelines in preparation for mounting your Kinetix 7000 drive components.

Topic

System Design Guidelines

Minimizing Electrical Noise

Mount the Kinetix 7000 Drive

28

39

Page

22

ATTENTION:

Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

21

Chapter 2

Install the Kinetix 7000 Drive System

System Design Guidelines

To design your enclosure and plan where to mount the system components on the panel, use this section and the information in the Kinetix Servo Drives

Specifications Technical Data, publication GMC-TD003 .

For online product selection and system configuration tools, including

AutoCAD (DXF) drawings of the product, go to: http://www.rockwellautomation.com/en/e-tools/ .

System Mounting Requirements

Follow these system mounting requirements.

•

To comply with UL and CE requirements, the Kinetix 7000 drive system must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to NEMA/UL Type IP2X such that they are not accessible to an operator or unskilled person. A

NEMA/UL Type 4X enclosure exceeds these requirements providing protection to IP66.

•

The panel you install inside the enclosure for mounting your system components must be on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors (as

specified in Environmental Specifications on page 154

).

•

Size the drive enclosure so as not to exceed the maximum ambient temperature rating. Consider heat dissipation specifications for all drive components.

•

Segregate input power wiring and motor power cables from control wiring and motor feedback cables. Use shielded cable for power wiring and provide a grounded 360° clamp termination.

•

Use high-frequency (HF) bonding techniques to connect the modules, enclosure, machine frame, and motor housing, and to provide a lowimpedance return path for HF energy and reduce electrical noise.

See the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , to better understand the concept of electrical noise reduction.

Transformer Selection

The Kinetix 7000 drive does not require an isolation transformer for three-phase input power. However, a transformer may be required to match the voltage requirements of the controller to the available service.

22

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

To size a transformer for the AC power inputs to devices peripheral to the

Kinetix 7000 drive, refer to the manufacturer continuous output power specification.

IMPORTANT

If using an autotransformer, make sure that the phase to neutral/ground voltages do not exceed the input voltage ratings of the drive.

IMPORTANT

Use a form factor of 1.5 for three-phase power (where form factor is used to compensate for transformer, drive module and motor losses, and to account for utilization in the intermittent operating area of the torque speed curve).

For example: using a secondary of 480 VAC and a 2099-BM06-S with a rated power output = 22 kW continuous:

22 * 1.5 = 33 kVA transformer

Circuit Breaker/Fuse Selection

The Kinetix 7000 drive uses internal solid-state motor short-circuit protection and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 200,000 A. Fuses or circuit breakers, with adequate withstand and interrupt ratings, as defined in NEC or applicable local codes, are permitted.

The 2094-BL50 and 2094-BL75S LIMs contain supplementary protection devices, but require a customer-supplied external line filter. See the Line Interface

Module Installation Instructions, publication 2094-IN005 , for power specifications and more information on using the LIM module.

The Bulletin 140M motor protection circuit breakers are another acceptable means of protection. As with fuses and circuit breakers, you must make sure that the selected components are properly coordinated and meet applicable codes including any requirements for branch circuit protection. When applying the

140M product, evaluation of the short circuit available current is critical and must be kept below the short circuit rating of the 140M product.

In most cases, fuses selected to match the drive input current rating will meet the

NEC requirements and provide the full drive capabilities. Dual element, time delay (slow acting) fuses should be used to avoid nuisance trips during the inrush current of power initialization.

See Circuit Breaker/Fuse Specifications on page 151

for recommended circuit breakers and fuses.

See Power Specifications on page 150 for input current and inrush current

specifications for your Kinetix 7000.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

23

Chapter 2

Install the Kinetix 7000 Drive System

Enclosure Selection

To assist you in sizing an enclosure, the following example is provided. The example system consists of the following components.

•

2-axis Kinetix 7000 servo drive system

•

ControlLogix chassis and modules

Size the Kinetix 7000 servo drive using Motion Analyzer software, version 4.2 or later, and use the results to predict the amount of heat dissipated into the enclosure. You will also need heat dissipation data from other equipment inside the enclosure (such as ControlLogix). Once the total amount of heat dissipation

(in watts) is known, the minimum enclosure size can be calculated. It is recommended that you also contact the enclosure manufacturer for the best enclosure fit, including possible cooling methods to help reduce enclosure size.

Using Motion Analyzer to Determine Heat Dissipation

To obtain Motion Analyzer software, go to: http://ab.rockwellautomation.com/Motion-Control/Motion-Analyzer-

Software

Complete the Motion Analyzer Axis View data to find an acceptable Kinetix

7000 drive and motor solution to meet the application needs. In the Axis View

Solutions window find the Drive Capacity value. In this example, the

2099-BM11-S Drive Capacity characteristic can be used for the estimation of the

Rated Power Output used for the percentage of watts dissipated.

24

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

Table 2 - Kinetix 7000 System Heat Dissipation Example

Enclosure

Component

Description

2099-BM08-S

2099-BM11-S

Kinetix 7000 Servo Drive

Kinetix 7000 Servo Drive

Total Wattage of Kinetix 7000 system

Loading

(1)

(Motion Analyzer)

50%

50%

Heat Dissipation

Watts

452

1275

1727

(1) Loading determined using Motion Analyzer software.

(2) To determine heat dissipation specifications for the Kinetix 7000 drive, see Power Dissipation

Specifications

on page

152

.

(2)

Table 3 - ControlLogix Heat Dissipation Example

Enclosure

Component

Description

1756-M08SE

1756-L5563

1756-IB16D

1756-OB16D

8-axis SERCOS interface module

L63 ControlLogix processor

16-point input module

16-point output module

EtherNet/IP communication module 1756-EN

x

T

x

Backplane total

1756-PB72

1756-A7

24V DC ControlLogix power supply

7-slot mounting chassis

Total ControlLogix system wattage

Backplane Power Load

(1)

Watts

3.2

4.5

0.84

4.64

4.0

17.18

N/A

N/A

(2)

(1) For ControlLogix module specifications, see the ControlLogix Selection Guide, publication 1756-SG001 .

(2) Real power heat dissipation is determined by applying the backplane power load (17.18 W) to the graph below.

Heat Dissipation

(1)

Watts

0.0

0.0

5.8

3.3

0.0

N/A

25.0

(2)

N/A

34.1

Figure 6 - ControlLogix Real Power

1756-P B72

1756-P B75

DC

Backplane

Power Load

(Watts)

75

60

45

30

15

0

0 20 40 60 80

Real Power (Watts)

100

For backplane power loading requirements of other ControlLogix power supplies, see the ControlLogix Selection Guide, publication 1756-SG001 .

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

25

Chapter 2

Install the Kinetix 7000 Drive System

In this example, the amount of power dissipated inside the cabinet is the sum of the Kinetix 7000 drive (2099-BM08-S and 2099-BM11-S) system value (1727

W) and the ControlLogix value (34.1 W) for a total of 1761 W.

With no active method of heat dissipation (such as fans or air conditioning) either of the following approximate equations can be used.

Metric Standard English

A

=

0.38

Q

1.8

T

– 1.1

A

=

4.08

Q

T

– 1.1

Where T is temperature difference between inside air and outside ambient (°C), Q is heat generated in enclosure

(Watts), and A is enclosure surface area (m

2

). The exterior surface of all six sides of an enclosure is calculated as

Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in enclosure

(Watts), and A is enclosure surface area (ft²). The exterior surface of all six sides of an enclosure is calculated as

A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144

Where d (depth), w (width), and h (height) are in meters. Where d (depth), w (width), and h (height) are in inches.

The maximum ambient rating of the Kinetix 7000 drive is 50 °C (122 °F) and if the maximum environmental temperature is 30 °C (86 °F) then Q=1761 and

T=20 in the equation below.

A = 19.2 m 2

In this example, the enclosure must have an exterior surface of 19.2 m

2

. If any portion of the enclosure is not able to transfer heat, it should not be included in the calculation. For instance, if an externally-mounted shunt system is used with the Kinetix 7000 system, it should not be included in the equation.

The minimum enclosure size must take into account the physical size and minimum clearance requirements of the two Kinetix 7000 drives and the additional ControlLogix and other devices required to meet the application needs.

If the enclosure size is considerably larger than what is necessary to house the system components, it may be more efficient to provide a means of cooling in a smaller enclosure. Contact your enclosure manufacturer for options available to cool your enclosure.

26

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

Minimum Clearance Requirements

This section provides information to assist you in sizing your cabinet and positioning your Kinetix 7000 system components.

IMPORTANT

Mount the module in an upright position as shown. Do not mount the module on its side.

Figure 7 - Minimum Clearance Requirements

101.6 mm (4.0 in.) clearance for airflow and installation

50.8 mm (2.0 in.) clearance left of module is required

50.8 mm (2.0 in.) clearance right of module is required

Minimum cabinet depth = 300 mm (11.8 in.)

Cable bend radius requires a minimum of

60 mm (2.4 in.) from the front panel connections.

101.6 mm (4.0 in.) clearance for airflow and installation

See page

152 for power dissipation specifications.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

27

Chapter 2

Install the Kinetix 7000 Drive System

Minimizing Electrical Noise

This section outlines best practices that minimize the possibility of noise-related failures as they apply specifically to Kinetix 7000 drive installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, see the System Design for Control of

Electrical Noise Reference Manual, publication GMC-RM001 .

Bonding Modules

Bonding is the practice of connecting metal chassis, assemblies, frames, shields, and enclosures to reduce the effects of electromagnetic interference (EMI).

Unless specified, most paints are not conductive and act as insulators. To achieve a good bond between the drive and subpanel, surfaces need to be unpainted or plated. Bonding metal surfaces creates a low-impedance return path for highfrequency energy.

IMPORTANT

To improve the bond between the drive and subpanel, construct your subpanel out of zinc plated (unpainted) steel.

Improper bonding blocks the direct return path and routes high-frequency energy to elsewhere in the cabinet. Excessive high-frequency energy can effect the operation of other microprocessor controlled equipment.

The illustrations that follow show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

28

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

Subpanel

Star Washer

Nut

Figure 8 - Recommended Bonding Practices for Painted Panels

Stud-mounting the Subpanel to the Enclosure Back Wall

Back Wall of

Enclosure

Stud-mounting a Ground Bus or Chassis to the Subpanel

Mounting Bracket or

Ground Bus

Welded Stud

Use a wire brush to remove paint from threads to maximize ground connection.

Flat Washer

Nut

Use plated panels or scrape paint off front of panel.

Star Washer

Subpanel

Welded Stud

Flat Washer

Scrape Paint

If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole.

Ground Bus or

Mounting Bracket

Bolt-mounting a Ground Bus or Chassis to the Back-panel

Subpanel

Tapped

Hole

Nut

Flat Washer

Nut

Star Washer

Bolt

Star

Flat Washer

Washer

Star Washer

Scrape paint on both sides of panel and use star washers.

If the mounting bracket is coated with a non-conductive material (anodized, or painted for example), scrape the material around the mounting hole.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

29

Chapter 2

Install the Kinetix 7000 Drive System

Bonding Multiple Subpanels

Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels.

Figure 9 - Multiple Subpanels and Cabinet Recommendations

Bond the top and bottom of each subpanel to the cabinet using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.

Cabinet ground bus bonded to the subpanel.

Scrape the paint around each fastener to maximize metal to metal contact.

Establish Noise Zones

When designing a panel for a Kinetix 7000 system, observe the following guidelines with additional attention to zone locations.

30

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Clean Wireway (C

x

)

C1

Kinetix 7000 Drive

Install the Kinetix 7000 Drive System

Chapter 2

Noise Zones when Using Regenerative Power Supplies (with/without a Line Filter Unit)

Observe the following guidelines when laying out a Kinetix 7000 system panel if a regenerative power supply (8720-RPS

xxxxx

) is used (see

Figure 10 ), and if a

regenerative power supply and line filter unit are used (see

Figure 11 on page 32 ).

•

Mount the regenerative power supply to the right of the drive.

•

The clean zone (C) is beneath and left of the Kinetix 7000 drive. This zone includes the motor feedback, auxiliary feedback and registration signals from the IOD connector (grey wireway).

•

The dirty zone (D) is to the right of the Kinetix 7000 drive. This zone includes the motor power, GPIO, GPR, SO, and IOD connections (black wireway).

•

The very dirty zone (VD) includes both the 8720MC-RPS DC output to the Kinetix 7000 drive and the fuses, contactors, circuit breakers, and AC line input to the EMC line filter to the right of the 8720MC-RPS.

Shielded cable is required only if the very dirty cables enter a wireway.

•

The SERCOS fiber-optic cables are immune to electrical noise.

Figure 10 - Establishing Noise Zones (Regenerative Power Supply)

GPIO, GPR, and SO Cables Dirty Wireway (D

x

) Dirty Wireway (D

x

)

D1

D3

8720MC-RPS065BM-HV2

Regenerative Power Supply

No sensitive equipment within

150 mm (6.0 in.)

Registration I/O

Encoder Feedback

24V DC I/O

Shielded Cable

Shield Clamps

(beneath cover)

A

V k W

R T PRG

ENT

8720 MC

REGENERATI V E PO V W ER S UPPLY S U P P LY

Varistor

V D

C1

24V DC

Shielded Cable or

Conduit

24V DC

Power

Supply

D2

Motor Power

Shielded Cable

Route Encoder/Analog/Registration

Shielded Cable

DC Bus

≤

2 m (78.7 in.)

V D

8720MC

Line Reactor

Keep very dirty (VD) connections as short as possible and segregated (not in wireway)

Magnetic

Contactor

Harmonic

Filter

Line

Fuses

Circuit

Breaker

AC

Line

Filter

D2

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

31

Chapter 2

Install the Kinetix 7000 Drive System

Clean Wireway (C

x

)

C1

Kinetix 7000 Drive

No sensitive equipment within

150 mm (6.0 in.)

Registration I/O

Encoder Feedback

Figure 11 - Establishing Noise Zones (Regenerative Power Supply with Line Filter Unit)

GPIO, GPR, and SO Cables Dirty Wireway (D

x

)

8720MC-RPS190BM-HV2

Regenerative Power Supply

D3

Dirty Wireway (D

x

)

D1

24V DC I/O

Shielded Cable

Shield Clamps

(beneath cover)

A

V k W

S T PRG ENT

8720

MC

REGENERATI V E PO W ER S UPPLY S U P P LY

1.5 m

(5 ft)

V D

R

8 720

MC

REGENERATIVE POWER S UPPLY

Line

Fuses

Circuit

Breaker

8720MC-EF190-VB

EMC Line Filter

V D

C1

24V DC

Shielded Cable or

Conduit

24V DC

Power

Supply

D2

Route Encoder/Analog/Registration

Shielded Cable

DC Bus

≤

2 m (78.7 in.)

V D

V D

Keep very dirty connections as short as possible and segregated (not in wireway)

Line

Reactor

V D

Line

Reactor

8720MC -LR10-100B

Line Reactors

Motor Power

Shielded Cable

D2

32

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Clean Wireway (C)

Install the Kinetix 7000 Drive System

Chapter 2

AC Power Noise Zones

Observe the following guidelines when laying out a Kinetix 7000 system panel, if an AC power supply is used (and regenerative power will not be used).

•

The clean zone (C) is beneath and left of the Kinetix 7000 drive. This zone includes the motor feedback, auxiliary feedback and registration signals from the IOD connector (grey wireway).

•

One dirty zone (D) is beneath and right of the Kinetix 7000 drive. This zone includes fuses, contactors, circuit breakers, AC line input to the

EMC line filter (black wireway).

•

The very dirty zone (VD) is limited to where the AC line output exits from the EMC line filter and connects to the Kinetix 7000 drive. Shielded cable is required only if the very dirty cables enter a wireway.

•

The SERCOS fiber-optic cables are immune to electrical noise.

Figure 12 - Establishing Noise Zones (AC Power)

Dirty Wireway (D)

Kinetix 7000 Drive

No sensitive equipment within 150 mm (6.0 in.)

(1)

24V DC I/O Shielded

Cable

Shield Clamps

(beneath cover)

Motor Power

Shielded Cable

C

V D

D

Keep very dirty connections as short as possible and segregated (not in wireway)

AC Line

Filter

Line

Fuses

Circuit

Breaker

Contactor

C

Route Encoder/Analog/Registration

Shielded Cable

D

Shielded Clamps

Shielded Cable or

Conduit

(1)

When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, see the System

Design for Control of electrical Noise Reference Manual

,

publication GMC-RM001 .

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

33

Chapter 2

Install the Kinetix 7000 Drive System

1756-MxxSE SERCOS Interface Module Noise Zones

Observe the following guidelines when installing your 1756-M

xx

SE SERCOS interface module.

•

The clean zone (C) is beneath the less noisy I/O modules (analog, encoder, registration) - - (grey wireway).

•

The dirty zone (D) is above and below the power supply and noisy modules (black wireway).

•

The SERCOS fiber-optic cables are immune to electrical noise.

Figure 13 - Establishing Noise Zones (ControlLogix)

Dirty Wireway (D)

D

Route dirty wireways directly above the ControlLogix rack

(shielded by the chassis).

Clean Wireway (C)

AC Line

Filter

D

Spare Slot(s)

C

Line Filter/Power Supply

Connections Segregated

(not in wireway)

Dirty I/O

(24V DC I/O, AC I/O)

Clean I/O

(Analog, Encoder

Registration)

34

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

Cable Categories for Kinetix 7000 Systems

The table below indicates the zoning requirements of input power cables connecting to the Kinetix 7000 drive.

Table 4 - Kinetix 7000 Drive

Wire/Cable

Control Power

DC-/DC+

L1, L2, L3 (shielded cable)

L1, L2, L3 (unshielded cable)

DPI

Connector Zone

Very

Dirty

CP

X

PTB

X

DPI

Dirty

X

X

Clean

Method

Ferrite

Sleeve

Shielded

Cable

X

X

X

The table below indicates the zoning requirements of power and control cables connecting to the Kinetix 7000 system.

Table 5 - Kinetix 7000 System

Wire/Cable Connector Zone

Very

Dirty

MP

GPR

Dirty

X

X

Method

Clean Ferrite

Sleeve

Shielded

Cable

X U, V, W (Motor Power)

GPR+, GPR- (Motor Brake)

24V DC (PWR), COM, filtered

24V DC (PWR), COM, unfiltered

24V DC (PWR), COM, safety enable, and feedback signals for safe-off feature

Motor Feedback

Auxiliary Feedback

Registration and Analog Outputs

Others

Fiber-optic

GPIO, GPR

SO

MF

AF

X

X

IOD

Rx and Tx No Restrictions

X

X

X

X

X

X

X

X

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

35

Chapter 2

Install the Kinetix 7000 Drive System

36

Table 6 - Line Interface Module

Wire/Cable

VAC line (main input)

230V AC input

VAC load (shielded option)

VAC load (unshielded option)

Control power output

MBRK PWR, MBRK COM

Status I/O

Auxiliary 230V AC

Connector Zone

Very

Dirty

IPL

APL

OPL

CPL

P1L/PSL

IOL

P2L

X

Table 7 - External Shunt Resistor Kit

Wire/Cable Connector Zone

Very

Dirty

COL, DC+ (shielded option)

COL, DC+ (unshielded option)

Thermal switch

Fan (if present)

RC

TS

N/A

X

Dirty

X

X

X

X

X

X

X

X

X

Method

Clean Ferrite

Sleeve

Shielde d Cable

X

X

Method

Dirty Clean Ferrite

Sleeve

X

Shielded

Cable

X

Noise Reduction Guidelines for Drive Accessories

When mounting an AC (EMC) line filter or external shunt resistor refer to the sections below for guidelines designed to reduce system failures caused by excessive electrical noise.

AC Line Filters

Observe the following guidelines when mounting your AC (EMC) line filter.

See the Establishing Noise Zones (AC Power) on page 33 for an example.

•

Mount the ac line filter on the same panel as the Kinetix 7000 drive and as close to the power input as possible.

•

Good HF bonding to the panel is critical.

For painted panels, refer to the examples on page 29.

•

Segregate input and output wiring as far as possible.

IMPORTANT

CE test certification applies only to ac line filter and single drive. Sharing a line filter with multiple drives may perform satisfactorily, but the user takes legal responsibility.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

Clean Wireway

C1

No sensitive equipment within

150 mm (6.0 in.)

Shunt Resistor

Observe the following guidelines when mounting your external shunt resistor outside the enclosure.

•

Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI.

•

Mount resistors (other than metal-clad) in a shielded and ventilated enclosure outside the cabinet

•

Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.

•

Route thermal switch and fan wires separate from shunt power.

Figure 14 - External Shunt Resistor Outside the Enclosure

Customer-supplied metal enclosure

Minimum of 150 mm (6.0 in.) of clearance on all sides of the shunt module

Metal conduit

(where required by local code)

Route Encoder/Analog/

Registration

Shielded Cables Dirty Wireway

D3

D1

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice)

Shielded twisted pair (2nd choice)

Twisted pair, 2 twists per foot min. (3rd choice)

I/O and Feedback

Cables

C1

Route 24V DC I/O

Shielded Cable

D2

Kinetix 7000 drive

V D

Very dirty connections segregated (not in wireway)

V D

V D

Motor Power Cables

Enclosure

D2

D1

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

37

Chapter 2

Install the Kinetix 7000 Drive System

Clean Wireway

C1

No sensitive equipment within

150 mm (6.0 in.)

C1

I/O and Feedback

Cables

Route 24V DC I/O

Shielded Cable

D2

When mounting your shunt module inside the enclosure, follow these additional guidelines.

•

Metal-clad modules can be mounted anywhere in the dirty zone, but as close to the Kinetix 7000 system as possible.

•

Shunt power wires can be run with motor power cables.

•

Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.

•

Separate shunt power cables from other sensitive, low voltage signal cables.

•

The shunt module watts dissipation must be included in the Kinetix 7000 system heat dissipation calculation for selecting an enclosure.

Figure 15 - External Shunt Resistor Inside the Enclosure

Dirty Wireway

Route Encoder/Analog/Registration

Shielded Cables

Shunt Module

D3

Observe minimum clearance requirements for shunt module spacing.

D1

Kinetix 7000

V D

Shunt Wiring Methods:

Twisted pair in conduit (1st choice).

Shielded twisted pair (2nd choice).

Twisted pair, 2 twists per foot min.

(3rd choice).

V D

V D

AC Line

Filter

Very dirty connections segregated (not in wireway)

Motor Power Cables

Enclosure

D2

D1

38

Motor Brake and Thermal Switch

The thermal switch and brake are mounted inside the motor, but how you connect to the axis module depends on the motor series.

See Wire Motor Output Power on page 92

for wiring guidelines specific to your

drive/motor combination, and to Interconnect Diagram Notes on page 162 for

the interconnect diagram of your drive/motor combination.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System

Chapter 2

Mount the Kinetix 7000 Drive

SHOCK HAZARD:

To avoid hazard of electrical shock, perform all mounting and wiring of the drive prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.

ATTENTION:

Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

Follow these steps to install your Kinetix 7000 drive.

1.

Layout and mark the position for your drive in the enclosure.

Follow the Kinetix 7000 mounting information provided in

Figure 16 on page 40

. Clearance requirements on page 27

must also be followed.

2.

Attach the drive to the cabinet.

The recommended mounting bolts are listed in the table on page 40

.

Follow the recommended high-frequency (HF) bonding techniques as

shown in Bonding Modules beginning on page 28 .

Follow the lifting instructions found in the Kinetix 7000 High Power

Servo Drive Installation Instructions, publication 2099-IN003 .

3.

Tighten all mounting fasteners.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

39

Chapter 2

Install the Kinetix 7000 Drive System

Figure 16 - Kinetix 7000 Approximate Mounting Dimensions

B

M2 M3 C

A

M1

2099-BM07 shown

Kinetix 7000 Drive

Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Dimensions in mm (in.)

A B

517.5 (20.37) 254.12 (10.0)

644.5 (25.37)

690.3 (38.47)

977.1 (38.47)

331.9 (13.07)

331.9 (13.07)

429.2 (16.90)

C

224.3 (8.83)

286.7 (11.29)

286.7 (11.29)

282.7 (11.13)

M1

495.0 (19.49)

M2

192.0 (7.56)

625.0 (24.61)

625.0 (24.61)

824.0 (32.44)

225.0 (8.86)

225.0 (8.86)

300.0 (11.81)

M3

15.3 (0.60)

37.5 (1.48)

37.5 (1.48)

49.6 (1.95)

Mounting Screw Size

M6 (0.25)

M6 (0.25)

M6 (0.25)

M8 (0.3125)

IMPORTANT

Each Kinetix 7000 drive requires four mounting screws.

40

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Chapter

3

Kinetix 7000 Connector Data

This chapter provides power, feedback, and I/O connector locations and signal descriptions for a Kinetix 7000 drive.

Topic

Locate and Identify Connectors and Indicators

Control Signal Specifications

Control Power Specifications

Motor (MF) and Auxiliary Feedback (AF) Connections

54

65

Page

42

66

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

41

Chapter 3

Kinetix 7000 Connector Data

Locate and Identify

Connectors and Indicators

9

Although the physical size of the drives vary, the location of the connectors and indicators is identical.

Figure 17 - Kinetix 7000 Front Panel Connectors and Displays

SERCOS

Node Address

1

SERCOS

Node Address

Fault/Status

Fault/Status

Drive

Comm

Bus

2

Drive

Comm

Bus

3

4

5

I/O

Motor

Feedback

Auxiliary

Feedback

I/O

Motor

Feedback

Auxiliary

Feedback

6

7

8

10

Power terminal block located behind protective cover.

42

CP

2099-BM08-S shown

8

9

10

6

7

4

5

2

3

Item Designator/Label Description

1 Node Address SERCOS Node Address Switches

Fault/Status

Drive

Fault Status Display

Drive Status LED

Comm

Bus

AF

MF

Communication Status LED

Bus Status LED

Auxiliary Feedback Connector

Motor Feedback Connector

IOD

–

PTB

Connector

–

–

–

Digital and Analog Input/Output Connector 26-pin high-density D-shell

Control Power Status LED –

Power Terminal Block Terminal block

See Page

Chapter 6

Chapter 7

Chapter 7

–

–

15-pin high-density D-shell (male)

49

15-pin high-density D-shell (female)

47

Chapter 7

Chapter 7

45

Chapter 7

51

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Top View

Kinetix 7000 Connector Data

Chapter 3

Figure 18 - Kinetix 7000 Top Panel Connectors and Switches

2099-BM08-S shown

FDBK1+FDBK1-

ENABLE-

SO

DO1 DO2 N/C N/C

GPIO

COM

24VDC

FDBK1+FDBK1-

ENABLE-

SO

DO1

DO2

N/C N/C

GPIO

GPR2-

GPR2+

COM

24VDC

GPR

1 2 3 4 5 6 7

6

7

4

5

2

3

Item Designator/Label Description

1 SO Safe-off Terminal Block

GPIO

GPR

General Purpose I/O Terminal Block

General Purpose Relay Terminal Block

Rx

DPI

Tx

Baud Rate

SERCOS Fiber-optic Receive Port

Device Peripheral Interface Connector

Connector

SERCOS fiber-optic

–

SERCOS Fiber-optic Transmit Port SERCOS fiber-optic

SERCOS Baud Rate and Optical Power Switches –

See Page

9-position plug/header

50

8-position plug/header

63

6-position plug/header

64

65

–

65

65

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

43

Chapter 3

Kinetix 7000 Connector Data

1

Figure 19 - Kinetix 7000 Bottom Panel Connectors

2

Bottom View 2099-BM06-S and 2099-BM07-S shown

Item Designator/Label

1 CP

2 PTB

Description

Control Power Terminal Block

Power Terminal Block Access

Connector

2-position terminal

Terminal block

See Page

51

51

44

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Pin 19

Pin 10

Kinetix 7000 Connector Data

Chapter 3

Digital and Analog Input/Output (IOD) Connector Pinout

The following diagram and table provide the signal description and pin-out information for the 26-pin Digital and Analog Input/Output connector.

See Kinetix 7000 Front Panel Connectors and Displays on page

42 for the

location of the 26-pin connector. IOD signals are described in greater detail later in this chapter.

Figure 20 - Pin Orientation for 26-pin I/O (IOD) Connector

Pin 18

Pin 9

Pin 26

Pin 1

8

9

10

6

7

4

5

2

3

Pin

1

11

12

13

Description

Drive supplied +24V DC

Hardware Enable Switch Input

Hardware Enable Common

Signal Name

HW_Enable_Pwr

HW_Enable_In

HW_Enable_Com

Drive supplied +24V DC

Home Switch Input

Home Common

Drive supplied +24V DC

Home_Switch_Pwr

Home_Switch_In

Home_Switch_Com

Pos_OverTravel_Pwr

Positive Overtravel Limit Switch Input Pos_ OverTravel_In

Positive Overtravel Common Pos_OverTravel_Com

Drive supplied +24V DC Neg_OverTravel_Pwr

Negative Overtravel Limit Switch Input Neg_OverTravel_In

Negative Overtravel Common Neg_OverTravel_Com

Drive supplied Registration 1 Output

Power

Reg_1_Pwr

Table 8 - Digital and Analog Input/Output 26-pin (IOD) Connector

21

22

23

19

20

17

18

15

16

Pin

14

24

25

26

Description

Registration 1 Input

Registration 1 Common

Drive supplied Registration 2 Output

Power

Signal Name

Reg_1_In

Reg_1_Com

Reg_2_Pwr

Registration 2 Input

Registration 2 Common

Reg_2_In

Reg_2_Com

Differential Analog Channel 1 Input Analog_Input_1

Differential Analog Channel 1 Common Analog_Input_1_Ret

Differential Analog Channel 2 Input Analog_Input_2

Differential Analog Channel 2 Common Analog_Input_2_Ret

Programmable Analog Channel 1

Output

Analog_Out_1

Analog Channel 1 Common

Programmable Analog Channel 2

Output

Analog Channel 2 Common

Analog_Out_1_Ret

Analog_Out_2

Analog_Out_2_Ret

IMPORTANT

The Drive supplied +24V DC and Common source signals (at pins 1, 3, 4, 6,

7, 9, 10, and 12) can only be used for the inputs listed above.

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46

General Purpose I/O (GPIO) Terminal Block Connections

The following diagram and table provide the orientation and signal description for the General Purpose Input/Output terminal block.

Figure 21 - Orientation for General Purpose I/O (GPIO) Terminal Block

DO1

DO2

N/C N/C

GPIO

Table 9 - General Purpose I/O (GPIO) Terminal Block

6

7

4

5

8

2

3

Terminal Description

1 Digital Output 1

+24V DC for digital output 1 (customer-supplied)

+24V DC for digital output 2 (customer-supplied)

Digital Output 2

Reserved

Reserved

Regenerative power supply OK (customer supplied)

Common for Regenerative power supply OK

Signal Name

Digital_Out_1

DO_24VDC_1

DO_24VDC_2

Digital_Out_2

N/C

N/C

Regen_OK+

Regen_OK-

General Purpose Relay (GPR) Terminal Block Connections

The following diagram and table provide the orientation and signal description for the General Purpose Relay terminal block.

Figure 22 - Orientation for General Purpose Relay (GPR) Terminal Block

Note: The GPR terminal number orientation is rotated 180 degrees relative to the other I/O connectors.

GPR2-

COM

24VDC

GPR

Table 10 - General Purpose Relay (GPR) Terminal Block

4

5

6

2

3

Terminal Description

1 24V DC customer-supplied power input for Relay 1

Programmable N.O. Relay 1 output

Programmable Relay 1 common

24V DC customer-supplied power supply common

Programmable N.O. Relay 2 output

Programmable Relay 2 common

Signal Name

24VDC

GPR1+

GPR1-

COM

GPR2+

GPR2-

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Chapter 3

Motor Feedback (MF) Connector Pinouts

The following diagram and tables provide the orientation and signal description for the Motor Feedback (MF) connector for each applicable feedback device.

Figure 23 - Pin Orientation for 15-pin Motor Feedback (MF) Connector

Pin 15

Pin 11

Pin 6

Pin 10

Pin 5

Pin 1

Table 11 - Motor Feedback (MF) Connections for Stegmann Hiperface (SRS/SRM)

6

7

4

5

8

2

3

Pin

1

Description

Sine differential input+

Sine differential input-

Cosine differential input+

Cosine differential input-

Hiperface data channel

Common

Encoder power (+9V)

Reserved

(1) Not applicable unless the motor has integrated thermal protection.

(2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

Signal

SIN+

SIN-

COS+

COS-

DATA+

ECOM

EPWR_9V

(2)

—

14

15

12

13

Pin

9

10

11

Description

Reserved

Hiperface data channel

Motor thermal switch (normally-closed)

(1)

Reserved

Reserved

Encoder power (+5V)

Reserved

Signal

—

DATA-

TS

—

—

EPWR_5V

(2)

—

Table 12 - Motor Feedback (MF) Connections for TTL or Sine/Cosine with Index Pulse and Hall

Commutation

6

7

4

5

8

2

3

Pin

1

Description

AM+ / Sine differential input+

AM- / Sine differential input-

BM+ / Cosine differential input+

BM- / Cosine differential input-

Index pulse+

Common

Encoder power (+9V)

Single-ended 5V hall effect commutation

(1) Not applicable unless motor has integrated thermal protection.

(2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

Signal

AM+ / SIN+

AM- / SIN-

BM+ / COS+

BM- / COS-

IM+

ECOM

EPWR_9V

(2)

S3

14

15

12

13

Pin

9

10

11

Description

Reserved

Index pulse-

Motor thermal switch (normally-closed)

(1)

Single-ended 5V hall effect commutation

Single-ended 5V hall effect commutation

Encoder power (+5V)

Reserved

Signal

—

IM-

TS

S1

S2

EPWR_5V

(2)

—

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Kinetix 7000 drives do not natively support Heidenhain EnDat high-resolution feedback. However, you can use the drive motor feedback connection with the

2090-K7CK-KENDAT feedback module to convert Heidenhain EnDat 2.1 high-resolution feedback from an RDD motor. Use the table below to connect the motor feedback wires to the 2090-K7CK-KENDAT feedback module.

IMPORTANT

Only 2099-BM

xx

-S drives with firmware revision 1.104 or higher support the use of 2090-K7CK-KENDAT feedback modules.

6

7

4

5

2

3

Pin

1

Description

Sine differential input+

Sine differential input-

Cosine differential input+

Cosine differential input-

Encoder power (+5V)

Common

Serial data clock signal +

(1) Not applicable unless motor has integrated thermal protection.

Table 13 - Connections for Heidenhain EnDat

Signal

SIN+

SIN-

COS+

COS-

EPWR_5V

ECOM

CLK+

11

12

13

9

10

Pin

8

Description

Serial data clock signal -

Serial data differential signal+

Serial data differential signal -

Motor thermal switch+

(1)

Reserved

Reserved

TS+

—

—

Signal

CLK-

DATA+

DATA-

IMPORTANT

Drive-to-motor power cables must not exceed 90 m (295.3 ft).

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Chapter 3

Auxiliary Feedback (AF) Connector Pinouts

For TTL devices, the position count will increase when A leads B. For sinusoidal devices, the position count will increase when cosine leads sine.

Figure 24 - Pin Orientation for 15-pin Auxiliary Feedback (AF) Connector

Pin 6

Pin 11

Pin 15

Pin 1

Pin 5

Pin 10

Table 14 - Stegmann Hiperface (SRS and SRM only)

6

7

4

5

8

2

3

Pin

1

Description

Sine differential input+

Sine differential input-

Cosine differential input+

Cosine differential input-

Hiperface data channel

Common

Encoder power (+9V)

Reserved

(1) Encoder power supply uses either 5V or 9V DC based on encoder used.

Signal

SIN+

SIN-

COS+

COS-

DATA+

ECOM

EPWR_9V

(1)

—

14

15

12

13

10

11

Pin

9

Table 15 - TTL or Sine/Cosine with Index Pulse

Description

Reserved

Hiperface data channel

Reserved

Reserved

Reserved

Encoder power (+5V)

Reserved

6

7

4

5

8

2

3

Pin

1

Description

A+ / Sine differential input+

A- / Sine differential input-

B+ / Cosine differential input+

B- / Cosine differential input-

Index pulse+

Common

Encoder power (+9V)

Reserved

(1) Encoder power supply uses either 5V or 9V DC based on encoder used.

Signal

A+ / SIN+

A- / SIN-

B+ / COS+

B- / COS-

I+

ECOM

EPWR_9V

(1)

—

14

15

12

13

10

11

Pin

9

Description

Reserved

Index pulse-

Reserved

Reserved

Reserved

Encoder power (+5V)

Reserved

Signal

—

I-

—

—

—

EPWR_5V

(1)

—

Signal

—

DATA-

—

—

—

EPWR_5V

(1)

—

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Kinetix 7000 Connector Data

Safe-off (SO) Terminal Block Connections

Figure 25 - Safe-off (SO) Terminal Block

6

7

4

5

8

9

FDBK1+FDBK1-

ENABLE-

Table 16 - Safe-off (SO) Terminal Block

Terminal Description

1 Normally-closed monitoring contact for safety relay 2

2 Return for safety relay 2

Return for safety relay 1

Coil of safety relay 2

Common for safety relays 1 and 2

Coil of safety relay 1

24V DC, 500 mA max., power for Safe Off circuit

Common for 24V power Safe off circuit

SO

Signal Name

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

IMPORTANT

Terminals 8 and 9 (24V+ and Common) are only used by the motionallowed jumper. When using the Safe-off feature, the 24V supply must come from an external source.

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Chapter 3

Control Power (CP) Terminal Block Connections

Kinetix 7000 drives must be wired to a 24V DC control power source through the Control Input Power (CP) connector. The Control Power input terminal is

located on the bottom of the drive as illustrated in Figure 19 on page 44

.

IMPORTANT

An external power supply provides the ability to retain control of the drive’s logic independent of its bus power status.

Figure 26 - Control Power (CP) Terminal Block Detail

Terminal Block

(on bottom of drive)

Label

(on front of drive)

CP

Table 17 - Control Power (CP) Terminal Block

Terminal Description

1

Control Power 24V DC Input

2

Signal Name

CP_24VDC

CP_COM

Power Terminal Block (PTB) Connections

The power terminals are located behind the lower front panel of the drive. The figures below identify the input power, motor power, DC bus, ground, and cooling fan input terminals.

The 2099-BM09-S or 2099-BM10-S drives (frame 5), and the 2099-BM11-S or

2099-BM12-S drives (frame 6) provide connections for you to supply 120V AC or 240V AC to power an internal cooling fan. The fan VA rating is 100 VA for

2099-BM09-S and 2099-BM10-S, and 138 VA for the 2099-BM11-S and 2099-

BM12-S drives.

The 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S drives (frame 3) use the internal power supply for fan power and thus no terminals are provided.

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Figure 27 - 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S

PS-

PS+

Cable clamps for

Motor and AC inputs.

Figure 28 - 2099-BM09-S

PS-

PS+

Figure 29 - 2099-BM10-S

PS-

Motor

AC Line

Fan Terminals

Enlarged View

Fan Terminals

Enlarged View

PS+

Motor AC Line

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Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Figure 30 - 2099-BM11-S and 2099-BM12-S

PS-

Kinetix 7000 Connector Data

Chapter 3

Fan Terminals

Enlarged View

PS+

FAN

Motor AC Line

Table 18 - Power Terminal Block

Terminal Description

DC+ DC Bus Power

DC-

PE

GND

U-T1

V-T2

W-T3

R-L1

S-L2

T-L3

120VAC

240VAC

0VAC

PS-

PS+

Main Ground of the Drive System

Motor Ground

Motor Phase U Output

Motor Phase V Output

Motor Phase W Output

Main 380…480V AC +/-10% Input Power, Three-phase to R, S and T Input Terminals R

+120V AC Input for Fan Power

+240V AC Input for Fan Power

Fan Common

For factory use only

For factory use only

Name

DC Bus (+)

DC Bus (-)

PE Ground

Motor Ground

U (T1)

V (T2)

W (T3)

S

T

VAC_FAN_1

VAC_FAN_2

GND_FAN

–

–

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Control Signal Specifications

This section provides specifications for the Kinetix 7000 drive input/output

(IOD), SERCOS, motor feedback (MF), auxiliary feedback (AF) and brake

(BC) connectors.

Digital Inputs (IOD Connector)

Two fast registration inputs and four other inputs are available for the machine interface on the Kinetix 7000 drive. The drive supplies 24V DC @ 300 mA for the purpose of registration, home, enable, over-travel positive, and over-travel negative inputs. These are sinking inputs that require a sourcing device. A 24V

DC power and common connection is provided for each input.

IMPORTANT

To improve registration input EMC performance, see the System Design for

Control of Electrical Noise Reference Manual, publication GMC-RM001 .

IOD Pin Signal

IOD-2

IOD-5

IOD-14

IOD-17

IOD-8

IOD-11

ENABLE

HOME

REG1

REG2

OT+

OT-

Table 19 - Digital Input Descriptions

Description

Single optically isolated, single-ended active high signal. Current loading is nominally 10 mA. A 24V DC input is applied to this terminal to enable each axis.

Capture Time Edge/Level

Sensitive

20 ms Level

Single optically isolated, single-ended active high signal. Current loading is nominally 10 mA. Home switch (normally-open contact) inputs for each axis require 24V DC (nominal).

20 ms Level

Fast registration inputs are required to inform the motor interface to capture the positional information with less than 3

μ s uncertainty. Single optically isolated, singleended active high signal. Current loading is nominally 10mA. A 24V DC input is applied to this terminal to enable each axis.

500 ns

Overtravel detection is available as a dual-input, optically isolated, single-ended active high signal. Current loading is nominally 10 mA per input. The pos/neg limit switch

(normally-closed contact) inputs for each axis require 24V DC (nominal).

20 ms

Edge

Level

Table 20 - Digital Input Specifications

Parameter Description

ON-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an ON-state.

ON-state current Current flow to guarantee an ON-state

OFF-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an OFF-state.

Min

10.8V

3.0 mA

-1.0V

Max Leakage

26.4V

—

10.0 mA

3.0V

—

<1.5 mA

24V I/O Power

IMPORTANT

Signals +24V_PWR and +24V_COM are a 24V DC source that can be used only for the inputs listed below.

The Kinetix 7000 drive provides 24V DC power @ 300 mA total for the

HW_Enable_Pwr, Home_Switch_Pwr, Pos_OverTravel_Pwr,

Neg_OverTravel_Pwr, Reg_1_Pwr, and Reg_2_Pwr inputs on the specific drive.

The supply is protected with an automatically reset fuse. A temperature versus time curve automatically controls closing of the fuse.

A common mode choke filters the registration power connection. An additional common mode choke is provided for the remaining inputs.

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Chapter 3

Hardware Enable

The Hardware Enable input is an optically isolated (500V), single-ended, active high signal. A 24V DC input applied to this pin enables the drive.

The status of this digital input can be monitored in the axis servo drive tag in

RSLogix.

I/O SUPPLY

INPUT

IO_COM

Customer-supplied Input Device

If the Drive Hardware Enable option is selected in Logix, an MSO (Motion

Servo On) instruction must be executed in RSLogix software. This causes IOD-1 to supply 24V DC to IOD-2, and completes the enable circuit for servo loop and drive power structure.

If the Drive Hardware Enable option is not selected in Logix, an MSO instruction will enable the drive without the need for a Drive Enable signal confirmation.

This input is level sensitive. See Table 19 - Digital Input Descriptions and

Table 20 - Digital Input Specifications starting on page 54 for On/Off signal voltages and current levels.

Kinetix 7000 drive Hardware Enable functions and faults actions are programmed through RSLogix software. Kinetix 7000 dive firmware provides an additional 50 ms of debounce.

ATTENTION:

Overvoltage protection is not provided for the Hardware Enable input signal.

It is recommended to use the on-drive power to power the Hardware Enable signal.

If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.

IOD-1

IOD-2

The schematic below depicts the Hardware Enable circuit. It is provided as a reference only.

Figure 31 - Hardware Enable Digital Input Circuit Diagram

+24V DC

(1)

VCC

2k

Ω

0.1

μ

F

511

Ω

IOD-3

1k

Ω

CTRL_INPUT

Kinetix 7000 Drive

(1) +24V DC source (range) = 21.6V…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

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Home

The Home input is an optically isolated (500V), single-ended, active high signal.

A 24V DC input applied to this pin by a normally-open contact indicates this axis is in the home position. Firmware provides an additional 50 ms of debounce.

You can configure the required Home type in the axis servo drive properties in

RSLogix. You can monitor the Home input “on/off ” status in the axis servo drive tag.

I/O SUPPLY

INPUT

IO_COM

Customer-supplied Input Device

IOD-4

IOD-5

This input is level sensitive. See Table 19 - Digital Input Descriptions and

Table 20 - Digital Input Specifications starting on page 54 for On/Off signal voltages and current levels.

ATTENTION:

Overvoltage protection is not provided for the Home input signal.

It is recommended to use the on-drive power to power the Home signal. If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.

The schematic below depicts the Home circuit. It is provided as a reference only.

Figure 32 - Home Digital Input Circuit Diagram

24V DC

(1)

VCC

2k

Ω

0.1

μ

F

511

Ω

IOD-6

1k

Ω

CTRL_INPUT

Kinetix 7000 Drive

(1) +24V DC source (range) = 21.6…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

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Chapter 3

Positive and Negative Overtravel

The Positive and Negative Overtravel detection is provided by two optically isolated (500V), single-ended, normally-closed, active high signals. Breaking the

24V DC input at either pin indicates an overtravel condition.

You can enable hard travel limits on the axis servo drive Limit tab in RSLogix.

Hard travel limits require power to both the positive and negative overtravel inputs. You can monitor the positive and negative overtravel input status in the axis servo drive tag.

Notes:

•

A status of “1” indicates a normally closed input and a drive ready for movement.

•

Hard overtravel limits can only be selected in a linear conversion selection.

This input is level sensitive. See Table 19 - Digital Input Descriptions and

Table 20 - Digital Input Specifications starting on page 54 for On/Off signal voltages and current levels.

IMPORTANT

Overtravel limit input devices must be normally-closed.

Kinetix 7000 drive Positive and Negative Overtravel functions and faults actions are programmed through RSLogix software. Kinetix 7000 drive firmware provides an additional 50ms of debounce.

ATTENTION:

Overvoltage protection is not provided for the Positive and

Negative Overtravel input signal.

It is recommended to use the on drive power to power the Positive and Negative

Overtravel signals. If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.

The schematic below depicts the Positive and Negative Overtravel circuits. It is provided as a reference only.

Figure 33 - Positive and Negative Overtravel Input Diagram

+24V DC

(1)

I/O SUPPLY

INPUT

IOD-7, 10

IOD-8, 9

IO_COM

Customer-supplied Input Device

IOD-9, 12

2k

Ω

Kinetix 7000 Drive

0.1

μ

F

511

Ω

VCC

1k

Ω

Positive Overtravel or

Negative Overtravel

(1) +24V DC source (range) = 21.6…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

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Registration

The two fast Registration inputs are provided on the Kinetix 7000 drive, Reg 1

(IOD-14) and Reg 2 (IOD-17). Unlike the Drive Enable, Home, and Overtravel signals, these inputs are either positive-edge or negative-edge triggered. They are based on the user-defined MAR (Motion Axis Registration) configured using

RSLogix software.

Figure 34 - MAR (Motion Axis Registration) Entry in RSLogix Software

58

The MAR instruction captures position data within a 3 μs uncertainty. The position is directly input to the axis_servo_drive.Registration_Position register in Logix software.

Figure 35 - Logix Position Register Entry

Power for the inputs is supplied by an internally supplied 24V DC supply.

See Table 19 - Digital Input Descriptions and Table 20 - Digital Input

Specifications starting on page 54 for On/Off signal voltages and current levels.

Registration functions and faults actions are programmed through RSLogix software. Kinetix 7000 firmware provides an additional 50 ms of debounce.

ATTENTION:

Overvoltage protection is not provided for the Registration input signal.

It is recommended to use the on drive power to power Registration. If an external power source is used, you must take responsibility to be sure that the voltage/ current does not exceed the rating of the input.

The schematic below depicts the Registration circuits. It is provided as a reference only.

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Kinetix 7000 Connector Data

Chapter 3

Figure 36 - Registration Digital Input Circuit Diagram

I/O SUPPLY

IOD-13, or -16

+24V DC

(1)

INPUT

IOD-14, or -17

3k Ω

0.001

μ

F

511

Ω

IO_COM

IOD-15, or -18

Customer-Supplied

Registration Input Device

Kinetix 7000 Drive

HCPL-0631

(1) +24V DC source (range) = 21.6V…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

VCC

1k

Ω

REG_INPUT

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IOD-20

Analog_Input_1_Ret

IOD-19

Analog_Input_1

IOD-22

Analog_Input_2_Ret

IOD-21

Analog_Input_2

Customer-supplied

Input Device

0.1

μ

F

0.1

μ

F

Kinetix 7000 Drive

Analog Inputs (IOD Connector)

IMPORTANT

RSLogix 5000 software, version 15, does not support analog input utilization.

Two analog inputs are provided, with 14-bit resolution (13 data bits, plus sign).

The analog data streamed to RSLogix by these inputs is useful for managing dynamic machine operations, for example tension transducers in an outer tension control loop.

The input range of these inputs is ±10V, and overvoltage protection is ±12V.

Inputs are updated at the drive every 125 μs. Frequency response of the input is up to 4 kHz, and input impedance is 12 k

Ω

.

Analog inputs are available as a real time attribute and Get System Value (GSV) within RSLogix software.

ATTENTION:

Gain and offset attributes are not provided for the Analog Inputs input signals, and no drive faults are issued.

The schematic below depicts the Analog Input circuits. It is provided as a reference only.

Figure 37 - Analog Input Circuit Diagram

0.1

μ

F

0.1

μ

F

–

+

V+

V–

Sense

Out

Ref

100

Ω

Anlg In 1

–

+

V+

V–

Sense

Out

Ref

100

Ω

Anlg In 2

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Chapter 3

Reading Analog Input Voltage Values

When connecting to the Kinetix 7000 drive via DriveExecutive or DriveExplorer, the input voltage is displayed as a percentage in parameters 691 [AnaInput 1

Value] and 692 [AnaInput 2 Value].

In the example above, analog input 1 displays 69.79%. This value equals 100% of

±10V DC. Therefore the actual value of analog input 1 is 6.98V DC.

When viewed in RSLogix 5000 using a real time attribute on the Drive/Motor tab on the Module Properties dialog, the corresponding bit value displays as in the example below.

Divide the value displayed by 100 to determine the actual voltage on the input.

6978 / 100 = 69.78% or 6.98V DC.

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VDD

SCLK

SDIN

SYNC

LDAC

SDO

CLR

GND

RFSA

IOUT1A

IOUT2A

RFSB

IOUT1B

IOUT2B

VRBFA

VRBFB

–

V+

+

V–

Analog Outputs (IOD Connector)

The two analog outputs (Analog_Out_1 and Analog_Out_2) are strictly for troubleshooting and cannot be used to drive other loads.

The analog outputs provide 12-bit resolution (11 data bits, plus sign) of the gain and filtering parameters within RSLogix software. In this way a data stream can be displayed by a meter or scale as velocity, torque, or following error information.

The ±10V outputs provide positive and negative direction range, with a null setting of 0V. For example, ±10V range, with 0V = 0. The drive update rate for these outputs is 125 μs, and is current limited to 25 mA.

Analog output functions are programmed in RSLogix software using a message instruction. The default pin assignments and the default gain values for the velocity, torque, and following error parameters are listed below.

Signal

Analog_Out_1

Analog_Out_2

Default Pin

IOD-23

IOD-25

Parameter

Velocity

Torque

Gain Value

0.0060

0.1

Analog Output

1V = 1000 rpm

1V = 100% torque

A single pole low pass digital filter is provided for each analog output. The digital filter frequency range is 1…4 kHz.

The schematic depicts the Analog Output circuits. It is provided as a reference only.

Figure 38 - Analog Outputs Circuit Diagram

10 k

Ω

10 k

Ω

3.9

μ

F

0.1

μ

F 0.1

μ

F

4.09 k

Ω

–

+

V+

V–

100 k

Ω

2.2

μ

F

10

k

Ω

10 k

Ω

IOD-23

Analog_Out_1

IOD-24

Analog_Out_1_Ret

10 k

Ω

10 k

Ω

3.9

μ

F

–

V+

+

V–

4.09 k

Ω

–

V+

+

V–

100

k

Ω

2.2

μ

F

10 k

Ω

10 k

Ω

IOD-25

Analog_Out_2

IOD-26

Analog_Out_2_Ret

62

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Chapter 3

4

5

6

2

3

Pin

1

Signal

Digital_Out_1

DO_24VDC_1

DO_24VDC_2

Digital_Out_2

Reserved

Description

General Purpose I/O (GPIO Connector)

Two 24V digital outputs are user programmable. You can monitor the status the an optional regenerative power supply. An isolated, external 24V DC power source must be customer supplied to power the digital outputs.

Table 21 - General Purpose I/O Digital Output Specifications

Optically isolated to 500V, current sourcing up to 75 mA

24V DC power source to digital inputs (customer-supplied)

Optically isolated to 500V, current sourcing up to 75 mA

On Condition

24…40V DC

—

Off Condition Leakage

<0.25 mA

—

24…40V DC <0.25 mA

Dig_Out_1

1 k

Ω

The two DC current sourcing outputs default settings are Zero_Speed

(Digital_Out_1) and In_Position (Digital_Out_2). Zero_Speed is the motor at

0 rpm velocity. In_Position can be set to the commanded position by the Position

Lock Tolerance (set in Axis Properties/Limits). Default parameter selections can also be set with an IDN function.

Figure 39 - General Purpose I/O Digital Output Diagram

DO_24VDC_1

0.1

μ

F

3.32

k

Ω

10

Ω

Digital_Out_1

Dig_Out_2

1 k

Ω

DO_24VDC_2

0.1

μ

F

3.32

k

Ω

10

Ω

Digital_Out_2

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Chapter 3

Kinetix 7000 Connector Data

Pin

7

8

Signal

Regen_OK+

Regen_OK-

Regen_OK+

Regen_OK-

2 k

Ω

The regenerative power supply OK provides status on the regenerative converter; in doing so, provides status to the Kinetix 7000 drive that there is DC bus power.

Selecting the 8720MC-RPSxxx on the Power tab in the Kinetix 7000 drive I/O configuration in RSLogix requires the customer to provide a 24V DC power source to GPIO pins 7 and 8 as shown in

Table 22

and in the interconnect

diagrams in Appendix B. A failure to do so will cause a Regen_PS_OK (E111)

fault, which indicates that he Regen_OK signal is missing at pins 7 and 8 of the

GPIO connector. Kinetix 7000 drive firmware provides an additional 50 ms debounce.

Table 22 - General Purpose I/O Regenerative Power Supply OK Specifications

Description

Optically isolated (500V), single-ended active high signal

On Condition

12…38V DC @

3.3…12 mA

Off Condition

less than 6.6V DC, less than 1.5 mA

Figure 40 - General Purpose I/O Regenerative Power Supply OK Diagram

VCC

0.1

μ

F

511

Ω

Regen_OK

1 k

Ω

General Purpose Relay (GPR Connector)

Two general purpose relay connections are accessed through the GPR connector.

GPR1+ is a normally-open, dry relay contact, supporting 2 A at 30V DC ±10% with suppression. This relay defaults to Motor Brake control, and specifically provides suppression. GPR2+ is a normally-open, dry relay contact, supporting 2

A at 250V AC or 2 A at 30V DC without suppression. This relay defaults to

Drive OK. An external 24V DC power source must be supplied.

The following are default values for the general purpose relays.

Table 23 - General Purpose Relay Outputs Descriptions

Output:

GPR1+

Default Relay Setting in

RSLogix Software

Motor Brake

Description

Turn-on and turn-off delays are specified by the Brake

Engage Delay Time and Brake Release Delay Time in

RSLogix software.

GPR2+ Drive OK (DROK)

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Chapter 3

SERCOS Connections

Two fiber-optic connectors (transmit and receive) are provided on the Kinetix

7000 drive.

Table 24 - SERCOS Communications Specifications

Specification

Data Rates

Node Addresses

Description

4 and 8 Mbps

01…99

(1)

(1) Node addresses for additional axes on the same system are assigned by sequentially incrementing each additional axis. See Node

Addressing Examples on page

108 for more information.

Safe-off (SO Connector)

Kinetix 7000 drives provide safety functions and system integrity.

The Kinetix 7000 drive ships with a (9-pin) wiring-plug header having a motionallowed jumper installed in the safe-off (SO) connector. With the motionallowed jumper installed, the safe-off feature is disabled.

For safe-off wiring information, see the Kinetix Safe-off Feature Safety Reference

Manual, publication GMC-RM002 .

Figure 41 - Safe-Off, Motion-allowed Jumper

Motion-allowed Jumper

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

SO

Safe-off

(SO) Connector

1

1 2

3 4

FDBK2+

FDBK2-

FDBK1+

FDBK1-

5 6

7 8

9

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

SO

Wiring Plug Header

Control Power Specifications

The following table provides specifications for the Control Power (CP) connector.

Attribute

Auxiliary DC input voltage

Value

24V DC, 3 A max, range 18…30 V DC

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Chapter 3

Kinetix 7000 Connector Data

Motor (MF) and Auxiliary

Feedback (AF) Connections

The motor interface and auxiliary feedback interfaces are consistent across the

Kinetix product line. This section provides information on motor and auxiliary feedback connections.

The Kinetix 7000 motor (MF) and auxiliary (AF) feedback ports can accept the following encoder types:

•

SRM/SRS Stegmann Hiperface encoders

•

5V TTL differential line driver with index pulse and hall commutation

•

Sin/Cos differential input with index pulse and hall commutation

Motor feedback requires RSLogix 5000 motion.db file to properly commutate the motor. Motors available in RSLogix software include feedback types designated as S and M in Allen-Bradley catalog numbers. Following are further definitions of these feedback types.

•

S type - single-turn 1024 cycles per rotation (interpolated to over 2 million counts in the drive) For example, the MPL-B980D-SJ72AA has this feedback type.

•

M type - multi-turn 1024 cycles per rotation (interpolated to over 2 million counts in the drive). For example, the MPL-980D-MJ72AA has this feedback type. The “M” type allows for 4096 cycles absolute retention when the encoder is powered down.

RDD motor feedback from Heidenhain EnDat high-resolution encoders is also accepted, but only when using drive firmware revision 1.104 or higher and the

2090-K7CK-KENDAT low-profile feedback module.

Third-party motor requests must be pre-qualified and a custom motor file developed. Contact your local distributor or Rockwell Automation Sale

Representative for more information.

Kinetix 7000 drives cannot drive open loop (no feedback) or other motor types not defined in the Kinetix motor database.

Motor and Auxiliary Feedback Specifications

AM, BM, and IM input encoder signals are filtered using analog and digital filtering. The inputs also include illegal state change detection.

Figure 42 is a

schematic of the AM, BM, and IM inputs.

66

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

+

-

1k

Ω

Drive

Kinetix 7000 Connector Data

Chapter 3

Figure 42 - AM, BM, and IM Motor Encoder Inputs

1k

Ω

+5 V

10k

Ω

56 pF

+

1k

Ω

1k

Ω

1k

Ω

56 pF

100 pF

10k

Ω

1k

Ω

56 pF

1k

Ω

56 pF

-

10k

Ω

100 pF

Drive

AM and BM Channel Inputs

Table 25 - Motor Encoder Feedback Specifications

10k

Ω

1k

Ω

1k

Ω

Attribute

Encoder Types

Maximum Input Frequency

Commutation Feedback

Value

Incremental, A quad B, Sine/Cosine, Intelligent, and Absolute

5.0 MHz (TTL input) per channel

250 kHz (Sine/Cosine input)

Hall sensor

Table 26

provides a description of the AM, BM, and IM inputs for TTL encoders.

Table 26 - TTL Encoder Specifications

Parameter

AM, BM, and IM

ON-state

Input Voltage

AM, BM, and IM

OFF-state

Input Voltage

Common Mode

Input Voltage

DC Current Draw

AM, BM Input

Signal Frequency

Description

Input voltage difference between the + input and the - input that is detected as an ON-state.

Minimum

+1.0V

Input voltage difference between the + input and the - input that is detected as an OFF-state.

-1.0V

Potential difference between any encoder signal and logic ground.

Current draw into the + or - input.

-7.0V

Frequency of the AM or BM signal inputs. The count frequency is 4 times this frequency, since the circuitry counts all four transitions.

-30 mA

—

56 pF

56 pF

IM Channel Input

Maximum

+7.0V

-7.0V

+12.0V

30 mA

5.0 MHz

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68

Parameter

IM Pulse Width

AM, BM Phase Error

2.5 MHz Line

Frequency

AM, BM Phase Error

1 MHz Line

Frequency

Description

Pulse width of the index input signal. Since the index is active for a percentage of a revolution, the speed will determine the pulse width.

Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.

Minimum

125 nS

-22.5°

Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.

-45°

Maximum

—

+22.5°

+45°

The table provides a description of the AM and BM inputs for Sine/Cosine encoders.

Table 27 - AM, BM and IM Input Specifications for Sine/Cosine Encoders

Parameter

Sine/cosine

Input Signal

Frequency

Sine/cosine

Input Voltage

Description

Frequency of the Sine or Cosine signal inputs.

Peak-to-peak input voltages of the Sine or Cosine inputs.

Table 28 - Specifications for Heidenhain EnDat Encoders

Command Set

EnDat 2.1

Order

Designation

EnDat 01

Description

1V (p-p) Sin/Cos, <2 MHz clock frequency

Minimum

—

0.5V (p-p)

Maximum

250 kHz

2.0V (p-p)

Auxiliary Feedback (AF)

These requirements apply to the Auxiliary Feedback signals.

•

For TTL devices, the position count increases when A leads B.

•

For sinusoidal devices, the position count increases when cosine leads sine.

•

TTL devices must be 5V devices within the input voltage specification.

•

Use the Low Profile Connector Kit, catalog number 2090-K6CK-D15F to access the Auxiliary Feedback signals. You must supply cabling that has shielding, and other EMI protection for motor feedback cables.

Feedback Power Supply

The power circuit board generates the +5V and +9V DC for the motor and auxiliary feedback power supplies. Short-circuit protection and separate common mode filtering for each channel is included.

•

MP

x

-B, and HPK-B and -E motors all use 9V power sources from the MF connector.

•

Compatible Auxiliary Feedback devices include Stegmann Hiperface,

Sine/Cosine, and 5V TTL encoder types. Note: Heidenhain EnDat 2.1 encoders are only compatible when using the 2090-K7CK-KENDAT feedback module, however an interface module does not exist for the auxiliary encoder input.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Kinetix 7000 Connector Data

Chapter 3

•

See the Kinetix Motion Control Selection Guide, publication GMC-

SG001 , for cables compatible with the Kinetix 7000 drive and motor.

•

Low profile connector let you develop a custom cable for the Motor

Feedback (MF) or Auxiliary Feedback (AF) connectors.

The following table details power supply specifications for the motor and auxiliary feedback connectors.

Table 29 - Motor and Auxiliary Feedback Power Supply Specifications

Power

Supply

Signal Name Voltage (V DC) Current (mA)

(1) 400 mA on the 5V supply split in any manner between the channels with no load on the 5V supply.

(2) 275 mA on the 9V supply split in any manner between the channels with no load on the 9V supply.

(3) 300 mA on the 5V supply on one channel with 150 mA on the 9V supply on the second channel.

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Chapter 3

Kinetix 7000 Connector Data

Notes:

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Chapter

4

This chapter provides procedures for wiring your Kinetix 7000 drive system components and making cable connections.

Topic

Basic Wiring Requirements

Determine the Input Power Configuration

Setting the Ground Jumper in Ungrounded Power Configurations

Grounding the Kinetix 7000 Drive System

Input Power Wiring Requirements

Power Wiring Guidelines

Wire the Kinetix 7000 Drive Connectors

Feedback and I/O Cable Connections

Wire Feedback and I/O Connectors

External Shunt Module Connections

SERCOS Fiber-optic Cable Connections

88

88

81

85

75

78

Page

71

93

95

101

101

Basic Wiring Requirements

This section contains basic wiring information for the Kinetix 7000 drive.

ATTENTION:

Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, that can result in damage to components.

IMPORTANT

SHOCK HAZARD:

To avoid hazard of electrical shock, perform all mounting and wiring prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.

This section contains common PWM servo system wiring configurations, size, and practices that can be used in a majority of applications. National

Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.

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Building Your Own Motor Cables

IMPORTANT

Factory-made cables are designed to minimize EMI and are recommended over hand-built cables to optimize system performance.

•

Connect the cable shield to the connector shells on both ends of the cable with a complete 360° connection. If separate power wires are used in a customer-supplied power cable, the shield may alternatively be connected to a ground terminal.

•

Use a twisted pair cable whenever possible. Twist differential signals with each other and twist single-ended signals with the appropriate ground return.

•

Discrete power cables require 360° shielding. Connect the shield to a ground terminal.

See the Kinetix Motion Control Selection Guide, publication GMC-SG001 , for low-profile connector kit, drive-end (mating) connector kit, and motor-end connector kit catalog numbers.

Shielded Motor Cable

The use of a four-wire type Variable Frequency Drive (VFD), 600 volt, UL listed cable is strongly recommended for all motor currents at or below 130 Amperes.

The illustration below illustrates the type of cable required.

Figure 43 - Type of Cable Required for Kinetix 7000 Drive Interconnects

Stranded Drain Wire

Foil Shield

Cable Jacket

Tinned Copper Braid with 85% Coverage

Stranded Tinned Copper

Conductors

Oversized Insulation

Required Cable Types

You should always use shielded motor cable. The shield must connect to the drive chassis (PE) connection and the motor frame. Make the connection at both ends to minimize the external magnetic field. If you use cable trays or large conduits to distribute the motor leads for multiple drives, use shielded cable to reduce noise from the motor leads.

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Chapter 4

55 A

65 A

95 A

130 A

12 A

17 A

21 A

30 A

Cable Sizes

In the table below the appropriate VFD shielded cable to use based on 150% overload capability and 25 °C (77 °F) operating temperature is shown.

For applications above 130 Amps, use thick insulation lead wire, such as RHW-2 or equal. Make sure you thread the four wires (U, V, W, and ground) through a single, grounded, metal conduit.

Table 30 - 1.5x Rated Continuous Motor Current Cable Size

Motor Current

10

16

4

6

mm

2

Cable Size

AWG

1.5

2.5

16

14

25

35

4

2

8

6

12

10

Conduit

For applications above 130 Amperes, metal conduit is required for cable distribution. Follow these guidelines:

•

Drives are normally mounted in cabinets, and ground connections are made at a common ground point in the cabinet. If the conduit is connected to the motor junction box and the drive end is connected to the ground panel in the cabinet, you do not need any additional conduit connections.

•

Route no more than three sets of motor leads and a ground wire through a single conduit. This minimizes cross talk that also reduces the effectiveness of the noise reduction methods described. If more than three drive/motor connections per conduit are required, use shielded cable. If practical, each conduit should contain only one set of motor leads.

•

You should use a thick insulation lead wire, such as type RHW-2 or equal.

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Chapter 4

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General Wire Guidelines

Observe all applicable safety and national and local regulations when selecting the appropriate wire size for your system. Due to the drive overload capacity of

150% of the continuous current rating, the conductors for the transformer primary and secondary must be sized (at a minimum) for 125…160% of the maximum continuous input current for the motor selected. The motor conductors must also be rated for a minimum of 125…160% of the full load motor continuous current. If less than 150% overload is required the torque limit parameters must be set in the drive accordingly. The distance between the drive and motor may affect the size of the conductors used. To protect against interference, use shielded wire in motor and control circuits. A shielded cable is required for all feedback signal wires.

ATTENTION:

To avoid a possible shock hazard caused by induced voltages, ground unused wires in the conduit at both ends.

For the same reason, if a drive sharing a conduit is being serviced or installed, disable all drives using this conduit. This removes the possible shock hazard from cross-coupled drive motor leads.

Routing the Power and Signal Cables

Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic drives can be induced into motor or encoder feedback signals, input/output communications, or other sensitive low voltage signals. This can cause system faults and communication problems.

See Minimizing Electrical Noise on page 28 for examples of routing high and low

voltage cables in wireways, and to the System Design for Control of Electrical

Noise Reference Manual, publication GMC-RM001 , for more information.

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Chapter 4

Determine the Input Power

Configuration

Before wiring input power to your Kinetix 7000 drive system you must determine the type of input power to which you are connecting. The Kinetix 7000 drive is configured at the factory to operate in a grounded power environment.

ATTENTION:

When using a LIM with your Kinetix 7000 drive, the AC line input power must come from a grounded configuration.

When not using a LIM with your Kinetix 7000 drive, ungrounded configurations are acceptable, but you must set the jumper to prevent high electrostatic build-up.

See Setting the Ground Jumper in Ungrounded Power Configurations on page 78

for additional information.

Grounded Power Configurations

Grounded (WYE) power wiring lets you ground your three-phase power at a neutral point.

Figure 44 - Grounded Three-phase Power Wiring - WYE Secondary (Recommended)

2099-BM08-S shown with

Lower Front Panel Removed

Three-phase

Input VAC

Phase Ground

Transformer (WYE) Secondary

Transformer

L1

L2

L3

Bonded Cabinet

Ground

Ground Grid or

Power Distribution Ground

Line

Filter

To Ground Stud

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Chapter 4

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This is an example of a grounded B-phase (delta secondary).

Figure 45 - Grounded B-phase Power Wiring - Delta Secondary

2099-BM08-S Shown with Lower

Front Panel Removed

Transformer (Delta) Secondary

Transformer

L1

L2

L3

Bonded Cabinet

Ground

Ground Grid or

Power Distribution Ground

Line Filter

To Ground Stud

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Chapter 4

Power Distribution Systems Without a Ground Reference

Kinetix 7000 drives contain protective MOVs and Common Mode Capacitors that are referenced to ground. To guard against unstable operation and/or drive damage, these devices must be disconnected if the drive is installed on an ungrounded, impedance grounded, high resistive grounded, B phase grounded, or common DC bus power distribution system.

ATTENTION:

Disconnect the protective MOVs and capacitors if the drive is installed on a high resistive grounded or ungrounded system where the line-toground voltages on any phase exceed 125% of the nominal line-to-voltage.

Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground.

A Kinetix 7000 drive application using a common DC bus is considered an ungrounded power distribution system.

Figure 46 - Ungrounded Power Wiring

2099-BM08-S Shown with Lower

Front Panel Removed

Three-Phase Input

VAC

Ground

Conduit/4-Wire Cable

L1

L2

L3

Bonded Cabinet

Ground

Ground Grid or Power

Distribution Ground

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 to Ground Stud

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Chapter 4

Connect the Kinetix 7000 Drive System

Setting the Ground Jumper in Ungrounded Power

Configurations

To disconnect the ground reference for Kinetix 7000 drives in an ungrounded, impedance grounded, high-resistive grounded, B-phase grounded, or common

DC bus power distribution system, remove the jumpers or wires as instructed in the following table.

ATTENTION:

Kinetix 7000 drives contain protective metal oxide varistors

(MOVs) and common mode capacitors that are referenced to ground. In a grounded power distribution system, these devices assist in isolating the drive from electromagnetic interference (EMI).

These devices must be disconnected if the drive is installed in an ungrounded, unbalanced, impedance grounded, or common DC bus power distribution system.

ATTENTION:

To avoid an electrical shock, verify that the voltage on the bus capacitors has discharged before removing or installing jumpers.

Measure the DC bus voltage at the DC+ and DC- terminals on the power terminals.

The voltage must be zero.

Drive

2099-BM06-S, 2099-BM07-S and

2099-BM08-S

Jumper/Wire ID No.

Component

PEA Common mode capacitor

1

PEB

Table 31 - Jumper/Wire Location and Removal Instructions

Location

Remove the two jumpers located above the power terminal block. See

Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and 2099-

BM08-S Drives on page 79

.

2

MOVs

2099-BM09-S and

2099-BM10-S

2099-BM11-S and

2099-BM12-S

Green/yellow wire

Green/yellow wire

3

4

5

6

Common mode capacitor

MOVs/input filter cap

Common mode capacitor

MOVs

Remove DC-DC converter and drive top cover, and disconnect the green/ yellow wire from the drive chassis. Insulate and secure the wire to prevent

unintentional contact with the chassis or components. See Removing the

Ground Wires on 2099-BM09-S and 2099-BM10-S Drives on page 80

.

Disconnect the green/yellow wire next to the power terminal block. Insulate and secure the wire to prevent unintentional contact with the chassis or components. See

Removing the Ground Wires on 2099-BM09-S and 2099-

BM10-S Drives on page 80

.

Disconnect the two green/yellow wires from the PE terminals on the power terminal block. Insulate and secure each of these wires to prevent

unintentional contact with the chassis or components. See Removing the

Ground Wires on 2099-BM11-S and 2099-BM12-S Drives on page 80

.

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Chapter 4

Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and

2099-BM08-S Drives

Figure 47 shows the location of the jumpers in 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S drives on the power chassis. The common mode capacitor jumper is indicated by callout 1 (PEA) and the MOV jumper is indicated by callout 2 (PEB).

Remove each jumper by carefully pulling it straight out.

Figure 47 - Ground Jumper Location on 2099-BM06-S, 2099-BM07-S, and

2099-BM08-S

2

1

MOV

PE B

CM Cap

PE A

PE B

PE A

WIRE

STRIP

BR1 BR2

75C Cu Wire

6 AWG [10MM2] Max.

12 IN. LBS.

1.4 N-M

} TORQUE

3 AWG [25MM ] Max.

16 IN. LBS.

1.8 N-M

} TORQUE

AUX IN

+ –

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3

PE

SHLD

SHLD

Important:

Do not discard or replace the grounding hardware.

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Chapter 4

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Removing the Ground Wires on 2099-BM09-S and 2099-BM10-S

Drives

Figure 48 shows the locations of the common mode capacitor and MOV/input filter capacitor ground wires in 2099-BM09-S and 2099-BM10-S drives. The common mode capacitor ground wire is indicated by callout 3 and the MOV/ input filter cap ground wire is indicated by callout 4.

Figure 48 - Ground Wire Locations on Terminal Block of 2099-BM09-S and 2099-BM10-S

3

CM Cap -

Newer Drives

3

CM Cap -

Older Drives

Optional

Communications

Module

Note: You must remove the DC-DC converter and drive top cover to access and remove the common mode capacitor ground wire. See the Kinetix

7000 DC-DC Converter and Control Board

Kits Installation instructions, publication

2099-IN002 , for instructions.

POWER TERMINAL RATINGS

WIRE RANGE: 14-1/0 AWG (2.5-35 MM 2

TORQUE: 32 IN-LB (3.6 N-M)

)

STRIP LENGTH: 0.67 IN (17 MM)

USE 75 C CU WIRE ONLY

GROUND TERMINAL RATINGS (PE)

WIRE RANGE: 6-1/0 AWG (16-35 MM

2

TORQUE: 44 IN-LB (5 N-M)

)

STRIP LENGTH: 0.83 IN (21 MM)

17

21

OUTPUT

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM 2 )

TORQUE: 5.3 IN-LB (0.6 N-M)

STRIP LENGTH: 0.35 IN (9 MM)

9

INPUT AC

4 MOV

MOV/Input

Filter Cap

4

Removing the Ground Wires on 2099-BM11-S and 2099-BM12-S

Drives

Figure 49 shows the locations of the common mode capacitor and MOV ground wires in 2099-BM11-S and 2099-BM12-S drives. The common mode capacitor ground wire is indicated by callout 5 and the MOV ground wire is indicated by callout 6.

Figure 49 - Ground Wire Location on Power Terminal Block of 2099-BM11-S and 2099-BM12-S

DO NOT REMOVE

5

CM Cap

U

T1

V

T2

OUTPUT

MOV

W

T3

PE PE R

L1

S

L2

INPUT

T

L3

6

PE PE

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Chapter 4

Grounding the Kinetix 7000

Drive System

All equipment and components of a machine or process system must have a common earth ground point connected to their chassis.

A grounded system provides a ground path for short-circuit protection.

Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short-circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.

See Agency Compliance on page 18 for CE grounding requirements.

IMPORTANT

To improve the bond between the drive and subpanel, construct your subpanel out of zinc-plated (paint-free) steel.

Grounding Your System to the Subpanel

In Figure 50

, the drive is shown properly grounded to the bonded cabinet ground on the subpanel.

ATTENTION:

The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system.

See the Interconnect Diagram Notes diagrams beginning on page 162 .

Figure 50 - Drive Chassis Ground Connection

Bonded Cabinet Ground *

Kinetix 7000

Drive

Braided Ground Strap *

Ground grid or power distribution ground *

* Indicates customer-supplied item.

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Grounding Multiple Subpanels

To extend the chassis ground to multiple subpanels, see

Figure 51 .

IMPORTANT

HF bonding is not illustrated. For HF bonding information, see Bonding

Multiple Subpanels on page 30

.

Figure 51 - Subpanels Connected to a Single Ground Point

Always follow NEC and applicable local codes

Bonded Ground Bus

Ground grid or power distribution ground

Motor Power Cable Shield Termination

Factory-supplied motor power cables for MP-series motors are shielded, and the braided cable shield must terminate at the drive when installed. A small portion of the cable jacket must be removed to expose the shield braid. The exposed area must be clamped (using the clamp provided on the 2099-BM06-S, -BM07-S and

-BM08-S drives) to the drive to provide a 360° termination. Factory-supplied power cables must also be terminated in the motor power (MP) connector plug.

ATTENTION:

To avoid hazard of electrical shock, be sure the shielded power cables are grounded at a minimum of one point for safety.

Customer-supplied power cables must be shielded, and the braided cable shield or conduit must terminate at the drive when installed. An area of the power cable shield must be exposed and terminated for 360° at the drive. In a similar manner, conduit enclosing discrete power cables must be terminated for 360° at the drive.

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Chapter 4

Figure 52 - Power Cable Shielding Techniques Recommended for Kinetix 7000 Drives

Conduit or Cable Braid Clamped at Drive Frame Provides 360° Shield Termination.

Clamp Also Connects to the Nearest Available Bonded Cabinet Ground.

Drive

Enclosure

Wire Restraint

Enclosure Clamp Terminates

360° Shield at Enclosure

(1)(2)

Conduit in Contact with Clamp

Cable Shield Under

Clamp

Metallic Conduit with Wires

Cable with Braided Shield

1) For examples of shield clamp attachment, see the System Design for Control of Electrical Noise Reference Manual, publication

GMC-RM001 .

2) If enclosure is painted, remove paint to provide metal-to-metal contact.

Junction Box Beneath

Drive

(2099-BM10-S,

2099-BM11-S, and

2099-BM12-S Only)

Three-phase Power with

Ground

MP-Series (Bulletin MPL) Motor Connectors

Bayonet Connectors with Brake

Bulletin MPL motors equipped with circular DIN connectors (specified by 7 in the catalog number) are not compatible with cables designed for motors equipped with bayonet connectors (specified by 2 in the catalog number). The motors with bayonet connectors are being discontinued.

Bayonet connectors can be mounted facing the motor shaft or end plate and provide a separate connector for power, feedback, and brake connections.

Circular DIN connectors rotate up to 180° and combine power and brake wires in the same connector, eliminating the brake connector.

Figure 53 - Bayonet and Circular DIN Motor Connectors

Bayonet Connectors without Brake

Circular DIN Connectors

Feedback / Power / Brake

Motor Connectors

Feedback / Power

Motor Connectors Power and Brake

Motor Connector

Feedback Motor

Connector

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Table 32 - Motor Power Cable Compatibility

Motor/Actuator

MP-Series (Bulletin MPL)

Connector

Circular DIN

Motor/Actuator Cat. No.

MPL-B5

MPL-B9

xxx xxx

, MPL-B6

xxx

, MPL-B8

xxx,

and

Motor Power Cables

(with brake wires)

2090-CPBM7DF-

xx

AA

xx

or

2090-XXNPMF-

xx

S

xx

(standard, non-flex)

2090-CPBM7DF-

xx

AF

xx

(1)

(continuous-flex)

N/A

Motor Power Cables

(without brake wires)

2090-CPWM7DF-

xx

(standard, non-flex)

AA

xx

2090-CPWM7DF-

xx

AF

xx

(1)

(continuous-flex)

MP-Series (Bulletin MPM)

Bayonet

Circular DIN

MPL-A/B5

xxx

, MPL-B6

xxx

, and

MPL-B8

xxx

MPL-B960B, MPL-B960C,

MPL-B980B, and MPL-B980C

MPL-B960D and MPL-B980D

MPM-B165 and MPM-B215 2090-CPBM7DF-

xx

AA

xx

or

2090-XXNPMF-

xx

S

xx

(standard, non-flex)

2090-CPBM7DF-

xx

AF

xx

(1)

(continuous-flex)

N/A

2090-XX

x

PMP-

xx

2090-CPWM7DF-

S

xx

2090-MCNPMP-6S

xx xx

(standard, non-flex)

(2)

AA

xx

2090-CPWM7DF-

xx

AF

xx

(1)

(continuous-flex)

RDD-Series Circular DIN RDB-B

xxxx

2090-CPWM7DF-

xx

AA

xx

(standard, non-flex)

2090-CPWM7DF-

xx

AF

xx

(1)

(continuous-flex)

HPK-Series N/A HPK-B

xxxxx,

HPK-E

xxxxx

Customer-supplied

(1) You must remove the motor-side o-ring when using 2090-CP

x

M7DF-

xx

A

xxx

cables.

(2) For Bulletin MPL motors equipped with bayonet connectors. These cables are available as standard, non-flex (catalog number 2090-XXNPMP-xxSxx) and continuous-flex (catalog number 2090-XXTPMPxxSxx).

Motors may have a separate brake connector or need routing of thermal switch wires. These are often separately shielded and routed in an existing cable.

See Wiring Examples beginning on page

162

for interconnect diagrams, and the

Power Terminal Block (PTB) Connections diagram on page 51

for the location of the U, V, W, and ground (PE) motor power terminals.

IMPORTANT

Securing the cable shield in the clamp with a tie wrap is recommended to improve stress relief.

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Requirements

Connect the Kinetix 7000 Drive System

Chapter 4

National codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices.

ATTENTION:

To avoid personal injury and/or equipment damage, make sure installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code

(NEC) and local codes outline provisions for safely installing electrical equipment.

To avoid personal injury and/or equipment damage, make sure motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.

To avoid personal injury and/or equipment damage, make sure shielded power cables are grounded to prevent potentially high voltages on the shield.

Acceptable Cable Types

Do not use cable with an insulation thickness less than or equal to 15 mils (0.4 mm/0.015 in.). Use copper wire only. Wire gauge requirements and recommendations are based on 75

°

C. Do not reduce wire gauge when using higher temperature wire.

As an approximate guide, provide spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communications and networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks.

Consideration should be given to the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least

75%. An additional foil shield can greatly improve noise containment.

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A good example of recommended cable is Belden/E 295

xx

(

xx

determines gauge). This cable has four XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a

PVC jacket.

Other types of shielded cable are available, but the selection of these types may limit the allowable. Particularly, some of the newer cables twist four conductors of THHN wire and wrap them tightly with a foil shield. This construction increases the cable charging current required and reduces the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.

The table below describes the recommended shielded cables.

Table 33 - Shielded Cable Ratings and Types

Location

Standard

(Option 1)

Standard

(Option 2)

Class I & II;

Division 1 & II

Rating/Type

600V, 90 °C (194 °F),

XHHW2/RHW-2

Anixter B209500-B209507,

Belden B29501-B229507, or equivalent

600V, 90 °C (194 °F),

RHH/RHW-2

Anixter OLF-7

xxxxx

, or equivalent

Tray rated 600V, 90 ° C (194 ° F),

XHHW2/RHW-2

Anixter 7V-7

xxxxx

-3g, or equivalent

Description

•

Four tinned copper conductors with XLPE insulation

•

Copper braid/aluminum foil combination shield and tinned copper drain wire

•

PVC jacket

•

Three tinned copper conductors with XLPE insulation

•

5 mil single helical copper tape (25% overlap minimum) with three bare copper grounds in contact with shield

•

PVC jacket

•

Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor

•

Black sunlight resistant PVC jacket overall

•

Three copper grounds on 5 mm

2

(10 AWG) and smaller

Contactors

A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed four cycles per minute maximum, or damage will occur to the drive precharge circuit.

The start/stop/enable control circuitry for the drive includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional stop circuitry may be required to remove the AC line to the drive. An auxiliary braking method also may be required.

IMPORTANT

It is recommended that the drive safe-off function be used to minimize contactor cycling.

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Chapter 4

Power Wire Specifications

Wire should be copper with 75 °C (167 °F) minimum rating. Phasing of main

AC power is arbitrary and earth ground connection is required for safe and proper operation.

For additional information see Power Specifications on page 150 , and

Interconnect Diagram Notes on page 162

for interconnect diagrams.

ATTENTION:

This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures.

See publication 8000-4.5.2

, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook.

ATTENTION:

To avoid personal injury and/or equipment damage, be sure the installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code

(NEC) and local codes outline provisions for safely installing electrical equipment

To avoid personal injury and/or equipment damage, be sure the motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.

To avoid personal injury and/or equipment damage, be sure the shielded power cables are grounded to prevent potentially high voltages on the shield.

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Power Wiring Guidelines

Use these guidelines when wiring the power connectors on your Kinetix 7000 drive (without a LIM).

IMPORTANT

To achieve system performance, run wires and cables in the wireways as established in

Chapter 1

.

IMPORTANT

To limit coil switching transients generated by the LINE contactor, use of a surge suppressor is recommended. For an example, see

Appendix B

.

This procedure assumes you have separate power supply/line filter components mounted on your panel and are ready to wire the AC input power to the drive.

1.

Prepare the wires for attachment to each connector by removing insulation equal to an acceptable strip length.

The actual strip length will vary based on the wire gauge and terminal size of the Kinetix 7000 drive.

2.

Route the wires to your Kinetix 7000 drive.

3.

Insert the wires into the connector or connect the wires to the terminals.

4.

Tighten the terminal screws/nuts to the recommended torque for the specific terminal.

5.

Pull on each wire to make sure it does not come out of its terminal. If any wires are loose, reinsert/connect and tighten the wire to the recommended torque.

Wire the Kinetix 7000 Drive

Connectors

See

Appendix B

for all Kinetix 7000 drive interconnect diagrams.

Wire the Control Power (CP) Connector

Wire the 24V DC control power supply to your Kinetix 7000 drive as described

in Table 34

. See Control Power (CP) Terminal Block Connections for more

information.

Table 34 - Control Power Connections

Signal

CP_24VDC

CP_COM

Terminal

1

2

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm

2

(in.)

7.0 (0.275)

Torque

N

• m (lb

• in)

0.235 (2.0)

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Chapter 4

Wire AC Input Power

Wire 460V AC input power to your Kinetix 7000 drive as described in

Table 35 .

See Power Terminal Block (PTB) Connections for more information.

Table 35 - AC Input Power Connections

Kinetix 7000

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Signal

L1

L2

L3

Ground

L1

L2

L3

Ground

L1

L2

L3

Ground

L1

L2

L3

Ground

Terminal

R

S

T

PE

R

S

T

R

S

T

PE

PE

R

S

T

PE

Recommended Wire Size mm

2

(AWG)

25…2.5 (3…14)

50…4 (1/0…12)

50…4 (1/0…12)

70…10 (2/0…8)

50…4 (1/0…12)

100…10 (4/0…8)

50…4 (1/0…12)

Torque

N

• m (lb

• in)

1.8 (16)

3.6 (32)

5 (44)

15 (133)

5 (44)

12 (104)

5 (44)

Wire DC Input Power (Common Bus Configurations Only)

Wire the DC input power from a leader regenerative power supply (8720MC-

RPS) to a Kinetix 7000 drive as described in Table 36

. See Power Terminal Block

(PTB) Connections on page 51 for more information.

IMPORTANT

DC power from the regenerative power supply (8720MC-RPS) is typically routed to a power distribution box. Fusing will be placed before and after the distribution box, providing protection for both the 8720MC-RPS and

Kinetix 7000 drive.

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Table 36 - DC Input Power Connections

Kinetix 7000

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

DC+

DC-

DC+

DC-

DC+

DC-

Signal Description

DC+

DC-

Terminal(s) Recommended Wire Size mm

2

(AWG)

DC+

DC25…2.5 (3…14)

DC+

DC-

DC+

DC-

DC+

DC-

50…4 (1/0…12)

70…10 (2/0…8)

100…10 (4/0…8)

Torque

N

• m (lb

• in)

1.8 (16)

3.6 (32)

15 (133)

12 (104)

Wire the Safe-off (SO) Connector

Wire the Safe-off connections to your Kinetix 7000 drive as described in

Table 37

. See Safe-off (SO) Terminal Block Connections for more information.

IMPORTANT

Terminals 8 and 9 (24V+ and Common) are only used by the motionallowed jumper. When using the Safe-off feature, the 24V supply must come from an external source.

Table 37 - Safe-off Connections

Signal

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

Terminal

7

8

5

6

9

3

4

1

2

Recommended Wire Size mm

2

(AWG)

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm

2

(in.)

Torque

N

• m (lb

• in)

7.0 (0.275) 0.235 (2.0)

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Chapter 4

Wire the General Purpose Relay (GPR) and General Purpose I/O (GPIO)

Connectors

Wire the control and interface signals on the General Purpose Relay (GPR) and

General Purpose I/O (GPIO) connectors as described in

Table 38 and Table 39 .

See General Purpose I/O (GPIO) Terminal Block Connections on page 46 and

General Purpose Relay (GPR) Terminal Block Connections on page 46

for more information.

ATTENTION:

Wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your safety control string.

In common bus configurations, a REGEN connection on the General Purpose Input/

Output connector is also required for the drives. This connection must be wired in series to the safety control string, and also wired from the 8720MC-RPS to the

Kinetix 7000 drive to indicate bus voltage is present.

Signal

DRIVE OK+

DRIVE OK-

5

6

Terminal Description

Table 38 - General Purpose Relay Connections

Recommended Wire Size mm

2

(AWG)

Programmable N.O. Relay 2 output

Programmable Relay 2 common

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Signal

Regen_OK+ 7

Regen_OK8

Terminal Description

Table 39 - General Purpose I/O Connections

Recommended Wire Size mm

2

(AWG)

Regenerative power supply status

Regenerative power supply status common

0.75 (18)

(stranded wire with ferrule)

1.5 (16)

(solid wire)

Strip Length mm (in.)

7.0 (0.275)

Strip Length mm (in.)

7.0 (0.275)

Torque Value

N•m (lb•in)

0.235 (2.0)

Torque Value

N•m (lb•in)

0.235 (2.0)

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Wire Motor Output Power

Wire motor output power as described in

Table 40

. See Power Terminal Block

(PTB) Connections on page 51 for more information.

Table 40 - HPK-Series and MP-Series Servo Motor Power Connections

Kinetix 7000

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Signal

U / Brown

V / Black w / Blue

Green/Yellow

U / Brown

V / Black w / Blue

Green/Yellow

U / Brown

V / Black w / Blue

Green/Yellow

U / Brown

V / Black w / Blue

Green/Yellow

U

V

W

Terminal

U

V

W

U

V

W

U

V

W

Recommended Wire Size mm

2

(AWG)

25…2.5 (3…14)

50…4 (1/0…12)

50…4 (1/0…12)

70…10 (2/0…8)

50…4 (1/0…12)

100…10 (4/0…8)

50…4 (1/0…12)

Torque

N

• m (lb

• in)

1.8 (16)

3.6 (32)

5 (44)

15 (133)

5 (44)

12 (104)

5 (44)

Wire the Motor Brake

Wire the motor brake (if applicable) as described in

Table 41

. See Power

Terminal Block (PTB) Connections on page 51 for more information on the

motor power connections.

IMPORTANT

Use surge suppression when controlling a brake coil.

See Figure 81 on page 172 .

Table 41 - Motor Brake Connections

Motor Brake Terminal (Signal)

Bulletin MPL w/Bayonet Connector

Bulletin MP

x

w/Circular DIN Connector

A (BR+)

C (BR-)

F (BR+)

G (BR-)

Drive Terminal

(Signal)

2 (GPR1+)

3 (GPR1-)

Recommended Wire Size mm

2

(AWG)

2.5 (14)

Strip Length mm (in.)

10 (0.38)

Torque Value

N•m (lb•in)

0.5…0.6

(4.4…5.3)

Notes: HPK-Series motor brake terminations are BR+ and BR-. RDD-Series motors do not have a motor brake.

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Chapter 4

Feedback and I/O Cable

Connections

Motor brake wiring varies slightly, depending on the motor connector type. The table below identifies the brake wire option for your servo motor and the appropriate brake cable or connector kit catalog number required.

Motor Series Connector

Type

Bulletin MPL

Bayonet The motor has a separate brake connector and requires a brake power cable.

Bulletin MPM Circular DIN The brake terminals are in the motor power connector. Drive to motor power cables must be ordered with the brake option.

HPK-Series

Circular DIN

N/A

Brake Wire Option

The brake terminals are in the motor power connector. Drive to motor power cables must be ordered with the brake option.

The motor has a separate brake wiring connection.

Cable Cat. No.

2090-CPBM7DF-

xx

AA

xx

(1)

2090-XXNPMF-

xx

S

xx

(standard, non-flex)

2090-CPBM

x

DF-

xx

AF

xx

(1)

(continuous-flex)

2090-UX

x

BMP-18S

xx

brake cable

(2)

2090-CPBM7DF-

2090-XXNPMF-

xx

S

xx

(standard, non-flex)

(continuous-flex)

xx

Customer-supplied

AA

xx

(1)

2090-CPBM

x

DF-

xx

AF

xx

(1)

(1) You must remove the motor-side o-ring when using 2090-CP

x

M7DF-

xx

A

xxx

cables.

(2) For Bulletin MPL motors equipped with bayonet connectors. These cables are available as standard, non-flex (catalog number 2090-

UXNBMP-18Sxx) and continuous-flex (catalog number 2090-UXTBMP-18Sxx).

Factory-made cables with premolded connectors are designed to minimize EMI and are recommended over hand-built cables to improve system performance.

However, other options are available for building your own feedback and I/O cables.

Table 42 - Motor Feedback Cable Compatibility - Bayonet Connectors

Motor/Actuator

MPL-B

xxxx

-S

Connector

Type

Bayonet

Feedback Type

Premolded

Feedback Cable

Flying-lead

High-resolution encoder 2090-UXNFBMP-S

xx

2090-XX

x

FMP-S

xx

(1)

(1) For Bulletin MPL and 1326AB (M2L/S2L) motors equipped with bayonet connectors. These cables are available as standard, non-flex

(catalog number 2090-XXNFMP-Sxx) and continuous-flex (catalog number 2090-XXTFMP-Sxx).

Table 43 - Motor Feedback Cable Compatibility - Circular DIN Connectors

Motor/Actuator

Connector

Type

Feedback Type

Premolded

Feedback Cable

(1)

Flying-lead

MPL-B5

xxx

-S/M

x

7

x

AA,

MPL-B6

xxx

-S/M

x

7

x

AA,

MPL-B8

xxx

-S/M

x

7

x

AA

MPL-B9

xxx

-S/M

x

7

x

AA

MPM-B

xxxxx-

S/M

2090-CFBM7DD-CEAA

xx

(standard, non-flex) or

2090-CFBM7DD-CEAF

xx

(continuous-flex)

2090-CFBM7DF-CEAA

xx

(standard, non-flex) or

2090-CFBM7DF-CEAF

xx

(continuous-flex)

RDB-B

xxxx

-7/3

HPK-Series

SpeedTec DIN

High-resolution encoder

N/A

2090-XXNFMF-S

xx

(standard, non-flex) or

2090-CFBM7DF-CDAF

xx

(continuous-flex)

2090-XXNFMF-S

xx

(standard, non-flex)

2090-CFBM4DF-CDAF

xx

(continuous-flex)

(1) You must remove the motor-side o-ring when using 2090-CFBM7

xx

-

xx

A

xxx

cables.

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94

Flying-lead Feedback Cable Pinouts

Table 44 - 2090-XX

x

FMP-S

xx

Feedback Cable

(1)

Motor Bayonet

Connector Pin

U

V

S

T

P

R

L

N

F

K

D

E

A

B

C

Rotary Motors with High Resolution Feedback:

MPL-B5

xxxx-

M/S

x

2

x

AA, MPL-B6

xxxx

-M/S

x

2

x

AA,

MPL-B8

xxxx-

M/S

x

2

x

AA, and MPL-B9

xxxx

-M/S

x

2

x

AA

Signal

Sine+

Sine-

Cos+

Cos-

Data+

Data-

Reserved

Reserved

EPWR_9V

ECOM

TS+

TS-

Reserved

Reserved

Reserved

Drive MF

Connector Pin

–

–

–

–

6

11

–

7

10

–

4

5

1

2

3

(1) The 2090-XX

x

FMP-S

xx

cables are available as standard, non-flex (catalog number 2090-XX

N

FMP-S

xx

) and continuous-flex (catalog number 2090-XX

T

FMP-S

xx

).

Table 45 - 2090-XXNFMF-S

xx

and 2090-CFBM

x

DF-CDAF

xx

Feedback Cable

16

17

14

15

12

13

10

11

6

9

4

5

1

2

3

Motor

Circular DIN

Connector Pin

Motors with High Resolution Feedback:

MPL-B5

xxxx

-M/S

x

7

x

AA, MPL-B6

xxxx

-M/S

x

7

x

AA,

MPL-B8

xxxx

-M/S

x

7

x

AA, MPL-B9

xxxx

-S/M-M/S

x

7

x

AA,

HPK-B

xxxx

-S/M, and HPK-E

xxxx

-S/M

Signal

Sine+

Sine-

Cos+

Cos-

Data+

Data-

Reserved

Reserved

EPWR_9V

ECOM

TS+

TS-

Reserved

Reserved

Reserved

Drive MF

Connector Pin

–

–

–

–

6

11

–

7

10

–

4

5

1

2

3

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Wire Feedback and I/O

Connectors

Connect the Kinetix 7000 Drive System

Chapter 4

14

15

12

13

16

17

10

11

8

9

6

7

4

5

1

2

3

Table 46 - 2090-XXNFMF-S

xx

and 2090-CFBM

x

DF-CDAF

xx

Feedback Cable

Motor Circular DIN

Connector Pin

RDB-B

xxxxx

-3/7 Motors 2090-K7CK-KENDAT

Pin

Signal

Sine+ 1

ECOM

Reserved

Reserved

TS+

TS-

Reserved

Reserved

Reserved

Sine-

Cos+

Cos-

Data+

Data-

CLK+

CLK-

EPWR_5V

–

–

–

–

–

11

6

–

8

5

10

7

4

9

2

3

Wire your feedback and I/O cables.

To make this type of connection

Premolded Cable

Panel-mounted Breakout Board

Low-profile Connector

Go to

Connect Premolded Motor Feedback Cables below.

Wire Panel-mounted Breakout Board Kits on page 96 .

Wire Low-profile Connectors on page 98 .

Connect Premolded Motor Feedback Cables

Motor feedback cables (with premolded connectors) plug directly into 15-pin motor feedback (MF) connectors on Kinetix 7000 drive (no wiring is necessary).

IMPORTANT

When using Bulletin 2090 cables with premolded connectors, tighten the mounting screws (finger tight) to improve system performance.

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Figure 54 - Premolded Motor Feedback Cable Connection

Kinetix 7000 Drive

(Side View)

Premolded Connector Cable:

2090-CFBM7DD-CEAAxx (standard, non-flex) or

2090-CFBM7DD-CEAF

xx

(continuous flex)

Wire Panel-mounted Breakout Board Kits

The panel-mounted breakout board kit (catalog number 2090-UXBK-D15

xx

) includes a (DIN rail) terminal block and cable. The cable connects between the terminal block and the motor feedback (MF) connector. Wires from your flyinglead motor feedback cable connect to the terminals.

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Chapter 4

Figure 55 - Panel-mounted Breakout Board Connection Example

Kinetix 7000 Drive

(Side View)

See the Motor Feedback Breakout Board

Installation Instructions, publication 2090-IN006 , for Connector Breakout Board Specifications.

2090-UXBB-D15xx

Panel-mounted Breakout Board

2090-UXBC-D15xx

Breakout Cable

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Connector Kit

Cat. No.

2090-K7CK-KENDAT

2090-K6CK-D15M

2090-K6CK-D15F

2090-K6CK-D26M

Wire Low-profile Connectors

Low-profile connectors (2090-K6CK-D

xxx

) are suitable for motor feedback

(MF), auxiliary feedback (AF), and I/O connections (IOD) on Kinetix 7000 drive.

Table 47 - Low-profile Connector Kits

Description Cable Compatibility

Low-profile feedback module for connecting to Heidenhain EnDat high-resolution feedback device (15-pin, male, D-sub).

Use with any Kinetix 7000 drive and Bulletin RDB direct-drive motor with EnDat high-resolution feedback.

NOTE:

Only 2099-BM

xx

-S drives with firmware revision 1.104 or higher support the use of this feedback module.

Low-profile connector kit for motor feedback (15-pin, male, D-sub). Use with any Kinetix 7000 drive and compatible motors.

Low-profile connector kit for auxiliary feedback (15-pin, female, D-sub). Use with any Kinetix 7000 drive for auxiliary feedback applications.

Low-profile connector kit for I/O (26-pin, male, D-sub). Use with any Kinetix 7000 drive or 2094-BL02 LIM module for making I/O connections.

2090-XX

x

FMP-S

xx,

2090-XXNFMF-S

xx,

2090-CFBM

x

DF-C

x

A

xxx

Customer supplied

Kinetix 7000 Drive

(Side View)

98

2090-Kxxx-Dxxx

Low-profile Connector Kit with Flying-lead Feedback or

I/O Cable

IMPORTANT

Tightening the mounting screws is essential to be sure of shield integrity between the low-profile connector covers and the drive feedback connector D-shells. Tightening torque is 0.4 N

• m

(35 lb

• in).

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Connect the Kinetix 7000 Drive System

Chapter 4

Figure 56 - Wiring (15-pin) Flying-lead Feedback Cable Connections

2090-K6CK-D15M and 2090-K6CK-D15F Connector Kits

15-pin (male) Motor Feedback

Low-profile Connector

15-pin (female) Auxiliary Feedback

Low-profile Connector

Bare wires

Wire insulation

Foil shield

Braided shield

Outer insulation

Mounting

Screws

Bulletin 2090

Feedback Cable

2090-K6CK-D15

x

Low-profile Connector Kit

Pin 10

Pin 5

Pin 1

Pin 15

Pin 11

Pin 6

Pin 1

Pin 5

Pin 10

Pin 6

Pin 11

Pin 15

Shield Clamp

Exposed Braid Under Clamp

Tie

Wrap

See page 66

for Feedback Signal Descriptions.

See Appendix B for the Motor Feedback

Interconnect Drawing for Your Application.

See the Low Profile Connector Kit Installation

Instructions, Publication

2094-IN007 , for Connector Kit Specifications.

Bulletin 2090 Feedback Cable

Turn Clamp Over to Hold

Small Wires Secure

Bare Wires

Wire Insulation

Foil Shield

Braided Shield

Outer Insulation

Turn Clamp Over to Hold

Small Wires Secure.

Figure 57 - Wiring (15-pin) Flying-lead Feedback Cable Connections

2090-K7CK-KENDAT Feedback Module

Status

Indicator

15-pin (male) Motor Feedback

Low-profile Connector

Pin 10

Pin 5 Pin 15

Mounting

Screws

Pin 1

Pin 11

Pin 6

Bulletin 2090

Feedback Cable

2090-K7CK-KENDAT

Low-profile Feedback Module

Shield Clamp

Exposed Braid Under Clamp

See

page 66 for Feedback Signal

Descriptions.

See

Appendix B for the Motor Feedback

Interconnect Drawing for Your Application.

Bulletin 2090

Feedback Cable

See the Low Profile Connector Kit Installation

Instructions, Publication

2094-IN007 , for Connector Lit Specifications.

IMPORTANT

The purpose of the cable shield clamp is to provide a proper ground and improve system performance, not stress relief.

Clamping the exposed braid under the shield clamp is critical. Turn the clamp over, if necessary, to be sure of a proper ground.

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Figure 58 - Wiring (26-pin) I/O Cable Connections

2090-K6CK-D26M Connector Kit

Mounting

Screws

2090-K6CK-D26M

Low-profile Connector Kit

12 11 10

Pin 18

Pin 9

Pin 26

Pin 1

Pin 19

Pin 10

26-pin (male) I/O

Low-profile Connector

See the Low Profile Connector Kit Installation

Instructions, Publication

2094-IN007 , for Connector Kit Specifications.

Tie Wrap Slot

Three Conductor

I/O Cable(s)

IMPORTANT

Turn Clamp Over to

Hold Small Wires

Secure

Discrete I/O Wire

The purpose of the cable shield clamp is to provide a proper ground and improve system performance, not stress relief.

Clamping the exposed braid under the shield clamp is critical. Turn the clamp over, if necessary, to be sure of a proper ground.

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External Shunt Module

Connections

Connect the Kinetix 7000 Drive System

Chapter 4

External active shunt modules listed in the table on page 156 are compatible with

Kinetix 7000 drives. Follow these guidelines when wiring your external active shunt module kit.

•

Refer to Shunt Resistor on page 37 for important wiring

recommendations.

•

Refer to

Appendix B

for the Kinetix 7000 drive interconnect diagrams.

•

Refer to the installation instructions provided with your shunt module.

IMPORTANT

When tightening screws to secure the wires to the DC bus terminals, see

Table 36 on page 90 for torque values.

SERCOS Fiber-optic Cable

Connections

This procedure assumes you have your Logix SERCOS interface module/PCI card and Kinetix 7000 drive mounted and are ready to connect the fiber-optic cables.

The SERCOS fiber-optic ring is connected using the SERCOS receive (Rx) and transmit (Tx) connectors.

See page

65 to locate the SERCOS connectors on your Kinetix 7000 drive. See

the figure below to locate the connectors on your SERCOS interface module or

PCI card.

Plastic cable is available in lengths up to 32 m (105 ft). Glass cable is available in lengths between 50 m (164 ft) and 200 m (656 ft).

IMPORTANT

When connecting Kinetix 7000 drives, use at least a 2090-SCEP1-0, 1 m (3 ft) or longer cable.

Larger drives may require longer cables.

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CompactLogix Platform

1768-M04SE SERCOS interface Module

Front View

Tx (rear)

Rx (front)

Bottom View

Figure 59 - CompactLogix, ControlLogix, and SoftLogix SERCOS Connector Locations

SERCOS interface TM

CP OK

ControlLogix Platform

1756-M

xx

SE SERCOS interface Module

RSLogix 5000 Software

D

E

F

9A

0

8

1

2

3

67

OK

CP

SoftLogix Platform

1756-PM16SE SERCOS interface PCI Card

(as viewed from the back of your personal computer)

TX

SERCOS Transmit Connector, Tx

RX

Tx (rear)

Rx (front)

Front View

SERCOS Receive Connector, Rx

SERCOS Receive Connector, Rx (front)

SERCOS Transmit Connector, Tx (rear)

Connect the cable from transmit on the Logix module to receive on the Kinetix

7000 drive, then transmit to receive (drive to drive), and from transmit on the last drive back to receive on the Logix module.

ATTENTION:

To avoid damage to the SERCOS Rx and Tx connectors use only finger-tight torque when attaching the fiber-optic cables to the Kinetix 7000 drive. Do not use a wrench or any other mechanical assistance.

For more information, see the Fiber-optic Cable Installation and Handling

Instructions, publication 2090-IN010 .

Figure 60 - Fiber-optic Cable Connections to a SoftLogix Module

Transmit

Receive

F

1

OK

CP

TX

RX

SoftLogix

1784-PM16SE SERCOS interface PCI Card

Receive

SERCOS Fiber-optic Ring

Transmit Receive

Transmit

Kinetix 6000 System

Kinetix 7000 Drive

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Chapter 4

The following fiber-optic cable examples are shown using ControlLogix modules. CompactLogix modules connect in the same way, however the ring cannot include more than four drives.

Figure 61 - Fiber-optic Cable Connections to ControlLogix/CompactLogix Modules

1756-M

xx

SE SERCOS interface Module

SERCOS interface TM

CP

OK

Transmit

Tx (rear)

Rx (front)

Receive

Logix Chassis

(ControlLogix is shown)

Receive

SERCOS Fiber-optic Ring

Transmit

Receive

Transmit

Kinetix 6000 System

Kinetix 7000 Drive System

You can also mount the two Logix SERCOS modules in two separate chassis, or you can mount them in the same chassis.

IMPORTANT

Clean the fiber-optic cable connectors prior to installation. Dust in the connectors can reduce signal strength.

See the Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010 , for more information.

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The following example depicts the second Kinetix system, consisting of Kinetix

7000 drives, located in a separate cabinet and connected with bulkhead adapters.

IMPORTANT

To avoid signal loss, do not use bulkhead adapters to connect glass cables.

Use bulkhead adapters for making plastic-to-plastic cable connections only.

Figure 62 - Fiber-optic Cable Connections (ControlLogix/CompactLogix)

1756-M

xx

SE SERCOS

Interface Module

SERCOS interface TM

CP OK

Logix Chassis

(ControlLogix is shown)

Transmit

Tx (rear)

Rx (front)

Receive

SERCOS

Fiber-optic

Bulkhead

Adapter

SERCOS Fiber-optic Ring

Receive Transmit

SERCOS Ring

Receive

SERCOS

Fiber-optic

Bulkhead

Adapter

Transmit

Kinetix 6000 System

Kinetix 7000 Drive System

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Chapter

5

Configure and Startup the Kinetix 7000 Drive

System

This chapter provides procedures for configuring your Kinetix 7000 system components with the Logix SERCOS module.

Topic

Configure the Drive Modules

Configure the Logix SERCOS interface Module

Apply Power to the Drive

Test and Tune the Axes

Configure Drive Parameters and System Variables

Page

106

110

126

129

134

Before you begin, make sure you know the characteristics of the following system components.

•

Logix processor

•

Logix module(s), including the SERCOS module

•

Kinetix 7000 drive(s) and accessories

•

Servo motor(s)/actuator(s)

•

transmission/load for the conversion constant

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Configure the Drive Modules

Follow these steps to configure the Kinetix 7000 drive.

1.

Verify that there is no power applied to the drive and that the SERCOS fiber-optic cables are plugged into the Tx and Rx connectors.

To verify your fiber-optic cable connections, refer to page

101 .

2.

Set the base node address for the drive by setting the SERCOS Node

Address switch.

Valid node addresses are 01...99. The left hand switch sets the most significant digit (MSD) and the right hand switch sets the least significant digit (LSD).

Refer to the table and figure below for switch operation.

Table 48 - Node Addressing Switch Settings

To

Increment the (MSD/LSD) node address

Decrement the (MSD/LSD) node address

Press

The plus (+) switch.

The minus (-) switch.

Figure 63 - N ode Addressing Switch Settings

Decrements MSD

MSD

Increments MSD

Decrements LSD

LSD

Increments LSD

IMPORTANT

When two or more drives are connected to the same SERCOS interface module, each node address must be unique.

Refer to the node addressing examples beginning on page

108 .

3.

Cycle control power to initialize the drive.

IMPORTANT

The base node address setting takes effect only after the drive is initialized.

4.

Set the SERCOS communications rate using DIP switches 2 and 3.

For This Communication Rate

4 Mbps

8 Mbps

Set Switch 2

OFF

ON

Set Switch 3

ON

OFF

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Chapter 5

5.

Set the SERCOS optical power level to High using DIP switch 1.

For This Optical Power Level

Low

High

Set Switch 1

OFF

ON

IMPORTANT

All drives on the SERCOS ring must have the same baud rate and power setting.

Figure 64 - SERCOS DIP Switch Settings and Locations

SERCOS switch and connectors

(typical orientation around DPI connector)

DIP Switches Set for

4 Mbps Applications

(high-power setting)

3 2 1

ON

OFF

ON

OFF

DIP Switches Set for

8 Mbps Applications

(high-power setting)

3 2 1

Switch in OFF Position

SERCOS Baud Rate and Optical Power Switches

Note: 8 Mbps setting shown.

6.

Repeat Steps 4 and 5 for each Kinetix 7000 drive.

Switch in ON Position

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Node Addressing Examples

The examples below illustrate how each axis in the fiber-optic ring is assigned a node address. The ControlLogix platform is used in the examples, but the node addressing is typical for Logix platforms.

Figure 65 - Node Addressing Example 1

1756-M

xx

SE SERCOS interface Module 1

Logix Chassis/PCI Card

(ControlLogix chassis is shown)

SERCOS interface TM

CP OK

Tx (rear)

Rx (front)

Transmit Receive

SERCOS interface TM

CP OK

1756-M

xx

SE SERCOS interface Module 2

Logix Chassis/PCI Card

(ControlLogix chassis is shown)

Tx (rear)

Rx (front)

Transmit Receive

Receive

Transmit

SERCOS Fiber-optic Rings

Receive Transmit

Kinetix 7000 Drive

System

03 = Drive (axis 3) Node Address

02 = Drive (axis 2) Node Address

01 = Drive (axis 1) Base Node Address

In this example, SERCOS interface module 1 controls Kinetix 7000 axes 1 and 2.

SERCOS interface module 2 controls Kinetix 7000 axis 3.

TIP

You can mount the two SERCOS interface modules in two separate Logix chassis (as shown above) or you can mount them in the same chassis.

Utilizing two SERCOS interface modules to control axes from a single Kinetix

7000 drive lets you reduce cycle times.

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Kinetix 6000

(8-axis power rail)

Figure 66 - Node Addressing Example 2

ERCO S interface TM

CP OK

1756-M

xx

SE SERCOS interface Module

Logix Chassis/PCI Card

(ControlLogix chassis is shown)

Tx (rear)

Rx (front)

Transmit Receive

SERCOS Fiber-optic Ring

Configure and Startup the Kinetix 7000 Drive System

Chapter 5

Kinetix 7000

(2-axis)

08 = Not Used (AM rightmost slot)

07 = AM (axis 4) Node Address

06 = Not Used (AM rightmost slot)

05 = AM (axis 3) Node Address

04 = Not Used (AM rightmost slot)

03 = AM (axis 2) Node Address

02 = Not Used (IAM rightmost slot)

01 = IAM (axis 1) Base Node Address

10 = Drive (axis 2) Node Address

09 = Drive (axis 1) Node Address

In this example, a Kinetix 6000 (8-axis) power rail contains a double-wide IAM, and three double-wide AMs.

The leftmost slot of a double-wide module determines the node address. So, in the example above, node addresses 02, 04, and 06 (the rightmost slots of the double-wide modules) are not used.

The Kinetix 7000 (2-axis) drive system contains two drives. The base node address of the system must be set for an address of

≥

9.

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Configure the Logix SERCOS interface Module

This procedure assumes that you have wired your Kinetix 7000 system and set the

Kinetix 7000 baud rate and optical power switches.

IMPORTANT

For the Kinetix 7000 drive to communicate with the SERCOS interface module

(indicated by three solid-green status indicators on the SERCOS module), your

RSLogix 5000 software must be revision 15.0 or later.

For resources on using RSLogix 5000 software as it applies to configuring the

ControlLogix, CompactLogix, or SoftLogix SERCOS modules, refer to

Additional Resources on page 9 .

Configure the Logix Controller

Follow these steps to configure the Logix controller.

1.

Apply power to your Logix chassis containing the SERCOS interface module and open your RSLogix 5000 software.

2.

From the File menu, choose New.

The New Controller dialog box opens.

110

3.

Configure the controller.

a. From the Type pull-down menu, choose the controller type.

b. From the Revision pull-down menu, choose the revision.

c. Type the file Name.

d. From the Chassis Type pull-down menu, choose the chassis.

e. Choose the Logix processor Slot.

4.

Click OK.

5.

From the Edit menu, choose Controller Properties.

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Configure and Startup the Kinetix 7000 Drive System

Chapter 5

The Controller Properties dialog box opens.

6.

Click the Date/Time tab.

7.

Check Enable Time Synchronization.

This assigns the controller as the Grandmaster clock. The motion modules set their clocks to the module you assign as the Grandmaster.

IMPORTANT

You can assign only one module in the Logix chassis as the

Grandmaster clock.

8.

Click OK.

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Configure the SERCOS Module

Follow these steps to configure the SERCOS module.

1.

Right-click on I/O Configuration in the Controller Organizer and choose

New Module.

The Select Module dialog box opens.

112

2.

Expand the Motion category and select 1756-M

xx

SE, 1756-L60M03SE,

1768-M04SE, or 1784-PM16SE as appropriate for your actual hardware configuration.

In this example, the 1756-M16SE module is selected.

3.

Click OK.

The New Module dialog box opens.

4.

Configure the module.

a. Type the module Name.

b. Enter the Logix SERCOS module slot (leftmost slot = 0).

c. Check Open Module Properties.

5.

Click OK.

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Configure and Startup the Kinetix 7000 Drive System

Chapter 5

Your new module appears under the I/O Configuration folder in the

Controller Organizer and the Module Properties dialog box opens.

6.

Click the SERCOS Interface tab and reference the table below.

Logix SERCOS Module

1756-M03SE or

1756-L60M03SE

1756-M08SE

1756-M16SE or

1784-PM16SE

1768-M04SE

Number of Axes

Up to 3

Up to 8

Up to 16

Data Rate

4 or 8 Mbps

Up to 4

7.

Verify that the Data Rate setting matches DIP switches 2 and 3

(communication rate) as set on the drive, or use the Auto Detect setting.

8.

From the Cycle Time pull-down menu, choose the Cycle Time according to the following table.

Data Rate

4 Mbps

8 Mbps

Number of Axes

Up to 2

Up to 4

Up to 8

No support for axes 9...16

Up to 4

Up to 8

Up to 16

Cycle Time

0.5 ms

1 ms

2 ms

0.5 ms

1 ms

2 ms

TIP

The number of axes/module is limited to the number of axes as shown in step 6 .

9.

Verify that the Transmit Power setting (high) matches the Optical Power

DIP switch 1 as set on the drive.

10.

Enter the Transition to Phase setting.

The Transition to Phase default setting is 4 (phase 4). The Transition to

Phase setting stops the ring in the phase specified.

11.

Click OK.

12.

Repeat steps 1...11 for each SERCOS module.

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Configure the Motion Group

Follow these steps to configure the motion group.

1.

Right-click Motion Groups in the Controller Organizer and choose New

Motion Group.

The New Tag dialog opens.

2.

Type the new motion group Name.

3.

Click OK.

The new motion group appears under the Motion Groups folder.

4.

Right-click the new motion group and select Properties.

The Motion Group Properties dialog box opens.

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Chapter 5

No axis have been created yet. For this setup, a servo axis named Axis_1 and a feedback only axis named Axis_1_Aux will be created. Both axes will be assigned to the Kinetix 7000 axis in the Configure the Kinetix 7000

Drive Modules section.

5.

Right-click the Motion group name created and select New Axis.

6.

Select an Axis_Servo_Drive (SERCOS controlled axis).

The New Tag dialog opens.

7.

Type Axis_1 (or the name of your axis) in the Name field.

Axis_Servo_Drive is the correct Data Type.

8.

Click Ok.

9.

Repeat steps 5 and 6 above for the Axis_1_Aux Feedback Only axis.

10.

Right-click on the Motion Group name created and select Properties.

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Both Axis_1 and Axis_1_Aux are Assigned to the Motion Group. This means both axis will be part of the SERCOS and Motion planner updates from/to the controller/SERCOS card/drive.

11.

Open the Attribute folder.

The Motion Planner coarse update period must be set according to the application needs. Guidelines for the coarse update period for the processor used and the number of servo drive axes created in the motion group can be found in the following resources.

•

Rockwell Automation Knowledgebase at: http://www.rockwellautomation.com/knowledgebase/

•

SERCOS and Analog Motion Configuration and Startup User

Manual, publication MOTION-UM001

•

The various Logix controller user manuals

Only 1 Motion group per processor is allowed.

12.

Click Ok.

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Chapter 5

Configure the Kinetix 7000 Drive Modules

Follow these steps to configure the Kinetix 7000 drive modules.

1.

Right-click the Logix module you just created and choose New Module.

The Select Module dialog box opens.

2.

Expand the Drives category and select your drive as appropriate for your actual hardware configuration.

IMPORTANT

In order for the Kinetix 7000 drive to communicate with the SERCOS interface module (indicated by three solid-green status indicators on the SERCOS module), your RSLogix 5000 software must be revision 15.0 or later.

3.

Click OK.

The New Module dialog box opens.

4.

Configure the new drive module.

a. Type the module Name.

b. Enter the Node address.

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Set the node address in the software to match the node setting on the

drive. Refer to Configure the Drive Modules,

step 2 , on page 106 .

c. Check Open Module Properties.

5.

Click OK.

6.

Select the Associated Axes tab.

7.

Assign Axis_1 to Node 1 in the Associated Axis folder. This assigns Axis 1 in the motion group to the Kinetix 7000 drive at node address 1. Select the

Associated Axes tab.

8.

Click Apply.

9.

Click next to Axis_1.

The Axis Properties dialog box opens on the General tab.

10.

Select the Units tab.

11.

Select the correct position units to be used in your application. This example uses load millimeter.

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12.

Select the Conversion tab. Based on the type of application, the system can be configured for a linear or rotary system. To simplify the setup, a linear system is utilized. The calculate tool on the Drive/Motor tab will be used to set the drive resolution and conversion constant. If a rotary system is used, the Drive/Motor tab calculate tool will be used to set the drive resolution, conversion constant, and position unwind.

13.

Click Apply.

14.

Select the Drive/Motor tab.

15.

Click Change Catalog in order to select the appropriate motor for configuration.

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16.

The Change Catalog Number dialog box appears.

17.

Select the appropriate motor catalog number for your application. It is important to verify the motor catalog number on the motor nameplate as well as in your design specification.

18.

Click OK.

19.

Click Calculate, to configure the drive resolution and conversion constant.

The position unwind is also calculated if rotary load is used.

20.

In this example, a linear load is used and a 25.4 mm (1 in.) movement on a ballscrew is made with every 1 motor revolution. The total position movement on the ballscrew is 254 mm (9.8 in.).

120

21.

Click Update.

22.

Click Close.

23.

The Drive Enable Input Checking is selected by default. When checked

(default) a hard drive enable input signal on the IOD connector (pin 2) is required. Uncheck Drive Enable Input Checking if a hard drive enable input signal is not required.

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The Drive/Motor tab and Conversion tabs should look similar to these examples or reflect your application configuration.

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24.

Click the Fault Actions tab.

25.

Click Set Custom Stop Action.

The Custom Stop Action Attributes dialog box opens and lets you set delay times for servo motors with a brake and resistive brake modules. For recommended motor brake delay times, refer to refer to the Kinetix

Motion Control Selection Guide, publication GMC-SG001 .

26.

Configure the delay times.

a. Type the Brake Engage Delay Time.

b. Type the Brake Release Delay Time.

c. Set the Resistive Brake Contact Delay time (0…1000 ms range).

d. Click Close.

27.

Click OK.

28.

In the Module Properties > Associated Axes tab, select the auxiliary axis

Axis_1_Aux and click Apply.

TIP

The base node is the servo axis utilizing the motor feedback, and the base node (plus 128) is a feedback-only axis utilizing the auxiliary feedback port (as shown below).

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Axis_1_Aux is configured similar to Axis_1, except that only a feedback device is configured.

29.

Configure the Auxiliary Axis properties. Click next to Axis_1_Aux.

The Axis Properties dialog box opens on the General tab.

If an axis is associated to the auxiliary axis node, set the Axis Configuration on the General tab of the Axis Properties dialog box to Feedback Only.

30.

Select the Units tab and configure the same as in steps 10…13 of this procedure.

31.

Select the Conversion tab and configure the same as in steps 10…13 of this procedure.

32.

Select the Drive/Motor tab.

The Drive/Motor tab displays the amplifier being used and the Loop

Configuration is Aux Feedback Only. This is the only choice if the amplifier is using the primary node for Servo (motor) configuration.

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33.

Configure the drive resolution / conversion constant (position unwind, if rotary) as in step 19…22 of this procedure.

34.

Click the Aux Feedback tab.

IMPORTANT

The Aux Feedback tab must be configured for the auxiliary feedback type being used. In this example, an SRM feedback device is being used.

35.

From the Feedback Type pull-down menu, choose the feedback type appropriate for your auxiliary feedback motor.

36.

Click Apply.

37.

Click OK.

38.

In the Module Properties, click the Power tab.

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39.

From the Bus Regulator Configuration pull-down menu, choose the component appropriate for your actual hardware configuration. Note: The

Kinetix 7000 drive internal dynamic brake IGBT is not utilized by the drive main control for bus regulation therefore any type of regulation must come from an external source.

If your drive requires

No bus regulator configuration

External Shunt configuration

Then choose

<none>

1336-MOD-KB005, KB010 or KB050

1336-WB009, WB035 or WB110

(1)

8720MC-RPS027, 8720MC-RPS065, or 8720MC-RPS190

(2)(3)(4)

External regeneration power supply

(1) External shunt configuration 1336 MOD-KB

xxx

and 1336-WB

xxx

are no longer available for new sale but are selectable as of this manual release.

(2) 8720MC-RPS

xxx

is an external regenerative converter system used to regulate the DC bus connected to the Kinetix 7000

drive. Selecting this device will require the Kinetix 7000 drive GPIO terminal block pins 7 and 8 to be wired. See Figure 74 on page 165 for an example.

(3) 8720MC-RPS027BM-HV1 is no longer available for sale.

(4) 8720MC-RPS065BM-HV1 has been superseded by 8720MC-RPS065BM-HV2.

40.

Click OK.

41.

Repeat steps 1…27 for each additional axis.

42.

Verify your Logix program and save the file.

Download the Program

After completing the Logix configuration you must download your program to the Logix processor.

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Apply Power to the Drive

This procedure assumes that you have completed the following tasks:

•

Wired your Kinetix 7000 drive.

•

Connected your Logix controller, SERCOS interface module fiber-optic connections to your Kinetix 7000 drive.

•

Configured and verified a RSLogix 5000 program.

•

Connected the motor power and motor feedback cables to your Kinetix

7000 drive.

SHOCK HAZARD:

To avoid hazard of electrical shock, complete all mounting and wiring prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.

Refer to the Line Interface Module Installation Instructions, publication

2094-IN005 , when troubleshooting the LIM status indicators, and for the location of LIM circuit breakers, connectors, and status indicators.

Follow these steps to apply power to the Kinetix 7000 system.

ATTENTION:

To avoid personal injury or damage to equipment, disconnect the load to the motor. Make sure each motor is free of all linkages when initially applying power to the system.

1.

Determine your source of control power.

If Your Control Power

Is sourced from a LIM module

Is not sourced from a LIM module

Then

1. Verify that the LIM CB1, CB2, and CB3 are in the OFF position.

2. Apply three-phase input power to the LIM VAC Line connector.

3. Set CB3 to the ON position.

4. Set CB2 to the ON position.

5. Go to main step 2 .

1. Apply 24V DC control power to the drive (CP connector).

2. Go to main step 2 .

2.

Verify the status of the drive logic power status indicator.

Seven-segment Fault Status Indicator

Logic Power Status Indicator

If the Logic Power Status Indicator is Then

Not ON

1. Check your control power connections.

2. Go back to main

step 1 .

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3.

Define the three-phase input power as described below.

If Your Three-phase Power

Is sourced from a LIM module

Is not sourced from a LIM module

Then

1. Set the LIM CB1 to the ON position.

2. Verify that the LIM, IPL, and OPL connections for phase-tophase voltage is 324…528V AC (460V).

3. Verify that the input voltage at terminals R (L1), S (L2), and T

(L3) on the Kinetix 7000 drive is 324…528V AC (460V).

4. If used, verify that the Kinetix 7000 drive Hardware Enable

Input signal (IOD pin 2) for each axis is off.

5. Go to main step 4 .

1. Apply 324...528V AC (460V) input power to the Kinetix 7000 drive R (L1), S (L2), and T (L3) input terminals.

2. If used, verify that the Kinetix 7000 drive Hardware Enable

Input signal (IOD pin 2) is off.

3. Go to main step 4 .

4.

Observe the seven-segment fault status indicator display on the drive.

Kinetix 7000 Drive Status Indicator

Actively cycling (phase 0)

Displaying a fixed 1 (phase 1

Displaying a fixed 2 (phase 2)

Displaying a fixed 3 (phase 3)

Displaying a fixed 4 (phase 4)

Flashing an E followed by two numbers

The status indicator will first flash the SERCOS node address, then cycle through phases until final configuration (phase 4) is reached.

Status

The drive is looking for a closed SERCOS ring. Wait for phase 1 or take corrective action until you reach phase 1.

The drive is looking for active nodes. Wait for phase 2 or take corrective action until you reach phase 2.

The drive is configuring nodes for communication. Wait for phase 3 or take corrective action until you reach phase 3.

The drive is configuring device specific parameters. Wait for phase 4 or take corrective action until you reach phase 4.

The drive is configured and active.

Drive is faulted.

Do This

Check fiber-optic connections.

Check node addressing.

Check program motor and drive configuration against installed hardware.

Check motor catalog number against selection.

(1)

Go to step 5 .

Go to Error Codes on page 138

.

(1) To get diagnostic information from the module, highlight the module name in RSLogix 5000 software. A Pseudo Key Failure often indicates that the motor selection does not match the motor installed.

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SERCOS Status Indicators

Flashing green and red

Steady green

Not flashing green and red/ not steady green

5.

Observe the three status indicators on the front of the drive.

Status Indicator

Drive

Comm

Bus

Condition

Off

Steady red

Flashing green

Steady green

Off

Steady green

Flashing green

(1)

Off

Status

Normal condition

Drive is faulted

Establishing communication with network

Communication is ready

No ring present

Axis is enabled when status should be disabled

Bus is up, axis is disabled (normal status)

DC bus is not present

Do This

Observe the Comm status LED.

Go to Status Indicators on page 143

.

Wait for steady green.

Observe the Bus status LED

Go to Interpret Error Codes and Status Indicators on page 138 .

1. Verify Hardware Enable Input (IOD-2) is open.

2. Verify MSO instruction is not commanded in RSLogix 5000 software.

3. Return to Apply Power to the Drive on page 126

.

Go to step 6 .

Go to Status Indicators on page 143

.

(1) The follower drive has a 2.5 second delay after DC bus voltage is applied before the Bus Status LED begins flashing. This provides the common bus leader time to complete precharge.

6.

Observe the three SERCOS status indicators on the SERCOS module.

Status

Establishing communication

Communication is ready

SERCOS module is faulted

Do This

Wait for steady green on all three LEDs.

Go to Test and Tune the Axes on page 129 .

Go to the appropriate Logix manual for specific instructions and troubleshooting.

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This procedure assumes that you have configured your Kinetix 7000 drive, your

SERCOS interface module, and applied power to the system.

For help using RSLogix 5000 software as it applies to testing and tuning your axes with ControlLogix, CompactLogix, or SoftLogix SERCOS modules, refer

to Additional Resources on page 9

.

Test the Axes

Follow these steps to test the axes.

1.

Verify the load was removed from each axis.

ATTENTION:

To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then reconnect the load and perform the tuning procedure again to provide an accurate operational response.

2.

Right-click an axis in your Motion Group folder and choose Properties.

The Axis Properties dialog box opens.

3.

Click the Hookup tab.

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4.

Type 2.0 as the number of revolutions for the test or another number more appropriate for your application.

This Test

Test Marker

Test Feedback

Test Command & Feedback

Performs this Test

Verifies marker detection capability as you rotate the motor shaft.

Verifies feedback connections are wired correctly as you rotate the motor shaft.

Verifies motor power and feedback connections are wired correctly as you command the motor to rotate. Also, lets you define polarity.

5.

If Drive Enable Input Checking was selected in step 18 of the Configure the Kinetix 7000 Drive Modules section, apply Hardware Enable Input signal (IOD-2) for the axis you are testing.

ATTENTION:

To avoid personal injury or damage to equipment, apply

24V ENABLE signal (IOD-2) only to the axis you are testing.

ATTENTION:

The drive will enable the power module at the appropriate time during hookup and autotune.

6.

Select the Test (Marker/Feedback/Command & Feedback) to verify connections.

The Online Command dialog opens. Follow the on-screen test instructions. When the test completes, the Command Status changes from

Executing to Command Complete.

130

7.

Click OK.

The Online Command - Apply Test dialog opens (Feedback and

Command & Feedback tests only). When the test completes, the

Command Status changes from Executing to Command Complete.

8.

Click OK.

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9.

Determine if your test completed successfully.

If

Your test completes successfully, this dialog box opens.

Then

1. Click OK.

2. Remove Hardware Enable Input signal (IOD-2).

3. Go to Tune the Axes on page 131 .

Your test failed, this dialog box opens. 1. Click OK.

2. Verify the Bus Status LED turned solid green during the test.

3. Verify that the Hardware Enable Input signal (IOD-2) is applied to the axis you are testing.

4. Verify conversion constant entered in the Conversion tab.

5. Return to main step 6 and run the test again.

Tune the Axes

Follow these steps to tune the axes.

1.

Verify the load is still removed from the axis being tuned.

ATTENTION:

To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then reconnect the load and perform the tuning procedure again to provide an accurate operational response.

2.

Click the Tune tab.

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3.

Enter values for Travel Limit and Speed.

In this example, Travel Limit = 5 and Speed = 10. The actual value of programmed units depend on your application.

4.

From the Direction pull-down menu, choose a setting (Forward Unidirectional is default).

5.

Check Tune boxes as appropriate for your application.

6.

Apply Hardware Enable Input signal (IOD-2) for the axis you are tuning.

ATTENTION:

To avoid personal injury or damage to equipment, apply

24V ENABLE signal (IOD-2) only to the axis you are tuning.

7.

Click Start Tuning to auto-tune your axis.

The Online Command - Tune Servo dialog box opens. When the test completes, the Command Status changes from Executing to Command

Complete.

8.

Click OK.

The Tune Bandwidth dialog box opens.

132

Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.

9.

Record your bandwidth data for future reference.

10.

Click OK.

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The Online Command - Apply Tune dialog box opens. When the test completes, the Command Status changes from Executing to Command

Complete.

11.

Click OK.

12.

Determine if your test completed successfully.

If

Your test completes successfully, this dialog box opens.

Then

1. Click OK.

2. Remove the Hardware Enable Input signal (IOD-2) applied earlier.

3. Go to step 13 .

Your test failed, this dialog box opens. 1. Click OK.

2. Make an adjustment to motor velocity.

3. Refer to appropriate Logix motion module setup and configuration manual for more information.

4. Return to step 7 and run the test again.

13.

Repeat Test and Tune the Axes for each axis.

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Configure Drive Parameters and System Variables

This section provides information for accessing and changing parameters not accessible through RSLogix 5000 software.

Tools for Changing Parameters

Most parameters are accessible through RSLogix 5000 software. Alternatives include the DPI compatible Human Interface Module (HIM), and

DriveExplorer and DriveExecutive software.

Table 49 - Software For Changing Parameters

Method

DriveExplorer

Description

DriveExplorer software

(1)

Serial to SCANport adapter

Cat. No.

9306-4EXP02ENE

1203-SSS (Series B), or

1203-USB

20-HIM-A3

(2)

Drive HIM Full numeric LCD HIM

(1) Refer to DriveExplorer Getting Results Manual, publication 9306-GR001 , for instructions.

(2) Compatible catalog numbers include all 20-HIM-A

x

.

Firmware Revision

2.01 or later

3.004 or later

N/A

Change Parameters with DriveExplorer Software

To edit a parameter using DriveExplorer software, refer to the example dialog box below. In this example, the I/O Interface group folder is open and the Analog

Outputs file is selected in the tree view pane on the left. The parameters and corresponding elements are displayed in the pane to the right. Double-click on a parameter in the list to open the edit dialog box where you can change the value for the desired parameter.

Figure 67 - DriveExplorer Software Example

Double-click on a parameter in the list to open the edit dialog box.

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Change Parameters with the HIM Module

When using the HIM module to monitor or change parameters, use the up and down arrows (

∧ and

∨

) to arrive at selections. Refer to the instructions that came with your HIM module for more information.

Follow these steps to monitor or change parameters with the HIM module.

1.

Select parameter, and press

↵

.

2.

Select I/O AM1 Group (for IAM module), and press

↵

.

3.

Select Analog Outputs, and press

↵

.

a. Analog Output 1 is displayed, and press

↵

.

b. For Analog Output 2 use arrows to select, and press

↵

.

4.

Press Sel.

5.

Enter parameter number, and press

↵

.

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Notes:

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Safety Precautions

Chapter

6

Troubleshoot the Kinetix 7000 Drive System

This chapter provides troubleshooting tables for your Kinetix 7000 system components.

Topic

Safety Precautions

Interpret Error Codes and Status Indicators

General System Anomalies

Logix/Drive Fault Behavior

Page

137

138

144

146

IMPORTANT

Equipment connected to the Kinetix 7000 drive may store error data, and may take precedence when troubleshooting the system.

For example, the regenerative power supply (8720MC-RPS

xxxxx

) should be examined first when the DC common bus is providing system power.

Refer to the product manuals listed in the Additional Resources section on

page 9 for troubleshooting information on other products.

Observe the following safety precautions when troubleshooting your Kinetix

7000 drive.

ATTENTION:

Capacitors on the DC bus may retain hazardous voltages after input power has been removed. Before working on the drive, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the front of the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:

Do not attempt to defeat or override the drive fault circuits. You must determine the cause of a fault and correct it before you attempt to operate the system. Failure to correct the fault could result in personal injury and/or damage to equipment as a result of uncontrolled machine operation.

ATTENTION:

Provide an earth ground for test equipment (oscilloscope) used in troubleshooting. Failure to ground the test equipment could result in personal injury.

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Interpret Error Codes and

Status Indicators

Refer to these troubleshooting tables to identify faults, potential causes, and the appropriate actions to resolve the fault. If the fault persists after attempting to troubleshoot the system, please contact your Rockwell Automation sales representative for further assistance.

E04

MotorOvertemp Fault

Error Codes

Common hardware errors that prevent a drive from completing the power sequencing and fault assessment are listed first. Error codes that may appear on the Fault Status display immediately follow the start-up errors.

When a fault is detected, the seven-segment status indicator will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the error code is cleared.

Table 50 - Seven-segment Status Indicator Error Codes

Error

Code

Fault Message RSLogix Anomaly or Symptom Potential Cause

Power (PWR) indicator not

ON

No AC power or auxiliary logic power.

Internal power supply malfunction.

No Error Code Displayed

Motor jumps when first enabled

Digital I/O not working correctly

Motor wiring error.

Incorrect motor chosen.

I/O power supply disconnected.

Motor thermal switch tripped

High motor ambient temperature and/or excessive current.

Motor wiring error.

Incorrect motor selection.

Mechanical failure.

Possible Resolution

Verify AC control power is applied to the Kinetix 7000 system.

Call your Rockwell Automation sales representative to return module for repair.

Check motor wiring.

Run Hookup test in RSLogix 5000 software.

Verify the proper motor is selected.

Verify connections and I/O power source.

Operate within (not above) the continuous torque rating for the ambient temperature, 40 °C (104 °F) maximum.

Lower ambient temperature, increase motor cooling.

Check motor wiring at MF connector on the drive.

Verify the proper motor has been selected.

Check for motor bearing failure or machine jam.

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Table 50 - Seven-segment Status Indicator Error Codes (Continued)

Error

Code

Fault Message RSLogix Anomaly or Symptom Potential Cause

E05

E06

E07

E09

E10

E11

E16

DriveOvercurrent Fault

HardOvertravelFault

MotFeedbackFault

BusUndervoltageFault

DriveOvervoltageFault

MotFeedbackFault

SoftOvertravelFault

Possible Resolution

Inverter Overcurrent (IOC) indicates a major power related fault condition.

Axis moved beyond the physical travel limits in the positive/negative direction.

With three-phase power present, the DC bus voltage is below precharge limits.

Motor cables shorted.

Motor winding shorted internally.

Drive temperature too high.

Operation above continuous power rating and/or product environmental ratings.

Kinetix 7000 drive has a short-circuit, overcurrent, or failed component.

Dedicated overtravel input is inactive.

The feedback wiring is open, shorted, or missing.

Bus voltage for 460V system is below 275V

DC.

Verify continuity of motor power cable and connector.

Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced.

Check for clogged vents or defective fan.

Verify cooling is not restricted by insufficient space around the unit.

Verify ambient temperature is not too high.

Operate within the continuous power rating.

Reduce acceleration rates.

Remove all power and motor connections, and preform a continuity check from the DC bus to the U,

V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair.

Check wiring.

Verify motion profile.

Verify axis configuration in RSLogix 5000 software.

Check motor encoder and wiring.

Run Hookup test in RSLogix 5000 software.

Verify voltage level of the incoming AC power.

Verify integrity and consistency of AC power source.

Install an uninterruptible power supply (UPS) on your AC input.

DC bus voltage fell below the undervoltage limit while an axis was enabled.

The DC bus voltage is above limits.

Bus voltage is at least 180V DC below the precharge level of 323… 525V DC.

Verify bus supply is OK.

Disable axis before removing input power.

One of more phases of AC input power failed.

Check AC input power on all phases.

Excessive regeneration of power.

When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the drive’s power supply. The system faults to save itself from an overload.

Change the deceleration or motion profile.

Use a larger system (motor and drive).

Install shunt module.

Install larger active shunt module or regenerative converter module.

Bus voltage for 460V system is over 800V DC.

Verify line input integrity and that it is within specification.

Verify the Hall wiring at the MF connector on the drive.

State of Hall feedback inputs is incorrect.

Improper connection.

Axis moved beyond the software axis position in either the positive or negative direction.

Verify 5V power supply to the encoder.

Check feedback device.

Verify motion profile.

Verify overtravel settings are appropriate.

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Table 50 - Seven-segment Status Indicator Error Codes (Continued)

Error

Code

Fault Message RSLogix

E18

E19

E20

E21

E23

E30

E34

E35

E37

OverSpeedFault

PositionErrorFault

MotFeedbackFault

AuxFeedbackFault

DriveOvertempFault

MotFeedbackFault

GroundShortFault

DriveUndervoltageFault

PowerPhaseLossFault

Anomaly or Symptom Potential Cause

Motor speed has exceeded 150% of maximum rated speed. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed.

Position error limit exceeded.

Motor encoder state error.

The motor encoder encountered an illegal transition.

Communication was not established with an intelligent encoder.

IPM thermal protection fault

Communication was not established with an intelligent encoder.

Excessive ground current detected in the converter.

Converter precharge cycle failed.

The internal filter protecting the drive from overheating has tripped.

Wiring error.

Motor internal ground short.

Internal malfunction.

Low AC input voltage.

Internal malfunction.

One or more phases of the ac input power is missing.

Possible Resolution

Check cables for noise.

Check tuning.

Check feedback device.

Verify velocity limit settings.

Increase the feed forward gain.

Increase following error limit or time.

Check position loop tuning.

Verify sizing of system.

Verify mechanical integrity of system within specification limits.

Use shielded cables with twisted pair wires.

Route the feedback away from potential noise sources.

Check the system grounds.

Replace the motor/encoder.

Check feedback device and wiring.

Verify auxiliary encoder wiring.

Reduce acceleration rates.

Reduce duty cycle (ON/OFF) of commanded motion.

Increase time permitted for motion.

Use larger Kinetix 7000 drive and motor.

Check tuning.

Verify motor selection.

Verify the motor supports automatic identification.

Verify motor encoder wiring.

Check motor power wiring.

Check input power wiring.

Replace motor.

Disconnect motor power cable from drive and enable drive with current limit set to 0. If fault clears, then a wiring error or motor internal problem exists. If fault remains, call your Rockwell Automation sales representative.

Remove ground from control power input.

Wire control power to use main power as shown in

Appendix B.

Add isolation transformer for control power.

Check input AC voltage on all phases.

Call your Rockwell Automation sales representative.

Check input ac voltage and fusing on all phases and

DC bus.

Disable axis before removing power.

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Chapter 6

Table 50 - Seven-segment Status Indicator Error Codes (Continued)

Error

Code

Fault Message RSLogix Anomaly or Symptom Potential Cause

E38

E39

E43

E49

E50

E54

E61

E62

E63

E64

E65

E66

E67

E68

SERCOSFault

DriveHardFault

DriveEnableInputFault

DriveHardFault

SERCOSFault

DriveHardFault

AuxFeedbackFault

AuxFeedbackFault

AuxFeedbackNoise

MotorFeedbackNoise

No Fault Message

(condition indicated by on-screen message)

No Fault Message

(condition indicated by on-screen message)

DriveHardFault

DriveHardFault

Possible Resolution

The SERCOS ring is not active after being active and operational.

Cable disconnected.

Self-sensing Commutation

Startup Error.

Check that fiber-optic cable is present and properly connected.

Verify that there are no impediments to motion at startup, such as hard limits.

Obstruction prevents motion required for selfsensing startup commutation.

Increase self-sensing current if high friction or load conditions exist.

Check motor or encoder wiring using wiring diagnostics.

Missing Drive Enable input signal.

Attempted to enable the axis through software while the Drive Enable hardware input was inactive.

The Drive Enable input transition from active to inactive occurred while the axis was enabled.

Disable the Drive Enable Input fault.

Verify that Drive Enable hardware input is active whenever the drive is enabled through software.

Verify wiring and shielding.

If error persists, return the drive to Rockwell

Automation.

Safe-off function mismatch.

Drive will not permit motion.

Loose wiring at SO connector.

Cable/header not seated properly in SO connector.

Safe-off circuit missing +24V DC.

Verify wire terminations, cable/header connections, and +24V DC.

Reset error and run proof test.

If error persists, return the drive to Rockwell

Automation.

Refer to the Kinetix Safe-off Feature Safety Reference Manual, GMC-RM002 , for additional troubleshooting information and proof test procedures.

Duplicate node address detected on SERCOS ring.

Excessive Current Feedback

Offset.

Auxiliary Encoder State

Error.

The feedback wiring is open, shorted, or missing.

Noise on auxiliary feedback cable.

Noise on motor feedback cable.

Defective current feedback sensing.

The auxiliary encoder encountered an illegal transition.

Recommended grounding, per installation instructions, has not been followed.

Verify that each SERCOS drive is assigned a unique node address.

If error persists, return the drive to Rockwell

Automation.

Use shielded cables with twisted pair wires.

Route the feedback away from potential noise sources.

Check the system grounds.

Replace the motor/encoder.

Check the motor feedback cable connectors/wiring to the drive and motor.

•

Verify grounding.

•

Route feedback cable away from noise sources.

•

Refer to System Design for Control of Electrical

Noise Reference Manual, publication GMC-

RM001 .

Check motor power/feedback wiring.

Hookup procedure failed.

Motor or feedback device malfunction.

Refer to displayed message for resolution.

Autotune procedure failed.

Operating system failed.

DPI communication failed.

Motor or feedback device malfunction.

Software initialization fault detected due to hardware failure.

The DPI device or cable is faulty.

Check motor power/feedback wiring.

Refer to displayed message for resolution.

Perform Hookup in RSLogix 5000 software.

Consult RSLogix 5000 help message.

Cycle power.

If fault persists, replace module.

Check DPI connections.

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Table 50 - Seven-segment Status Indicator Error Codes (Continued)

Error

Code

Fault Message RSLogix Anomaly or Symptom Potential Cause

E69

E70

E71

E72

E76

E78

E80

DriveHardFault

DriveHardFault

DriveHardFault

DriveOvertemp Fault

(Drive Overtemp)

DriveHardFault

DriveHardFault

(Sercos Init)

DriveHardFault

(CPLD Flt)

E109

IGBT_TempFault

E110

EEPROM_Fault

E111

Regen_PS_OK

Possible Resolution

Nonvolatile memory is corrupt due to control board hardware failure.

Nonvolatile memory is corrupt due to control board software error.

RAM or flash memory validation failure.

Load default parameters, save to nonvolatile memory, and recycle power or reset the drive.

If fault persists, replace module.

Load default parameters, save to nonvolatile memory, and recycle power or reset the drive.

If fault persists, replace module.

Cycle power.

If fault persists, replace module.

Replace the failed module.

Check the cabinet temperature. See System Design

Guidelines on page 22

.

Inverter thermal switch tripped

The drive fan failed.

The cabinet ambient temperature is above rating.

The machine duty cycle requires an RMS current exceeding the continuous rating of the controller.

The airflow access to the Kinetix 7000 drive is limited or blocked.

Change the command profile to reduce speed or increase time.

Check airflow and remove any fan blockage.

DPI hardware initialization fault detected.

Control board hardware failure.

Control hardware fault detected.

Control hardware fault detected.

Junction temperature of Insulated Gate Bipolar Transistor exceeded.

Reset System.

If fault persists, replace system module.

Cycle power.

If fault persists, replace module.

A-to-D conversion state machine error.

If fault persists, replace module.

Check for proper drive sizing.

Install larger kW rated drive.

EEPROM failed.

EEPROM data corrupted or bus not calibrated.

If fault persists, replace module.

The Regen_OK signal is missing at pins 7 and 8 of the GPIO connector.

Check error displays on RPS, and troubleshoot per error message.

Reset system.

All others RESERVED.

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Chapter 6

Status Indicators

Table 51 - Drive Status Indicator

Drive Status LED

Off

Steady Red

Status

Normal, no faults

Drive faulted

Comm Status LED

Off

Flashing Green

Steady Green

Status

No communication

(1)

Establishing communication

Communication ready

Potential Cause

Loose fiber-optic connection.

Broken fiber-optic cable.

Receive fiber-optic cable connected to SERCOS transmit connector and vice versa.

System is still in the process of establishing SERCOS communication.

Node address setting on the drive module does not match SERCOS controller configuration.

No faults or failures.

(1) Refer to Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010 , for more information.

Table 53 - Bus Status Indicator

Possible Resolution

Verify proper fiber-optic cable connection.

Replace fiber-optic cable.

Check proper SERCOS fiber-optic cable connections.

Wait for steady green indicator.

Verify proper node switch setting.

N/A

Bus Status LED

Off

Alternating Red-Green

Flashing Green

Steady Green

Bus power not present.

24V DC control power is present.

Bus power is present, axis disabled.

No faults or failures.

Bus power is present, axis enabled.

No faults or failures.

Potential Cause

N/A

Possible Resolution

N/A

Seven-segment status indicator displays error code.

See the Error Codes on page 138 section and continue

troubleshooting.

Table 52 - Comm Status Indicator

Status

Bus power not present.

Bus power is present in follower drive.

Condition

•

Normal when bus power is not applied.

•

Fault exists, see the Interpret Error Codes and Status Indicators beginning on page 138 .

•

Follower drive is not configured as Common Bus Follow in RSLogix 5000 software.

•

After DC bus voltage is applied, a 2.50 second delay occurs before the indicator begins flashing green.

This is normal operation and provides the common bus leader time to complete precharge.

•

Normal when bus power is not applied. Verify 460V AC connections.

•

Fault exists, see the Interpret Error Codes and Status Indicators beginning on page 138 .

Normal when:

•

24V is not applied to Hardware Enable Input (IOD-2).

•

MSO instruction is not commanded in RSLogix 5000 software.

Normal when:

•

24V is applied to Hardware Enable Input (IOD-2).

•

MSO instruction is commanded in RSLogix 5000 software.

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Table 54 - SERCOS Status Indicator

SERCOS Status

Actively cycling

Phase 0

Displaying a fixed 1

Phase 1

Displaying a fixed 2

Phase 2

Displaying a fixed 3

Phase 3

Status

The drive is looking for a closed SERCOS ring. Wait for phase 1 to complete or take corrective action to reach phase 1.

Condition

Check fiber-optic connections.

Serial ring must enter at the Rx connector and exit TX connector.

Baud rate switch settings conflict.

Verify drive and Logix setup parameters.

Check node addressing on drive and in ControlLogix and RSLogix 5000.

The drive is looking for active nodes. Wait for phase 2 to complete or take corrective action to reach phase 2.

Logix is configuring nodes for communication.

Wait for phase 3 to complete or take corrective action to reach phase 3.

Check RSLogix programming to verify drive configuration against installed hardware.

Verify the appropriate drive model is selected in RSLogix software.

The drive is configuring device specific parameters. Wait for phase 4 to complete or take corrective action to reach phase 4.

Check RSLogix software programming to verify motor configuration against installed hardware.

Verify motor feedback cable connects to MF connector on the drive.

The drive is configured and the SERCOS ring is active.

If low profile connector is used, verify the connection for correct pinout, pinched insulation, and loose wires.

Verify motor feedback cable for continuity and shorts.

Replace the motor.

(1)

Displaying a fixed 4

Phase 4

Flashing an E followed by two numbers

Drive is faulted.

See the Error Codes section on page .

138.

(1) You can access diagnostic information from the module by highlighting the module name in RSLogix 5000 software. A Pseudo Key Failure often indicates that the motor selection does not match the motor installed.

Table 55 - Control Power Status Indicator

CP Status LED

Off

Steady Green

Status

Control power not present.

Control power applied.

Condition

Normal when auxiliary power is not applied to the Control Power (CP) terminal.

Normal when auxiliary power is applied to the Control Power (CP) terminal.

General System Anomalies

These anomalies do not always result in a fault code, but may require troubleshooting to improve performance.

Condition

Axis or system is unstable.

Potential Cause

The position feedback device is incorrect or open.

Unintentionally in Torque mode.

Motor tuning limits are set too high.

Position loop gain or position controller accel/decel rate is improperly set.

Improper grounding or shielding techniques are causing noise to be transmitted into the position feedback or velocity command lines, causing erratic axis movement.

Possible Resolution

Check wiring.

Check to see what primary operation mode was programmed.

Run Tune in RSLogix 5000 software.

Run Tune in RSLogix 5000 software.

Check wiring and ground.

Motor Select limit is incorrectly set (servo motor is not matched to axis module).

Mechanical resonance.

•

Check setups.

•

Run Tune in RSLogix 5000 software.

Notch filter or output filter may be required.

Refer to Axis Properties dialog, Output tab in RSLogix 5000 software.

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Chapter 6

Condition

You cannot obtain the motor acceleration/deceleration that you want.

Motor does not respond to a velocity command.

Presence of noise on command or motor feedback signal wires.

No rotation.

Motor overheating.

Potential Cause

Torque Limit limits are set too low.

Incorrect motor selected in configuration.

The system inertia is excessive.

The system friction torque is excessive.

Possible Resolution

Verify that current limits are set properly.

Select the correct motor and run Tune in RSLogix 5000 software.

•

Check motor size against the application need.

•

Review servo system sizing.

Check motor size against the application need.

Available current is insufficient to supply the correct accel/decel rate.

Acceleration limit is incorrect.

Velocity Limit limits are incorrect.

The axis cannot be enabled for 1.5 seconds after disabling.

Enable signal has not been applied or the enable wiring is incorrect.

The motor wiring is open.

The motor thermal switch has tripped.

•

Check motor size against the application need.

•

Review servo system sizing.

Verify limit settings and correct them, as necessary.

Verify limit settings and correct them, as necessary.

Disable the axis, wait for 1.5 seconds, and enable the axis.

•

Check the controller.

•

Check the wiring.

Check the wiring.

•

Check for a fault.

•

Check the wiring.

Repair or replace the motor.

The motor has malfunctioned.

The coupling between motor and machine has broken.

For example, the motor moves, but the load/machine does not.

Primary operation mode is set incorrectly.

Velocity or current limits are set incorrectly.

Recommended grounding per installation instructions have not been followed.

Line frequency may be present.

Check and correct the mechanics.

Check and properly set the limit.

Check and properly set the limits.

•

Verify grounding.

•

Route wire away from noise sources.

•

Refer to System Design for Control of Electrical Noise, publication

GMC-RM001 .

•

Verify grounding.

•

Route wire away from noise sources.

Variable frequency may be velocity feedback ripple or a disturbance caused by gear teeth, ballscrew balls, or other mechanical wear. The frequency may be a multiple of the motor power transmission components or ballscrew speeds resulting in velocity disturbance.

The motor connections are loose or open.

Foreign matter is lodged in the motor.

The motor load is excessive.

The bearings are worn.

The motor brake is engaged (if supplied).

•

Decouple the motor for verification.

•

Check and improve the performance of the gearbox, ballscrew, and other mechanical items.

Check motor wiring and connections.

Remove foreign matter.

Verify the servo system sizing.

Return the motor for repair.

•

Check brake wiring and function.

•

Return the motor for repair.

The motor is not connect to the load.

The duty cycle is excessive.

Check coupling.

Change the command profile to reduce accel/decel or increase time.

The rotor is partially demagnetized, causing excessive motor current.

Return the motor for repair.

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Condition

Abnormal noise

Erratic operation -

Motor locks into position, runs without control or with reduced torque.

Potential Cause

Motor tuning limits are set too high.

Loose parts are present in the motor.

Through bolts or coupling is loose.

The bearings are worn.

Mechanical resonance.

Motor power phases U and V, U and W, or V and W reversed.

Sine, Cosine or Rotor leads are reversed in the feedback cable connector.

Sine, Cosine, Rotor lead sets of resolver feedback are reversed.

Possible Resolution

Run Tune in RSLogix 5000 software again.

•

Remove the loose parts.

•

Return motor for repair.

•

Replace motor.

Tighten bolts.

Return motor for repair.

Notch filter may be required (refer to Axis Properties dialog, Output tab in RSLogix 5000 software).

Check and correct motor power wiring.

Check and correct motor feedback wiring.

Check and correct motor feedback wiring.

Logix/Drive Fault Behavior

These RSLogix 5000 fault actions are configurable from the Axis Properties dialog box, Fault Actions tab.

Table 56 - Drive Fault Action Definitions

Drive Fault Action

Shutdown

Disable Drive

Stop Motion

Status Only

Definition

The drive is disabled and the contactor enable relay opens. An uncontrolled stop occurs, and the motor coasts to a stop.

The drive is disabled. An uncontrolled stop occurs, and the motor coasts to a stop.

Logix configuration for velocity loop Kp/Ki is followed. When zero speed is reached or stopping time is exceeded, the drive is disabled. Stopping time and stopping torque are configurable parameters in RSLogix 5000 software.

Drive continues to operate. Status is provided by the seven-segment status indicator, drive status indicator, and DPI (if used).

Only selected faults are programmable. In Table 57 on page 147 , the controlling

attribute is given for programmable fault actions.

Figure 68 - RSLogix 5000 Axis Properties - Fault Actions Tab Example

Drive Fault Action/Attribute for

Motor Overtemp fault (E04).

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Chapter 6

Table 57 - Logix/Drive Fault Behavior Definitions

Logix Fault Message

(HIM)

MotorOvertempFault

(Motor Overtemp)

Error

Code

Description Drive Fault Action/

Attribute

RSLogix

Programmable

Fault Action?

E04

(1)

The motor thermal switch was tripped.

Firmware I

2 t protection does not generate a fault, rather it dynamically folds back current when 110% of motor rating is reached. Setting the Motor Thermal fault action to Status Only will bypass this function.

STOP MOTION / Motor

Thermal

Yes

DriveOvercurrentFault

(Power Fault)

HardOvertravelFault

(+/- Hard Overtravel)

MotFeedbackFault

(Motor Feedback Loss)

E05

E06

E07

An instantaneous overcurrent was detected in the inverter power section

Axis moved beyond the physical travel limits in the positive/negative direction. This fault can be configured for status only.

The feedback wiring is open, shorted or missing.

SHUTDOWN

STOP MOTION / Hard

Overtravel

DISABLE DRIVE

No

Yes

No

BusUndervoltageFault

(Bus Under Voltage)

E09

E10

With three-phase present, the DC bus voltage is below limits.

The trip point is 800V DC for 460 drives.

DC bus voltage is below limits when any axis on common-bus follower was enabled.

The DC bus voltage is above limits.

The trip point is 800V DC for 460 drives.

SHUTDOWN

SHUTDOWN

No

No

DriveOvervoltageFault

(Bus Overvoltage)

MotFeedbackFault

(Illegal Hall State)

SoftOvertravelFault

(+/- Software Overtravel)

OverSpeedFault

(Overspeed Fault)

PositionErrorFault

(Follow Error)

MotFeedbackFault

(Mtr Fdbk AQB)

AuxFeedbackFault

(Aux Feedback Comm)

DriveOvertempFault

(Drive Overtemperature Fault)

MotFeedbackFault

(Motor Feedback Comm)

GroundShortFault

(Ground Fault)

DriveUndervoltageFault

(Precharge Fault)

E11

E16

E18

E19

E20

E21

E23

E30

E34

E35

State of Hall feedback inputs in incorrect.

Axis position exceeded maximum software setting in the positive/negative direction.

This fault can be configured for status only.

Axis speed has reached 150% of the maximum rated setting. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed.

STOP MOTION / Soft

Overtravel

DISABLE DRIVE

Axis position error limit has been exceeded. This fault can be configured for status only.

STOP MOTION /

Position Error

Motor encoder has encountered an illegal state transition.

Communication was not established with an intelligent (Stegmann) encoder on the

Auxiliary feedback port.

An IPM thermal protection fault occurred.

Communication was not established with an intelligent (Stegmann) encoder on the motor feedback port.

Excessive ground current in the converter was detected.

The converter precharge cycle has failed.

DISABLE DRIVE

DISABLE DRIVE

STOP MOTION

DISABLE

Drive Thermal

STOP MOTION

SHUTDOWN

SHUTDOWN

No

Yes

No

Yes

No

No

Yes

No

No

No

PowerPhaseLossFault

(Phase Loss Flt)

E37

•

One or more phases of the input ac power is missing.

•

Axis was enabled when main (three-phase) power was removed.

•

Common bus follower axis was enabled when dc bus power was removed.

SHUTDOWN/ STOP

MOTION

No

SERCOSFault

(SERCOS Ring Flt)

DriveHardFault

(Self Sense Flt)

DriveEnableInputFault

(Drive Enable Flt)

E38

E39

E43

The SERCOS ring is not active after being active and operational.

Self-sensing commutation fault detected

Generated when Enable input switches off when drive is enabled.

STOP MOTION

DISABLE DRIVE

STOP MOTION

No

No

Yes

DriveHardFault

(Safe-Off HW Flt)

E49

Safe-off function mismatch. Drive will not permit motion. Refer to the Kinetix Safe-off

Feature Safety Reference Manual, publication GMC-RM002 , for more information. Only applies to drives with Safe-off feature.

SHUTDOWN No

SERCOSFault

(SERCOS Same ADDR)

DriveHardFault

(Ifbk HW Fault)

E50

E54

Duplicate node address detected on SERCOS ring.

Current feedback hardware fault detected.

STOP MOTION

SHUTDOWN

No

No

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Troubleshoot the Kinetix 7000 Drive System

Logix Fault Message

(HIM)

Error

Code

Description Drive Fault Action/

Attribute

RSLogix

Programmable

Fault Action?

AuxFeedbackFault

(Aux Fdbk AQB)

AuxFeedbackFault

(Aux Fdbk Loss)

AuxFeedbackNoise

(Aux Fdbk Noise)

MotorFeedbackNoise

(Mtr Fdbk Noise)

No Fault Message

(condition indicated by onscreen message)

(Hookup Fault)

No Fault Message

(condition indicated by onscreen message)

(Atune Flt)

DriveHardFault

(Task Init)

DriveHardFault

(SCANport Comm)

DriveHardFault

(Objects Init)

DriveHardFault

(NV Mem Init)

DriveHardFault

(Memory Init)

DriveOvertempFault

(Drive Overtemp)

DriveHardFault

(Can Init)

DriveHardFault

SERCOS Init

HardwareFault

(CPLD FLT)

IGBTTempFault

(IGBTFLT)

EEPROMFault

(CPLD FLT)

RegenPSOK

(CPLD FLT)

All Others RESERVED

E61

E62

E63

E64

E65

E66

E67

E68

E69

E70

E71

E72

E76

E78

E80

E109

E110

E111

Auxiliary encoder has encountered an illegal state transition.

The feedback wiring is open, shorted or missing.

Presence of noise on auxiliary feedback cable.

Presence of noise on motor feedback cable.

Hookup procedure failed.

Autotune procedure failed.

Operating system failed.

DPI communication failed.

Nonvolatile memory attribute out of range.

Nonvolatile memory corrupted.

RAM or flash memory validation failure.

Inverter temperature limit exceeded. Firmware I

2 t protection does not generate a fault, rather it dynamically folds back current when 110% of drive rating is reached.

Either DPI or backplane CAN initialization failure.

Control hardware fault detected.

Control hardware fault detected.

Junction temperature of IGBT exceeded.

EEPROM failure. EEPROM data corrupt or bus not calibrated.

Regenerative PS+/- missing at GPIO.

DISABLE DRIVE

DISABLE DRIVE

DISABLE DRIVE /

Feedback Noise

DISABLE DRIVE

DISABLE DRIVE

SHUTDOWN

STOP MOTION

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

SHUTDOWN

No

No

Yes

No

No

No

No

No

No

No

Yes

No

No

No

No

No

No

(1) The Logix Motor Thermal Fault Action is tied to the motor thermostat fault. If this is set to Shutdown or Disable (in Logix), the drive will fold back the current when the I

2

T calculation indicates that the motor temperature has exceeded 10% of its rated temperature. If it is set to Stop Motion or Status Only, the drive will not fold back the current. The I

2

T calculation never generates a fault.

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Appendix

A

Specifications and Dimensions

This appendix provides product specifications and mounting dimensions for your Kinetix 7000 system components.

Topic

Power Specifications

Power Dissipation Specifications

General Specifications

AC Line Filter Specifications

AC Line Reactors

External Shunt Modules

Precharge Capacities of the Regenerative Power Supply

Product Dimensions

155

155

155

157

157

Page

150

152

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149

Appendix A

Specifications and Dimensions

Power Specifications

This section contains power specifications for the Kinetix 7000 drive.

Attribute

AC input voltage

AC input frequency

Bandwidth

(1)

Velocity loop

Current loop

PWM frequency

Main AC input current

Nom (rms)

Max inrush (A peak)

DC input voltage

DC input current

Control power input Voltage

Control power DC input current

Nom (rms)

Maximum inrush (rms)

Continuous output current (rms)

Continuous output current (0-pk)

Peak output current (rms)

3 s duration

60 s duration

Peak output current (0-pk)

3 s duration

60 s duration

Bus overvoltage

Bus undervoltage

Continuous power output, nom

Continuous power output (Hp)

Maximum power cycles/minute

AC line

DC bus

DC bus discharge time

Efficiency

Total capacitance

(3)

Short circuit current rating

2099-BM06-S

342…528V AC rms three-phase (380…480V nom)

47…63 Hz

500 Hz

1300 Hz

4 kHz

36.7 A

18.0 A

450…750V DC

42.9 A

3.3 A

6.0 A

40.0 A

56.0 A

47.7 A

18.0 A

55.7 A

18…30V DC (24V DC, nom)

68.0 A

51.0 A

96.0 A

72.0 A

800V DC

275…560V DC

22 kW

30 Hp

(2)

2099-BM07-S

52.0 A

73.0 A

80.0 A

60.0 A

113 A

84.8 A

30 kW

40 Hp

2099-BM08-S

59.6 A

18.0 A

69.7 A

65.0 A

92.0 A

104 A

78.0A

147 A

110 A

37 kW

50 Hp

4 per minute (pre-charge provided by drive)

3 minutes after removal of main AC power

97.5%

1800

μ

F 2400

μ

F

200,000 A (rms) symmetrical

3000

μ

F

2099-BM09-S

90.1 A

96.0 A

105 A

96.0 A

135 A

154 A

115 A

217.7 A

162.6 A

56 kW

75 Hp

2 per minute (DC pre-charge provided by the regenerative power supply)

4500

μ

F

2099-BM10-S

117 A

118 A

137 A

125 A

176 A

163 A

138 A

230.5 A

195 A

75 kW

100 Hp

6000

μ

F

2099-BM11-S

500 Hz

500 Hz

2 kHz

169 A

141 A

204 A

180 A

254 A

312 A

234 A

441 A

331 A

112 kW

150 Hp

8400

μ

F

2099-BM12-S

233 A

141 A

281 A

248 A

351 A

372 A

273 A

526 A

386 A

149 kW

200 Hp

8400

μ

F

(1) Bandwidth values vary based on tuning parameters and mechanical components.

(2) Bus undervoltage will vary based on input line voltage.

(3) If DC input is supplied to 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, or 2099-BM12-S drives, the precharge capability must be provided at the system level. Disconnect switches must not be used between the input of the drive and a common DC bus without the use of an external precharge device.

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Specifications and Dimensions

Appendix A

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Circuit Breaker/Fuse Specifications

While circuit breakers offer some convenience, there are limitations for their use.

Circuit breakers do not handle high current inrush as well as fuses.

Make sure the selected components are properly coordinated and meet acceptable codes including any requirements for branch circuit protection.

Evaluation of the short-circuit available current is critical and must be kept below the short-circuit current rating of the circuit breaker.

Use class CC, T, RK1, or J fuses, with current rating as indicated in the table below. The following fuse examples and short-circuit current ratings are recommended for use with the 2099-BM

xx

-S drives when the Line Interface

Module (LIM) is not used.

IMPORTANT

LIM modules (catalog numbers 2094-BL

xx

S and 2094-XL75S-C

x

) provide branch circuit protection to the Kinetix 7000 drive. Follow all applicable NEC and local codes.

Table 58 - 460V AC Input Drive Fuse and Motor Circuit Protector Specifications

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Bussmann

Fuse

LPJ-90SP

LPJ-110SP

LPJ-125SP

LPJ-200SP

LPJ-250SP

LPJ-400SP

LPJ-500SP

Dual Element Time Delay

Fuse (min/max)

A rms

50/90

60/110

80/125

125/200

150/250

225/400

300/550

Non-Time Delay

Fuse (min/max)

A rms

50/150

60/200

80/250

125/300

150/500

225/600

300/700

100

125

150

250

400

Motor Circuit

Protector (max)

A rms

50

70

Common DC Bus Fuse Specifications

Table 59 - Ferraz Shawmut Fuse Recommendations i²t (A²Sec)

69.7

105

137

204

281

Drive Current

Rating (Adc)

42.9

55.7

Recommended

Fuse

HSJ80

HSJ90

HSJ100

HSJ175

HSJ200

HSJ400

HSJ400

100

175

200

400

400

Fuse Current

Rating

80

90

Pre-Arc

1600

2300

2700

8000

14000

63000

63000

Max. Clearing @

600V AC

15000

21000

23000

60000

92000

450000

450000

Peak Let-Through Current at 100kA rms

7000 A

7400 A

7700 A

12000 A

13000 A

21000 A

21000 A

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151

Appendix A

Specifications and Dimensions

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Table 60 - Bussmann Fuse Recommendations i²t (A²Sec)

69.7

105

137

204

281

Drive Current

Rating (Adc)

42.9

55.7

Recommended

Fuse

FWJ-80A

FWJ-100A

FWJ-125A

FWJ-175A

FWJ-200A

FWJ-500A

FWJ-500A

125

175

200

500

500

Fuse Current

Rating

80

100

Pre-Arc

1550

2800

4800

7500

11700

39500

39500

Max Clearing @

600V AC

9700

17500

35000

65000

80000

329000

329000

Peak Let-Through Current at 100kA rms

6300 A

8000 A

10000 A

12000 A

13000 A

21000 A

21000 A

Contactor Ratings

The table below lists the recommended contactor ratings for Kinetix 7000 drives installed without a Line Interface Module (LIM).

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

Contactor

100-C43DJ01

100-D95EN11

100-D140EN11

100-D180EN11

100-D250EN11

(1) Electronic coil control power requirements = 24V DC @ 15 mA.

Safety Contactor

100S-C43-DJD4C

100S-D95EN22C

100S-D140EN22C

100S-D180EN22C

100S-D250EN22C

Coil Type

Standard with Diode

Electronic Coil

(1)

Coil Voltage Requirements

24V DC

24V DC for control and 480V AC for coil power

Power Dissipation

Specifications

Use this table to size an enclosure and calculate required ventilation for your

Kinetix 7000 drive system.

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

294

388

452

645

Usage as a % of Rated Power Output

W

50% 100%

465

619

730

1072

882

1275

1438

1479

2125

2437

152

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General Specifications

Specifications and Dimensions

Appendix A

Maximum Feedback Cable Lengths

Although motor power and feedback cables are available in standard lengths up to 90 m (295.3 ft), the drive/motor/feedback combination may limit the maximum feedback cable length. These tables assume the use of recommended

2090-series cables.

Table 61 - Cable Lengths for Compatible Rotary Motors

Motor Cat. No.

Absolute High-resolution (5V)

Encoder

m (ft)

Absolute High-resolution (9V)

Encoder

m (ft)

90 (295.3)

MPL-B5

xxx…

MPL-B9

xxx

-S/M

MPM-B165

xx…

MPM-B215

xx

-S/M

RDB-B215

xx

-7/3

RDB-B290

xx

-7/3 or

RDB-B410

xx

-7/3

HPK-B

xxxxx

-S/M or

HPK-E

xxxxx

-S/M

30 (98.4)

90 (295.3)

90 (295.3)

90 (295.3)

Weight Specifications

Weight, approx.

kg (lb)

Drive Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

18.55 (40.9)

37.2 (82.0)

71.4 (157.5)

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153

Appendix A

Specifications and Dimensions

Certifications

Agency Certification

c-UL-us

CE

C-Tick

KC

(2)

Functional Safety

(1)

Standards

UL Listed to U.S. and Canadian safety standards (UL 508C File E59272).

Solid-state motor overload protection provides dynamic fold-back of motor current when 110% of the motor rating is reached with a peak current limit based on the peak rating of the motor as investigated by UL to comply with UL 508C (UL File E59272, volume 1, section 22).

European Union 2004/108/EC EMC Directive compliant with:

•

EN 60034-1:2004: Rotating electrical machines - Part 1: Rating and performance

•

EN 61800-3:2004: Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

European Union 2006/95/EC Low Voltage Directive compliant with:

•

EN 50178:1997 - Electronic equipment for use in power installations

•

EN 60204-1:2006 - Safety of Machinery - Electrical equipment of machines - Part 1: General requirements

•

IEC 61508 Part 1-7:2000 - Functional safety of electrical/electronic/programmable electronic safety-related systems

•

EN ISO 13849-1:2008 - Safety of machinery. Safety-related parts of control systems - Part 1: General principles for design

•

Radiocommunications Act: 1992

•

Radiocommunications (Electromagnetic Compatibility) Standard: 1998

•

Radiocommunications (Compliance Labelling - Incidental Emissions) Notice: 1998

•

AS/NZS CISPR 11: 2002 (Group 2, Class A)

Korean Registration of Broadcasting and Communications Equipment, compliant with:

•

Article 58-2 of Radio Waves Act, Clause 3

•

Registration Number: KCC-REM-RAA-2099

(1) When product is marked, refer to www.rockwellautomation.com/products/certification/ for Declarations of Conformity Certificates.

(2) Underwriters Laboratories Inc. has not evaluated the safe-off, safe torque-off, or safe speed-monitoring options in these products.

Attribute

Temperature, ambient

Relative humidity

Altitude

Vibration

Shock

Environmental Specifications

Operational Range

0…50

°

C (32…122

°

F)

5…95% noncondensing

1000 m (3281 ft)

3000 m (9843 ft) with derating

Storage Range (nonoperating)

-40…70

°

C (-40…158

5…95% noncondensing

°

F)

3000 m (9843 ft) during transport

5…55 Hz @ 0.35 mm (0.014 in.) double amplitude, continuous displacement; 55…500 Hz @ 2.0 g peak constant acceleration (10 sweeps in each of 3 mutually perpendicular directions).

15 g, 11 ms half-sine pulse (3 pulses in each direction of 3 mutually perpendicular directions)

154

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Specifications and Dimensions

Appendix A

AC Line Filter Specifications

Line filters compatible with a Kinetix 7000 drive sourcing input power from an

AC power supply are listed below.

Kinetix 7000 Drive

Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

AC Line Filter

Cat. No.

2090- XXLF-TC350

2090- XXLF-TC365

2090- XXLF-TC3100

2090- XXLF-TC3150

2090- XXLF-TC3200

2090- XXLF-TC3250

Line filters compatible with a Kinetix 7000 drive sourcing input power from a regenerative DC bus with a 8720MC-RPS unit are listed below.

8720MC-RPS

Cat. No.

8720MC-RPS065BM-HV2

8720MC-RPS190BM

AC Line Filter

Manufacturer and Cat. No.

Schaffner: FN3100-80-35

Soshin Electric: HF3080C-TOA

8720MC-EF190-VB

AC Line Reactors

380…480V, 50/60 Hz, three-phase, line reactors compatible with a Kinetix 7000 drive connected to a three-phase, AC input power source are listed below.

Table 62 - Compatible Kinetix 7000 Drives and AC Line Reactors

Kinetix 7000 Drive

Cat. No.

2099-BM06-S

2099-BM07-S

2099-BM08-S

2099-BM09-S

2099-BM10-S

2099-BM11-S

2099-BM12-S

3% Impedance Input Line Reactor

(1)

IP00 (Open Style)

Cat. No.

IP11 (NEMA/UL Type 1)

Cat. No.

1321-3R45-B

1321-3R55-B

1321-3R80-B

1321-3R100-B

1321-3R130-B

1321-3R200-B

1321-3RB250-B

1321-3RA45-B

1321-3RA55-B

1321-3RA80-B

1321-3RA100-B

1321-3RA130-B

1321-3RA200-B

1321-3RAB250-B

(1) Input line reactors were sized based on the NEC fundamental motor amps.

5% Impedance Input Line Reactor

(1)

IP00 (Open Style)

Cat. No.

IP11 (NEMA/UL Type 1)

Cat. No.

1321-3R45-C

1321-3R55-C

1321-3R80-C

1321-3R100-C

1321-3RA45-C

1321-3RA55-C

1321-3RA80-C

1321-3RA100-C

1321-3R130-C

1321-3R200-C

1321-3RB250-C

1321-3RA130-C

1321-3RA200-C

1321-3RAB250-C

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

155

Appendix A

Specifications and Dimensions

External Shunt Modules

Line reactors compatible with a 8720MC-RPS Regenerative Power Supply sourcing input power from an AC power supply are listed below. They must be

configured as shown in the Regenerative Power Supply example on page 169

.

Table 63 - Compatible Kinetix 7000 Drives, 8720MC-RPS Regenerative Power Supplies and

8720MC Line Reactors

Kinetix 7000 Drive

Cat. No.

2099-BM07-S

2099-BM08-S

2099-BM09-S

8720MC-RPS Regenerative Power

Supply Cat. No.

(1)

8720MC-RPS065BM

8720MC Line Reactor

Cat. No.

8720MC-LR05-048B

2099-BM11-S

8720MC-RPS065BM and

8720MC-RPS065BS

8720MC-RPS190BM

8720MC-LR10-062B

8720MC-LR05-048B

(requires two units, one for the master

RPS unit and one for the slave RPS unit.)

8720MC-LR10-062B

(requires two units, one for the master

RPS unit and one for the slave RPS unit.)

8720MC-LR10-100B (required two units)

2099-BM12-S

(1) Regenerative Power Supply (RPS) selection is for a single motor/drive combination. When combining multiple drives on the same

RPS module, the selection will change.

Refer to this table for active shunt solutions for use with Kinetix 7000 drives from

Rockwell Automation Encompass Partners.

Rockwell Automation Encompass Partner

Powerohm Resistors, Inc.

Bonitron, Inc.

Contact Information

5713 13th Street

Katy, TX 77493

Tel: (800) 838-4694 http://www.powerohm.com

521 Fairground Court,

Nashville, TN 37211

Tel: (615) 244-2825 http://www.bonitron.com

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Specifications and Dimensions

Appendix A

Precharge Capacities of the

Regenerative Power Supply

Internal (built-in) and external precharge capacities of the regenerative power supply (RPS) are listed below.

Attribute 8720MC-RPS065B

x

-HV2

Rated Output kVa (750V DC bus)

(1)

45

8720MC-RPS190B

x

133

DC Amperes Continuous

(1)

64

DC Amperes Peak (1 minute)

(1)

190

96 285

Built-in Capacitor

Built-in Resistor (Resistance/W)

External Resistor (Min Resistance)

(2) (3)

External Circuit (Min Resistance)

(3)

1900 μF

7000 μF (22 Ohms/120 W)

110000 μF (20 Ohms)

220000 μF (4.7 Ohms)

7600 μF

25000 μF (10 Ohms/400 W)

165000 μF (10 Ohms)

495000 μF (1.5 Ohms)

(1) For 8720MC-RPS065-HV2 and 8720MC-RPS190, you may have up to two slave units with a master unit. Multiply these values by the number of slave units.

(2) Use this case only when the bus capacitance exceeds the internal precharge rating. You must use the specified resistor. Calculate rated wattage and surge resistivity for that resistor. See the 8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001 , for configuration details.

(3) Use this case only when the bus capacitance exceeds the external resistor rating. You must use the specified resistor. Calculate rated wattage and surge resistivity for that resistor. See the 8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001 , for configuration details.

IMPORTANT

Large levels of load capacitance may require modification of the 8720 regenerative power supply internal precharge/discharge circuit.

See the Wiring instructions in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , for information on how to determine the appropriate precharge/discharge resistance power value

(Ohms/Watt) to accommodate the capacitance of your system.

Product Dimensions

This section provides a quick reference table to common dimensions for Kinetix

7000 drives (height, width, depth, and mounting hole locations), and outline drawings with dimensions related to the specific frame sizes.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

157

Appendix A

Specifications and Dimensions

Ø 7.0

(0.28) X2

192

(7.56)

Figure 69 - 2099-BM06-S 2099-BM07-S, and 2099-BM08-S Approximate Dimensions

Dimensions are in millimeters (inches)

15.27

(0.60)

224.3

(8.82)

517.5

(20.37)

495.0

(19.49)

158

8.0

(0.31)

31.9

(1.26)

Ø 28.7

(1.13)

7.0

(0.28)

254.12

(10.00)

7.0

(0.28)

Ø 22.4

(0.88)

Ø 37.3

(1.47) X2

Important:

Additional clearance below the connector is necessary to provide the recommended cable bend radius.

Ø 47.0

(1.85) 2X

Ø 28.7

(1.13)

165.9

(6.53)

165.1

(6.50)

160.1

(6.30)

151.1

(5.95)

31.9

(1.26)

66.0

(2.60)

97.0

(3.82)

137.2

(5.40)

187.0

(7.36)

Bottom View

(2099-BM06-S and 2099-BM07-S)

165.9

(6.53)

165.1

(6.50)

160.1

(6.30)

31.9

(1.26)

66.0

(2.60)

130.0

(5.19)

186.0

(7.32)

Bottom View

(2099-BM08-S)

Ø 34.9

(1.37) 2X

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Ø 6.5

(0.26) 2X

Ø 15.0

(0.59) 2X

7.0

(0.28)

Specifications and Dimensions

Appendix A

225.0

(8.86)

Figure 70 - 2099-BM09-S and 2099-BM10-S Approximate Dimensions

Dimensions are in millimeters (inches)

37.5

(1.48)

286.7

(11.29)

644.5

(25.37)

625.0

(24.61)

644.5

(25.37)

2099-BM09

690.3

(27.18)

2099-BM10

12.0

(0.47)

31.9

(1.26)

259.1

(10.20) 2X

6.5

(0.26) 2X

300.0

(11.81)

Ø 34.9

(1.37) 2X

60.4

(2.38)

159.5

(6.28)

31.9

(1.26)

85.1

(3.35)

65.0

(2.56) 2X

130

(5.12)

170

(6.69)

20.4

(0.80) 2X

Ø 22.2 (0.87)

Ø 62.7 (2.47) 2X

45.5

(1.79)

70

(2.75)

35

(1.38)

31.8

(1.25)

24.5

(0.96) 2X

153.5

(6.04) 2X

Important:

Additional clearance below the connector is necessary to provide the recommended cable bend radius.

Ø 34.9

(1.37)

Ø 22.2

(0.87) 3X

Ø 62.7

(2.47) 2X

34.1

(1.34)

128.1

(5.04)

22.4

(0.88)

104.3

(4.10)

53.0

(2.08) 2X

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159

Appendix A

Specifications and Dimensions

8.5

(0.33) 2X

Ø 18.0

(0.71) 2X

7.9

(0.31)

300.0

(11.81)

Figure 71 - 2099-BM11-S and 2099-BM12-S Approximate Dimensions

Dimensions are in millimeters (inches)

49.6

(1.95)

282.8

(11.13)

850.0

(33.46)

824.0

(32.44)

849.97

(33.46)

977.1

(38.47)

160

14.5

(0.04)

30.0

(1.18)

8.5

(0.33) 2X

360.6

(14.20) 2X

399.2

(15.72)

Ø 22.2 (0.87) 4X

Ø 34.9

(1.37)

73.8

(2.90) 36.9 (1.45) 4X

148.4

(5.84)

31.69 (1.25)

22.0 (0.86) 2X

128

(5.04)

45.0

(1.77)

100

(3.94)

150 (5.90) 2X

200 (7.87)

67.2

(2.64)

151.7

(5.97)

Ø 62.7 (2.47) 2X

Important:

Additional clearance below the connector is necessary to provide the recommended cable bend radius.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Appendix

B

Interconnect Diagrams

This appendix provides wiring examples and system block diagrams to assist you in wiring your Kinetix 7000 system components.

Topic

Interconnect Diagram Notes

Page

162

Figure 72 Kinetix 7000 Drive AC Power Wiring 163

Figure 73 Kinetix 7000 Drive AC Powered with a 8720MC-RPS065BM Regenerative Power Supply 164

Figure 74 8720MC-RPS065BM Regenerative Power Supply to a Single Kinetix 7000 Drive

Figure 75 8720MC-RPS065BM Regenerative Power Supply to Multiple Kinetix 7000 Drives

165

166

Figure 76 Dual 8720MC-RPS065Bx Regenerative Power Supplies to a Single Kinetix 7000 Drive 167

Figure 77 Kinetix 7000 Drive AC Powered with a 8720MC-RPS190BM Regenerative Power Supply 168

Figure 78 8720MC-RPS190BM Regenerative Power Supply to a Single Kinetix 7000 Drive

Figure 79 8720MC-RPS190BM Regenerative Power Supply to Multiple Kinetix 7000 Drives

Figure 80 Dual 8720MC-RPS190Bx Regenerative Power Supplies to a Single Kinetix 7000 Drive

Figure 81 Motors with High Resolution Feedback (Bayonet Style Connector)

Figure 83 Motors with High Resolution Feedback (Circular DIN Style Connector)

Figure 84 HPK-Series High-power Motor with High Resolution Feedback

Figure 86 Example with RDD-Series (Bulletin RDB-B) Motors

Figure 87

Kinetix Safe-off Feature Block Diagram

174

175

177

178

169

170

171

172

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

161

Appendix B

Interconnect Diagrams

Interconnect Diagram Notes

The notes below apply to the Kinetix 7000 drive wiring examples on the following pages.

9

10

11

7

8

4

5

2

3

Note

1

Information

For power wiring specifications, refer to Power Wiring Requirements on page

85

.

For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Specifications on page 151

and 148.

Place AC (EMC) line filters as close to the drive as possible and do not route very dirty wires in wireway. If routing in wireway is unavoidable, use shielded cable with shields

grounded to the drive chassis and filter case. For line filter specifications, refer to the AC Line Filter Specifications on page 155

. See Establish Noise Zones on page 30 for wire

routing guidelines.

Contactor coil (M1) needs integrated surge suppressors for AC coil operation. Refer to the Contactor Ratings on page 152

for more information.

The default configuration for the ground jumper is for grounded power at the customer site. Ungrounded, impedance grounded, high resistive grounded, B phase grounded, or common DC bus power distribution system sites must disconnect the protective MOVs and Common Mode Capacitors to guard against unstable operation

and/or drive damage. Refer to Determine the Input Power Configuration on page 75 for more information.

6

ATTENTION:

Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN 1050 and EN 954 estimation and safety performance categories. For more information, refer to Understanding the Machinery Directive, publication SHB-900 .

Use of an external 24V DC control power supply is recommended for energizing the main control board. This allows the SERCOS ring to remain active when main power is removed. The main control board is powered from the DC bus during drive operation and can be used in this manner, if necessary.

The General Purpose Relay outputs on the Kinetix 7000 drive are configured as follows: GPR1+ and GRP1- have noise suppression circuitry and should be used for the motor brake, if used. The default setting for GPR2+ and GPR2- is DROK or Drive_OK. The GPR2 contacts close when external 24V DC control power is applied to the Control

Power terminals and there are no shutdown faults.

External AC input power for the cooling fan is required only for 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, and 2099-BM12-S drives. The cooling fans on 2099-BM06-S,

2099-BM07-S, and 2099-BM08-S drives are powered internally.

Dual 8720MC-RPS

xxx

units use a ribbon cable to connect the master unit to the slave unit control. The ribbon cable is included with the slave unit.

Contact for use with a safety circuit or other system requirement.

162

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Interconnect Diagrams

Appendix B

Power Wiring Examples

Figure 72 - Kinetix 7000 Drive AC Power Wiring

Power Cables*

DC Input Connections

Stop String See Note 8

Three Phase Motor Power Connections

AC Input and DC Bus Output Connections

Fan Power Connections See Note 9

1. Motor Brake (if used) and Feedback 2. Machine Feedback and Drive I/O 3. Drive Communications

AC Line Filter * See Note 3

(Drive Main Power On)*

(+10/-15%) 460VAC RMS,

50/60 Hz See Note 1

24V DC (Can also use 120/240V AC - see “General Purpose Relay (GPR Connector)” on page 61 for ratings. Connected components must match input power rating)*

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

163

Appendix B

Interconnect Diagrams

Regenerative Power Supply

*Line Reactor (8720MC for

*M1 AUX

*MC AUX

Figure 73 - Kinetix 7000 Drive AC Powered with a 8720MC-RPS065BM Regenerative Power Supply

Power Connections Stop-Start String (from PLC or other control string)

Control Stop String See Note 8 but not shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications

Fault Relay Contact

M1* Note 4

AC Line Fil

*Circuit Breaker

Fusing See Note 3

IMPORTANT

380V AC RMS, 50 Hz or 460V AC RMS, 6 Hz

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

164

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Interconnect Diagrams

Appendix B

Figure 74 - 8720MC-RPS065BM Regenerative Power Supply to a Single Kinetix 7000 Drive

Power Connections but not shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications

Fault Relay Contact

*Line Reactor (8720MC for

AC Line Filter See Note 3

AC Line Filter for Main Power See Note 3

*Circuit Breaker

IMPORTANT

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

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165

Appendix B

Interconnect Diagrams

Power Co

DC Bus Connections

(see table in Appendix A)

CR2* See

Figure 75 - 8720MC-RPS065BM Regenerative Power Supply to Multiple Kinetix 7000 Drives

Stop String See Notes 6 and 8

Stop String See Notes 6 and 8

Power Co

DC Bus Connections shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications

(see table in Appendix A)

CR2* See

Fault Relay Contact

*DC Line Fuses

Regenerative Power Supply

*Line Reactor (8720MC for

AC Line Filter See Note 3

380V AC RMS, 50 Hz or 460V AC RMS, 60 Hz

AC Line Filter for Main Power See Note 3

*Circuit Breaker

IMPORTANT

166

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Regenerative Power Supply

(see table in Appendix A)

DC Bus Co

Interconnect Diagrams

Appendix B

Figure 76 - Dual 8720MC-RPS065B

x

Regenerative Power Supplies to a Single Kinetix 7000 Drive

Stop String See Notes 6 and 8 and Power Connections but not shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications or 24V DC*

PIFS CN2

PIFS CN3

Regenerative Power Supply

DC Line Fuses*

Fault Relay Contact

*Line Reactor (8720MC for

Contactor* See Note 4

*Line Reactor (8720MC for

Contactor See Note 4

Input Fusing* See Note 2

Input Fusing* See Note 2

Three-phase AC Line Filter for Main Power*

AC Line Filter for Main Power*

IMPORTANT

(+10/-15%) 380V AC RMS, 50 Hz or 460V AC RMS, 60 Hz See Note 1

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

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167

Appendix B

Interconnect Diagrams

Figure 77 - Kinetix 7000 Drive AC Powered with a 8720MC-RPS190BM Regenerative Power Supply

Power Connections

Stop-Start String (from PLC or other control string)

Motion Control I/O See Note 11

Control Stop String See Note 8 but not shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications

Fault Relay Contact

Regenerative Power Supply

M1* Note 4

AC Line Fil

BLK

RED

YLW

BLK

RED

YLW

A1 A2 A3 A4 A5 B1 B2 B3 B4 B5

1 2 3

R1 S1 T1

A1 A2 A3 A4 A5 B1 B2 B3 B4 B5

MC1 MC2

0V2 NC

Fusing See Note 3

*Circuit Breaker See Note 2

Fusing See Note 2

380V AC RMS, 50 Hz or 460V AC RMS, 60 Hz See Note 1

IMPORTANT

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

168

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Interconnect Diagrams

Appendix B

Figure 78 - 8720MC-RPS190BM Regenerative Power Supply to a Single Kinetix 7000 Drive

Motion Control I/O See Note 11 shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications

Fault Relay Contact

Regenerative Power Supply

BLK

RED

YLW

BLK

RED

YLW

A1 A2 A3 A4 A5 B1 B2 B3 B4 B5

1 2 3

R1 S1 T1

A1 A2 A3 A4 A5 B1 B2 B3 B4 B5

MC1 MC2

0V2 NC

*Circuit Breaker See N\ote 2

Fusing See Note 2

IMPORTANT

(+10/-15%) 380V AC RMS, 50 Hz or 460V AC RMS, 60 Hz See Note 1

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

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169

Appendix B

Interconnect Diagrams

(see table in Appendix A)

DC Bus Connections

Power Co

Figure 79 - 8720MC-RPS190BM Regenerative Power Supply to Multiple Kinetix 7000 Drives

Stop String See Notes 6 and 8

Stop String See Notes 6 and 8

DC Bus Connections

Power Co

CR2* See

(see table in Appendix A)

CR2* See

*DC Line Fuses

Fault Relay Contact

Regenerative Power Supply shown in this diagram: 1. +24V DC Control Power 2. Motor Feedback, Brake (if used), and Power 3. Drive I/O and Communications

BLK

RED

YLW

BLK

RED

YLW

A1 A2 A3 A4 A5 B1 B2 B3 B4 B5

1 2 3

R1 S1 T1

A1 A2 A3 A4 A5 B1 B2 B3 B4 B5

MC1 MC2

0V2 NC

*Circuit Breaker See N\ote 2

Fusing See Note 2

(+10/-15%) 380V AC RMS, 50 Hz or 460V AC RMS, 60 Hz See Note 1

IMPORTANT

170

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Interconnect Diagrams

Appendix B

*Three-phase Input

(+10/-15%)

380V AC RMS, 50 Hz or 460V AC RMS, 60 Hz

See Note 1

*Circuit

Breaker

See Note 2

*Input

Fusing

See Note 2

TB1

L1

L2

L3

EMC Line Filter

8720MC-EF190-VB

TB1

L4

L5

L6

MC1

MC2

+24V2

0V2

NC

+24V3

0V3

SENS-out

+24V

MC

CN1

A5

B1

B2

B3

A1

A2

A3

A4

B4

B5

R1

S1

T1

CN4

2

1

3

A4

A5

B1

B2

CN2

A1

A2

A3

B3

B4

B5

2

*Circuit

Breaker

See Note 2

*Input

Fusing

See Note 2

TB1

L1

L2

L3

EMC Line Filter

8720MC-EF190-VB

TB1

L4

L5

L6

MC1

MC2

+24V2

0V2

NC

+24V3

0V3

SENS-out

+24V

MC

CN1

A5

B1

B2

B3

A1

A2

A3

A4

B4

B5

R1

S1

T1

CN4

1

3

2

CN2

A5

B1

B2

B3

A1

A2

A3

A4

B4

B5

1 2

Figure 80 - Dual 8720MC-RPS190B

x

Regenerative Power Supplies to a Single Kinetix 7000 Drive

L1

L2

L3

Line Reactor

8720MC-LR10-100B

Fan 2

L4

L5

L6

TB1

L1

L2

L3

Regenerative

Power Supply

8720MC-RPS190BM

DC Bus

Connections

TB1

DC+

DC-

*DC Line

Fuses

* DC Line Fuses

(see table in

Appendix A)

TB

DC+

DC-

DC Bus

Connections

Kinetix 7000 Drive

2099-BM

xx

-S

Axis

n

L1

L2

L3

Line Reactor

8720MC-LR10-100B

Fan 3

L4

L5

L6

L1

L2

L3

Line Reactor

8720MC-LR10-100B

Fan 2

L4

L5

L6

L1

L2

L3

Line Reactor

8720MC-LR10-100B

Fan 3

L4

L5

L6

RED

WHT

BLU

TB4

+24V3

0V3

SENS

+24V2

0V2

MC1

MC2

TB2

L1 AUX

L2 AUX

L3 AUX

PR1

PR2

PR3

Fault Relay

Contact

TB3

24V

COM

IP

RDY

MC

RST

PWR

0V

FR

FR

CR1*

8

7

GPIO

REGEN COM

REGEN OK

RED

WHT

BLU

TB4

+24V3

0V3

SENS

+24V2

0V2

MC1

MC2

TB2

L1 AUX

L2 AUX

L3 AUX

PR1

PR2

PR3

See Note 10

1

Motion

Control I/O

See Note 11

2

1

IOD

24V DC

ENABLE

24V COM

6

5

GPR

GPR2+

GPR2-

See Notes 6 and 8

Additional connections required, but not shown in this diagram:

1. +24V DC Control Power

2. Motor Feedback, Brake (if used), and Power

3. Drive I/O and Communications

TB1

L1

L2

L3

Regenerative

Power Supply

8720MC-RPS190BM

DC Bus

Connections

TB1

DC+

DC-

*DC Line

Fuses

120V/240V AC or

24V DC

*Single-phase

AC Line Filter

RPS Stop-Start String

CR1*

STOP* START (RPS On)*

CR1*

* Indicates User Supplied Component

IMPORTANT

This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply

Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

171

Appendix B

Interconnect Diagrams

Kinetix 7000 Drive/Rotary Motor Wiring Examples

IMPORTANT

The Bulletin MPL motor wiring example on this page applies to motors equipped with bayonet connectors.

Figure 81 - Motors with High Resolution Feedback (Bayonet Style Connector)

Kinetix 7000 Drive

MPL-B

xx

460V Servo Motors with High

Resolution Feedback

Cable Shield

Clamp

Motor Power

(MP) Connector

W

V

U

2

1

4

3

2090-XX

x

PMP-

xx

S

xx

Motor Power Cable

Green/Yellow

1/Blue

2/Black

3/Brown

D

C

B

A

Motor Connector Shell

W

V

U

GND

Motor Power (Three-phase)

(2)

K

General Purpose Relay

(GPR) Connector

GPR1-

GPR1+

COM

24VDC

Dashed lines denote an internal circuit

Motor Feedback

(MF) Connector

(3)

2090-K6CK-D15M connector kit

1

2

3

4

5

10

14

6

7

11

4

1

3

2

SIN+

SIN-

COS+

COS-

DATA+

DATA-

ECOM

+9VDC

TS+

2090-UX

x

BMP-18S

xx

Brake Cable

Black

White

Customer-supplied

24V DC (2A max)

(1)

C

A

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

WHT/GRAY

ORANGE

WHT/ORANGE

Cable shield clamp must be used to meet CE requirements. No external connection to ground required.

(3)

2090-XX

x

FMP-S

xx

(flying lead) or

2090-UXNFMP-S

xx

(premolded backshell)

BR-

BR+

Motor Brake

(2)

K

L

E

F

D

C

N

R

A

B

S

Motor Connector Shell

Motor Feedback

(2)

Thermostat

P

(1)

See

Customer-supplied 24V DC Power Supply Notes on page 173 for important wiring information.

(2)

See MP-Series (Bulletin MPL) Motor Connectors on page 83

for more information on bayonet and circular DIN connectors.

(3)

See Wire Low-profile Connectors on page 98

for more information on grounding feedback cables when using low-profile connectors.

172

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Interconnect Diagrams

Appendix B

Customer-supplied 24V DC Power Supply Notes

•

The contact connected to GPR1+ and GPR1- is rated 2 Amps inductive

@ 250V AC/30V DC maximum.

•

MPx motors with a brake have various coil current requirements. Refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001 for coil current requirements.

•

For motors that utilize above 2 Amp coil current it is recommended that a customer-supplied external device, such as an interposing relay, be used between the drive and motor. See

Figure 82 below.

•

A customer-supplied diode or metal oxide varistor (MOV) is recommended for use with an interposing relay to prevent an electrical arc that may occur before the brake coil power dissipates. Use of an MOV can also reduce the amount of time required to mechanically engage the brake.

See Figure 82 below.

Figure 82 - Customer-supplied 24V DC Power Supply Wiring Example

Kinetix 7000

Drive

*Dashed lines denote customer supplied components.

MPL Motor

GPR1-

GPR1+

COM

24VDC

3

2

4

1

C1

C1

C

A

BR-

BR+

+ -

24VDC

Supply

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

173

Appendix B

Interconnect Diagrams

174

IMPORTANT

The Bulletin MPL motor wiring example on this page applies to motors equipped with circular DIN connectors.

Figure 83 - Motors with High Resolution Feedback (Circular DIN Style Connector)

Kinetix 7000 Drive

Cable Shield

Clamp

Motor Power

(MP) Connector

W

V

U

4

3

2

1

2090-CPBM7DF-

xx

AA

xx

, or

2090-XXNPMF-

xx

S

xx

(standard, non-flex) or 2090-CPBM7DF-

xx

AF

xx

(continuous-flex)

Motor Power Cable

Shield

Green/Yellow

Blue

Black

Brown

D/

C/W

B/V

A/U

MPL-B

xx

and MPM-B

xx

460V Servo Motors with High

Resolution Feedback

Motor Connector Shell

W

V

U

GND

Motor Power (Three-phase)

(2)

General Purpose Relay

(GPR) Connector

K

GPR1-

GPR1+

COM

24VDC

3

2

4

1

Black

White

Customer-supplied

24V DC (2A max)

(1)

G/-

F/+

BR-

BR+

Motor Brake

(2)

Dashed lines denote an internal circuit

Motor Feedback

(MF) Connector

(3)

2090-K6CK-D15M connector kit

5

10

14

6

7

11

3

4

1

2

SIN+

SIN-

COS+

COS-

DATA+

DATA-

ECOM

+9VDC

TS+

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

WHT/GRAY

ORANGE

WHT/ORANGE

9

10

5

6

3

4

11

13

1

2

Motor Feedback

(2)

Thermostat

TS-

BLUE

14

Cable shield clamp must be used to meet CE requirements. No external connection to ground required.

COM

2090-CFBM7DF-CEAA

xx

, or

2090-XXNFMF-S

xx

(standard, non-flex) or

2090-CFBM7DF-CEAF

xx

(continuous-flex)

Flying-lead Feedback Cable

12

(1)

See Customer-supplied 24V DC Power Supply Notes on page 173 for important wiring information.

(2)

See MP-Series (Bulletin MPL) Motor Connectors on page 83

for more information on bayonet and circular DIN connectors.

(3)

See Wire Low-profile Connectors on page 98

for more information on grounding feedback cables when using low-profile connectors.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Interconnect Diagrams

Appendix B

K

Kinetix 7000 Drive

Cable Shield

Clamp

Motor Power

(MP) Connector

W

V

U

4

3

2

1

Figure 84 - HPK-Series High-power Motor with High Resolution Feedback

HPK-B/E

xxxx

460V High-power Servo Motors with High Resolution Feedback

Motor Power Cable

(customer-supplied)

Green/Yellow

1/Blue

2/Black

3/Brown

Motor Connector Shell

W

V

U

GND

Motor Power (Three-phase)

GPR1-

GPR1+

COM

24VDC

3

2

4

1

Customer-supplied

Interface to

460V AC Power

Customer-supplied

24V DC

(1)

BR-

BR+

Spring-set Brake

(Single-phase)

Dashed lines denote an internal circuit

FAN-

FAN+

Blower Connections

(2)

Motor Feedback

(MF) Connector

2090-K6CK-D15M connector kit

Cable shield clamp must be used to meet CE requirements. No external connection to ground required.

3

4

5

10

14

6

7

11

1

2

SIN+

SIN-

COS+

COS-

DATA+

DATA-

ECOM

+9VDC

TS+

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

WHT/GRAY

ORANGE

WHT/ORANGE

2090-XXNFMF-S

xx

or 2090-CFBM4DF-CDAF

xx

Feedback Cable

(1)

See Customer-supplied 24V DC Power Supply Notes (HPK-series motors) on page 176

for important wiring information.

(2)

See HPK-Series Motor Blower Connections on page 176

for more information.

P

K

L

N

R

E

F

C

D

A

B

S

Motor Connector Shell

Motor Feedback

Thermostat

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

175

Appendix B

Interconnect Diagrams

176

Customer-supplied 24V DC Power Supply Notes (HPK-series motors)

•

HPK-series motors require a customer-supplied 460V AC single-phase supply, rather than a 24V DC supply. However, the brake current ratings required by HPK-series motors are higher than the contact rating of the

GPR connector. Therefore, if using an HPK-series motor with a brake, it is recommended that a customer-supplied, external interposing relay or equivalent circuit be used. See

Figure 85 below.

•

The contact connected to GPR1+ and GPR1- is rated 2 Amps inductive

@ 250V AC/30 VDC maximum.

•

See the Kinetix Motion Control Selection Guide, publication

GMC-SG001 for HPK-series motor brake ratings.

Figure 85 - Customer-supplied HPK-Series Motor Brake Wiring Example

Kinetix 7000

Drive

*Dashed lines denote customer supplied components.

HPK-Series Motor

GPR1-

GPR1+

COM

24VDC

3

2

4

1

C1

C1

C

A

BR-

BR+

+ -

24V DC

Supply

L1 L2

460V AC

Supply

HPK-Series Motor Blower Connections

•

The HPK-series motor blower must be used to ensure proper motor performance.

•

The blower connections can use either a Star (460 V AC) or Delta (230V

AC) three-phase configuration. See the HPK-Series Asynchronous Servo

Motor Installation Instructions, publication HPK-IN001 , for connection diagrams.

•

HPK-series Motors with a brake and without a brake have different blower assemblies and, therefore, have different connection and electrical characteristics.

•

The HPK-series motor has a conduit box with terminals/leads for external power connections.

•

See the Kinetix Motion Control Selection Guide, publication

GMC-SG001 for HPK-series motors blower voltage and current specifications.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Interconnect Diagrams

Appendix B

Kinetix 7000 Drive

Cable Shield

Clamp

Motor Power

(MP) Connector

W

V

U

2

1

4

3

Motor Feedback

(MF) Connector

Figure 86 - Example with RDD-Series (Bulletin RDB-B) Motors

Shield

Green/Yellow

Blue

Black

Brown

2090-CPWM7DF-

xx

AA

xx

, or

2090-XXNPMF-

xx

S

xx

(standard, non-flex) or 2090-CPWM7DF-

xx

AF

xx

(continuous-flex)

Motor Power Cable

C/W

B/V

A/U

RDB-B

xxxx

Direct Drive

Servo Motors with

High Resolution Feedback

W

V

U

GND

Three-phase

Motor Power

Motor

Feedback

1

2

3

4

9

10

11

13

7

8

5

6

Thermistor

14

12

Refer to table on

page 162 for

note information.

BLACK

WHT/BLACK

RED

WHT/RED

GREEN

WHT/GREEN

BROWN

WHT/BROWN

GRAY

WHT/GRAY

ORANGE

WHT/ORANGE

BLUE

2090-K7CK-KENDAT

Feedback Module

SIN+

SIN-

COS+

COS-

DATA+

DATA-

CLK+

CLK-

+5VDC

ECOM

–

TS+

TS-

COM

3

4

1

2

7

8

9

10

5

6

11

Cable shield clamp must be used in order to meet CE requirements. No external connection to ground is required.

2090-XXNFMF-S

xx

(standard, non-flex) or

2090-CFBM7DF-CDAF

xx

(continuous-flex)

Flying-lead Feedback Cable

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177

Appendix B

Interconnect Diagrams

Kinetix Safe-off Feature

Block Diagram

Kinetix 7000 drives with the Safe-off feature installed ship with the wiring header and a motion-allowed jumper installed. In this configuration, the safe-off feature is disabled (not used).

Figure 87 - Kinetix Safe-off Feature

8

9

Safe-Off Option

Safe-Off (SO)

9-pin Connector

+24V

+24V_COM

K1-C

3

4

FDBK1+

FDBK1-

7

ENABLE1+

6

ENABLE-

5

ENABLE2+

1

2

FDBK2+

FDBK2-

K1

K2

K1-A

K2-A

Gate Control

Power Supply

Safety Monitor uC

Gate Control

Circuit (CCP)

K2-C

Motion Allowed Jumper

Wiring Header +24V

DRIVE ENABLE

+24V_COM

Gate Control

Enable Signal

M

178

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Before You Begin

Appendix

C

Upgrade Firmware

This appendix provides procedures for using ControlFlash utility to upgrade the firmware in a Kinetix 7000 drive.

Topic

Before You Begin

Upgrade Firmware

Page

179

180

Upgrading the firmware of a Kinetix 7000 servo drive using ControlFlash involves entering the name of the target device, locating the SERCOS interface module and Kinetix 7000 servo drive to be flashed, finding the existing new firmware levels, and flashing the drive firmware.

Before you begin this procedure, make sure you have the following.

Description

RSLogix 5000 Software

RSLinx Software

ControlFlash Kit

(1)

Firmware for Logix SERCOS interface module or

PCI card

Firmware upgrade file for Kinetix 7000

Catalog Numbers

9324-RLD300NE

0355-RSLETENE

N/A

1756-M

xx

SE

1756-L60M03SE

1768-M04SE

1784-PM16SE

(2),(3)

Version

15.0 or later

2.50.00 or later

4.00.09 or later

15.32 or later

15.4 or later

15.35 or later

15.33 or later

(1) For ControlFlash information not specific to the Kinetix 7000 drive family, refer to the ControlFlash Firmware Upgrade Kit Quick

Start, publication 1756-QS105 .

(2) Contact Rockwell Automation Technical Support at (440) 646-5800 for firmware upgrade files and assistance.

(3) Go to http://support.rockwellautomation.com/firmware.asp

for firmware upgrades.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

179

Appendix C

Upgrade Firmware

Upgrade Firmware

This procedure requires you to use ControlFlash software to upgrade the firmware in a Kinetix 7000 drive.

1.

Verify 24V DC control power is supplied to the Kinetix 7000 drive requiring firmware upgrade.

IMPORTANT

The seven segment LED on the Kinetix 7000 must display a 2, 3, or 4 before beginning this procedure. Only these displays indicates the drive has been recognized by the SERCOS interface.

ATTENTION:

To avoid injury or damage to equipment due to unpredictable motor activity, do not apply main input power to the drive, or source drive power from a DC common bus.

2.

Open your ControlFlash software or select ControlFlash from the Tools menu of RSLogix 5000 software.

The Welcome to ControlFlash dialog opens.

3.

Click Next.

The Catalog Number dialog opens.

180

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Upgrade Firmware

Appendix C

4.

Select the catalog number of the Kinetix 7000 (2099-BM

xx-

S) drive to upgrade.

5.

Click Next.

6.

Select the SERCOS interface module and Kinetix 7000 drive to flash in the RSLinx Gateway dialog.

7.

Click OK.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

181

Appendix C

Upgrade Firmware

8.

Select the firmware revision to use in this update.

Select the new firmware from the list, or browse for it using the Current

Folder option.

9.

Click Next.

10.

Confirm the catalog number and serial number of the drive, and its current revision and new revision of firmware.

11.

Click Finish.

182

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

12.

Click Yes to confirm updating of the target device.

Upgrade Firmware

Appendix C

13.

Click OK to acknowledge the Motion Stop notice.

A dialog will display the progress of the flash update.

While this display is active, the Status display on the drive will display an F.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

183

Appendix C

Upgrade Firmware

The Update Status dialog indicates success or failure as described below.

Flashing If

Succeeded 5. Update complete appears in a GREEN status dialog.

6. Go to Step 2.

Failed 1. Update failure appears in a RED status dialog.

2. Contact Technical Support.

14.

Click OK.

The ControlFlash software returns to the Welcome screen where you can flash another drive or select Cancel to exit the program.

184

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Index

Numerics

1756 module properties

112

1756-MxxSE interface module

110

2090-K6CK-D15F

98

2090-K6CK-D15M

98

2090-K6CK-D26M

98

2090-K7CK-KENDAT

48

,

98

,

99

A

AC line filters

noise reduction

36

accessories

10

applying power

126

auxiliary feedback

pin-outs

49

specifications

66

axis unstable

144

circuit breakers

126

sizing

23

configuring

base node address

106

baud rate, IAM

106

delay times

122

IAM

106

optical power level

107

SERCOS module

110

connecting

external shunt resistor

101

feedback

93

I/O

93

input power

88

motor brake

92

motor power

92

premolded feedback cables

95

,

96

SERCOS cables

101

connecting your Kinetix 7000

71

contactor specifications

Kinetix 7000

152

controller properties

110

conventions used in this manual

9

B

bandwidth

132

base node address

106

example with two ControlLogix chassis

108

,

109

baud rate,communication rate

106

block diagrams

safe-off feature

178

bonding build

EMI (ElectroMagnetic Interference)

28

high frequency energy

30

mounting

28

subpanels

30

motor cables

72

bus regulator

125

bus status LED

143

D

data rate

113

date and time tab

111

DC common bus

total bus capacitance

17

typical installation

16

delay times

122

digital inputs

54

dip switches

113

disable drive

146

download program

125

drive status indicators

128

drive status LED

143

drive tab

123

C

cables

build motor cables

72

categories

35

fiber optic

101

maximum fdbk cable length

153

maximum length of fiber-optic

101

catalog number

integrated axis module

18

CB1, CB2, CB3

126

CE

meeting requirements

20

certifications

Rockwell Automation Product Certification

10

changing parameters

HIM

135

circuit breaker specifications

Kinetix 7000

151

E

EMC

motor ground termination

82

EMI (ElectroMagnetic Interference)

bonding

28

enable time synchronization

111

enclosure

requirements

22

enclosure sizing

Kinetix 7000

152

environmental specifications

Kinetix 7000

154

erratic operation

146

error codes

138

establishing communications

143

external shunt resistor

wiring

101

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

185

Index

186

F

fault action

147

fault action, programmable

147

fault actions tab

122

feedback power supply

68

fiber optic cables

maximum length

101

receive and transmit connectors

101

fiber optic signals

65

full-line regen

typical installation

17

fuse sizing

23

fuse specifications

Kinetix 7000

151

G

grounding

high impedance ground

78

H

high frequency energy

30

hookup tab

129

I

I/O

connections

93

specifications

54

indicator

drive status

128

indicators

status

127

input power wiring

determining input power

75

three-phase delta

76

without LIM

88

installation

fiber optic cable

9

installing your Kinetix 7000

11

,

21

integrated axis module

catalog number

18

configuring

106

K

Kinetix 7000

accessories

10

motors

10

specifications circuit breaker/fuse

151

contactor ratings

152

enclosure sizing

152

environmental

154

maximum fdbk cable length

153

power dissipation

152

power section

150

weight

153

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 typical configuration

DC common bus

16

full-line regen

17

regen braking

15

typical installation, with LIM

13

typical installation, without LIM

14

L

LED

bus status

143

drive status

143

SERCOS interface module

128

status

127

logic power status indicator

126

low profile connector kits

wiring

98

M

maintenance

138

maximum fdbk cable length

Kinetix 7000

153

module properties

1756 SERCOS interface

112

Motion

10

motor accel/decel problems

145

motor overheating

145

motor velocity

145

motors

10

,

94

feedback pin-outs

47

feedback specifications

66

ground termination

82

power wiring

92

testing

129

tuning

129

motors brake wiring

92

mounting

external shunt resistor

37

,

38

guidelines to reduce noise

36

N

no communication

143

no rotation

145

node address

117

noise

abnormal

146

feedback

145

noise zones

31

,

32

,

33

,

34

O

optical power level

107

Index

P

panel

cable categories

35

noise zones

30

,

31

,

32

ControlLogix

33

,

34

requirements

22

pin-outs

auxiliary feedback connector

49

motor feedback connector

47

,

94

power dissipation specifications

Kinetix 7000

152

power supply, feedback

68

power up

126

premolded feedback cables

95

,

96

R

reference documents

A-B automation glossary

10

CompactLogix controllers user manual

9

CompactLogix Sercos interface installation instructions

9

control of electrical noise

9

ControlLogix motion module configuration

9

ControlLogix SERCOS interface installation

9

fiber optic cable installation and handling

9

Kinetix 7000 installation instructions

9

kinetix accelerator toolkit

10

Kinetix motion control selection guide

10

motion coordinate system configuration

10

national electrical code

10

safety guidelines for solid state controls

10

SoftLogix 5800 user manual

9

SoftLogix motion card configuration

9

understanding the machinery directive

10

routing power and signal wiring

74

RSLogix 5000 software

110

S

safe-off

block diagram

178

SERCOS

connecting cables

101

connections

65

seven segment status indicator

127

shutdown

146

software

RSLogix 5000

110

specifications

feedback motor and auxiliary

66

power supply

68

I/O digital inputs

54

Kinetix 7000 circuit breaker/fuse

151

contactor ratings

152

environmental

154

maximum fdbk cable length

153

power dissipation

152

power section

150

weight

153

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

SERCOS connections

65

status indicator

127

logic power

126

status LEDs

127

status only

146

stop motion

146

surge suppression

92

switches

base node address

106

baud rate

106

optical power level

107

system block diagrams

safe-off feature

178

system mounting requirements

circuit breakers

23

fuse sizing

23

transformer sizing

22

T

testing axes

hookup tab

129

total bus capacitance

17

training

9

transformer sizing

22

transmit power level

113

troubleshooting

bus status LED

143

disable drive

146

drive status LED

143

error codes

138

fault action

147

general system problems

144

abnormal noise

146

axis unstable

144

erratic operation

146

feedback noise

145

motor accel/decel problems

145

motor overheating

145

motor velocity

145

no rotation

145

Logix/drive fault behavior

146

programmable fault action

147

shutdown

146

status only

146

stop motion

146

tuning axes

bandwidth

132

tune tab

131

typical configuration

Kinetix 7000

DC common bus

16

full-line regen

17

regen braking

15

typical installation

Kinetix 7000, with LIM

13

Kinetix 7000, without LIM

14

187

Index

W

weight specifications

Kinetix 7000

153

who should use this manual

9

wiring

build motor cables

72

common dc bus power

78

external shunt resistor

101

ground reference

77

grounding

81

I/O connections

93

impedance grounded power system

78

input power determining type

75

without LIM

88

low profile connectors

98

motor brake

92

motor power

92

requirements

71

routing power and signal wiring

74

SERCOS fiber optic cables

101

unbalanced power system

78

ungrounded power system

78

188

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.

At http://www.rockwellautomation.com/support , you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums, software updates, and to sign up for product notification updates.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer

TechConnect SM support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/ .

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html

, or contact your local Rockwell

Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States

Outside United States

Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Please contact your local Rockwell Automation representative for the return procedure.

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Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002 , available at http://www.rockwellautomation.com/literature/ .

Publication 2099-UM001D-EN-P - December 2012

Supersedes Publication 2099-UM001C-EN-P - February 2010 Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.