Allen-Bradley 2198-CAPMOD-1300, Kinetix 5500 User Manual
Below you will find brief information for Kinetix 5500 2198-H003-ERS, Kinetix 5500 2198-H008-ERS, Kinetix 5500 2198-H015-ERS, Kinetix 5500 2198-H025-ERS, Kinetix 5500 2198-H040-ERS, Kinetix 5500 2198-H070-ERS, Kinetix 5500 2198-H003-ERS2, Kinetix 5500 2198-H008-ERS2, Kinetix 5500 2198-H015-ERS2, Kinetix 5500 2198-CAPMOD-1300. These servo drives offer standalone and multi-axis configurations, supporting various power structures and communication topologies. They integrate with Logix 5000 controllers for seamless motion control.
Advertisement
Advertisement
User Manual
Original Instructions
Kinetix 5500 Servo Drives
Catalog Numbers 2198-H003-ERS, 2198-H008-ERS, 2198-H015-ERS, 2198-H025-ERS, 2198-H040-ERS, 2198-H070-ERS
2198-H003-ERS2, 2198-H008-ERS2, 2198-H015-ERS2, 2198-H025-ERS2, 2198-H040-ERS2, 2198-H070-ERS2,
2198-CAPMOD-1300
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
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.
ARC FLASH HAZARD:
Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Start
Plan the Kinetix 5500 Drive
System Installation
Table of Contents
Preface
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
About the Kinetix 5500 Servo Drive System . . . . . . . . . . . . . . . . . . . . . 15
Drive Hardware and Input Power Configurations . . . . . . . . . . . . . . . 17
Standalone Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shared AC/DC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Shared DC Common-bus Configurations . . . . . . . . . . . . . . . . . . . 20
Shared AC/DC Hybrid Configuration . . . . . . . . . . . . . . . . . . . . . . 21
Motor Feedback and Feedback-only Configurations . . . . . . . . . . . . . 22
Typical Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . 23
Safe Torque-off Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hardwired Safety Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Integrated Safety Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 2
AC Line Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
24V Control Power Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Contactor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Passive Shunt Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 40
Bonding Multiple Subpanels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Establishing Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cable Categories for Kinetix 5500 Systems . . . . . . . . . . . . . . . . . . 45
Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . 46
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
3
Table of Contents
4
Mount the Kinetix 5500 Drive
System
Connector Data and Feature
Descriptions
Connect the Kinetix 5500 Drive
System
Chapter 3
Determine Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Zero-stack Tab and Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Shared-bus Connection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Single-axis Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Multi-axis Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Mount Your Kinetix 5500 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Chapter 4
Kinetix 5500 Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Module Status Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Safe Torque-off Connector Pinout. . . . . . . . . . . . . . . . . . . . . . . . . . 63
Input Power Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DC Bus and Shunt Resistor Connector Pinouts . . . . . . . . . . . . . . 64
Digital Inputs Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ethernet Communication Connector Pinout . . . . . . . . . . . . . . . . 65
Motor Power, Brake, and Feedback Connector Pinouts . . . . . . . 66
Motor Feedback Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . 66
Understand Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . 67
Ethernet Communication Specifications . . . . . . . . . . . . . . . . . . . . 68
Motor Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safe Torque-off Safety Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Servo Drives with Hardwired Safety. . . . . . . . . . . . . . . . . . . . . . . . . 72
Servo Drives with Integrated Safety . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chapter 5
Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . 74
Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . 75
Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Ungrounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 77
Remove the Ground Screws in Select Power Configurations . . . . . . 79
Ground the System Subpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Wire the Power Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Wire the 24V Control Power Input Connector . . . . . . . . . . . . . . 84
Wire the Input Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the
Kinetix 5500 Drive System
Table of Contents
Wire the Digital Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wire the Safe Torque-off Connector . . . . . . . . . . . . . . . . . . . . . . . . 86
Wire the Digital Inputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . 87
Wire Kinetix VP Motors and Actuators . . . . . . . . . . . . . . . . . . . . . . . . . 87
Maximum Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Motor Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Motor Brake Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Apply the Single Motor-cable Shield Clamp . . . . . . . . . . . . . . . . . 91
Wire Other Allen-Bradley Motors and Actuators . . . . . . . . . . . . . . . . 92
Install the Kinetix 5500 Add-On Profile. . . . . . . . . . . . . . . . . . . . . 93
Motor Power and Brake Connections . . . . . . . . . . . . . . . . . . . . . . . 94
Motor Power/Brake Cable Series Change. . . . . . . . . . . . . . . . . . . . 95
Maximum Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Motor Power/Brake Cable Preparation. . . . . . . . . . . . . . . . . . . . . . 96
Apply the Motor Power/brake Shield Clamp . . . . . . . . . . . . . . . . 98
Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Motor Feedback Cable Preparation . . . . . . . . . . . . . . . . . . . . . . . . 101
Capacitor Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
External Passive-shunt Resistor Connections . . . . . . . . . . . . . . . . . . . 105
Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Chapter 6
Understand the Kinetix 5500 Display. . . . . . . . . . . . . . . . . . . . . . . . . . 108
Set the Network Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Studio 5000 Logix Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Install the Kinetix 5500 Add-On Profile. . . . . . . . . . . . . . . . . . . . 114
Configure the Logix 5000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Configure the Kinetix 5500 Drive . . . . . . . . . . . . . . . . . . . . . . . . . 118
Configure the Motion Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Configure Feedback-only Axis Properties . . . . . . . . . . . . . . . . . . . . . . 129
Configure Induction-motor Frequency-control Axis Properties . . 130
General and Motor Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Basic Volts/Hertz Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Sensorless Vector Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Fan/Pump Volts/Hertz Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Configure SPM Motor Closed-loop Control Axis Properties. . . . . 138
Apply Power to the Kinetix 5500 Drive . . . . . . . . . . . . . . . . . . . . . . . . 143
Applying Power after Changing Input Voltage Range. . . . . . . . 143
Understand Bus-sharing Group Configuration . . . . . . . . . . . . . . . . . 144
Bus-sharing Group Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
5
6
Table of Contents
Troubleshoot the Kinetix 5500
Drive System
Configure Bus-sharing Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Chapter 7
Fault Code Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Kinetix 5500 Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 158
Kinetix 5500 Capacitor Module Status Indicators . . . . . . . . . . . 159
Logix 5000 Controller and Drive Behavior . . . . . . . . . . . . . . . . . . . . . 161
Chapter 8
Remove and Replace Servo Drives
Remove and Replace Kinetix 5500 Servo Drives . . . . . . . . . . . . . . . . 166
Remove Power and All Connections . . . . . . . . . . . . . . . . . . . . . . . 166
Remove the Servo Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Replace the Servo Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Start and Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Kinetix 5500 Safe Torque-off -
Hardwired Safety
Kinetix 5500 Safe Torque-off -
Integrated Safety
Chapter 9
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Category 3 Requirements According to ISO 13849-1. . . . . . . . 170
Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Performance Level (PL) and Safety Integrity Level (SIL) . . . . . 170
Probability of Dangerous Failure Per Hour . . . . . . . . . . . . . . . . . . . . . 173
Safe Torque-off Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Wire the Safe Torque-off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Safe Torque-off Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . 174
Safe Torque-off Feature Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Cascade the Safe Torque-off Signal. . . . . . . . . . . . . . . . . . . . . . . . . 176
Safe Torque-off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Chapter 10
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Table of Contents
Interconnect Diagrams
Upgrade the Drive Firmware
Size Multi-axis Shared-bus
Configurations
Category 3 Requirements According to ISO 13849. . . . . . . . . . 178
Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Performance Level (PL) and Safety Integrity Level (SIL) . . . . . 179
Probability of Dangerous Failure Per Hour . . . . . . . . . . . . . . . . . . . . . 181
Out-of-Box State Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Understand Integrated Safety Drive Replacement . . . . . . . . . . . . . . . 183
Replace an Integrated Safety Drive in a GuardLogix System . . . . . . 184
Configure Only When No Safety Signature Exists. . . . . . . . . . . 185
Configure Always . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Motion Direct Commands in Motion Control Systems . . . . . . . . . 186
Understand STO Bypass When Using
Motion Direct Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Logix Designer Application Warning Messages . . . . . . . . . . . . . 187
Torque Permitted in a Multi-workstation Environment . . . . . 189
Warning Icon and Text in Axis Properties . . . . . . . . . . . . . . . . . . 189
Functional Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Safe Torque-off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Appendix A
Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Single-axis Drive Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . 194
Bus-sharing Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Shunt Resistor Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Kinetix 5500 Servo Drive and Rotary Motor Wiring Examples . . . 199
Kinetix 5500 Drive and Linear Actuator Wiring Examples. . . . . . . 201
Appendix B
Configure Logix 5000 Controller Communication. . . . . . . . . . 209
Inhibit Feedback Only Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Appendix C
Shared-bus Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Shared AC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Shared DC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Shared AC/DC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Shared AC/DC Hybrid Configurations . . . . . . . . . . . . . . . . . . . . 221
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
7
Table of Contents
8
Power-sharing Sizing Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Shared DC Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Shared AC/DC Hybrid Example . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Shared AC/DC Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Control Power Current Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Kinetix 5500 System Current Demand Example . . . . . . . . . . . . 225
Appendix D
Motor Control Feature Support
Frequency Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Basic Volts/Hertz for Fan/Pump Applications . . . . . . . . . . . . . . 230
Current Limiting for Frequency Control . . . . . . . . . . . . . . . . . . . . . . . 232
The Effects of Current Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Enable the Current Limiting Feature . . . . . . . . . . . . . . . . . . . . . . . 234
Set the CurrentVectorLimit Attribute Value. . . . . . . . . . . . . . . . 234
Stability Control for Frequency Control . . . . . . . . . . . . . . . . . . . . . . . 235
Enable the Stability Control Feature . . . . . . . . . . . . . . . . . . . . . . . 236
Multiple Skip Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Flux Up Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Configure the Flux Up Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . 241
Current Regulator Loop Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Motor Tests and Autotune Procedure . . . . . . . . . . . . . . . . . . . . . . 244
Motor Analyzer Category Troubleshooting . . . . . . . . . . . . . . . . . 245
Selection of Motor Thermal Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Thermally Characterized Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Speed Limited Adjustable Torque (SLAT) . . . . . . . . . . . . . . . . . . . . . 250
Motion Polarity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
SLAT Min Speed/Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
SLAT Max Speed/Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Configure the Axis for SLAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Motor Overload Retention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Phase-loss Detection Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Phase-loss Detection Configuration . . . . . . . . . . . . . . . . . . . . . . . . 258
Phase Loss Detection Current Example . . . . . . . . . . . . . . . . . . . . 259
Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Frequency Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Velocity Droop Attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Velocity Droop Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Table of Contents
Index
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
9
Table of Contents
Notes:
10
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Preface
This manual provides detailed installation instructions for mounting, wiring, and troubleshooting the Kinetix® 5500 servo drives, and system integration for your drive and motor/actuator combination with a Logix 5000™ controller.
This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 5500 drives, and programmers directly involved in the operation, field maintenance, and integration of these drives with the EtherNet/IP™ communication module or controller.
If you do not have a basic understanding of Kinetix 5500 servo drives, contact your local Rockwell Automation sales representative for information on available training courses.
Summary of Changes
This manual contains new and updated information as indicated in the following table.
Topic
Added Access the Attachments that explains how the fault code tables (FLT S
xx
, FLT M
xx
, and INIT FLT for example), previously in Troubleshoot the Kinetix 5500
Drive System (chapter 7), moved to the attached spreadsheet.
Added Kinetix VP (Bulletin VPH) hygienic stainless-steel servo motors as another rotary motor compatible with Kinetix 5500 servo drives.
Added Kinetix VP (Bulletin VPAR) electric cylinders as another linear actuator compatible with Kinetix 5500 servo drives.
Page
throughout
Added 2198-DBR
xx
-F AC line filters.
Added Contactor Selection with information to help evaluate AC input power system requirements.
Added the 2198-CAPMOD-1300 capacitor module power dissipation specifications to the table.
Added new information regarding the use of 2198-DBR
xx
-F AC line filters and servo drive ground screw settings.
Updated the maximum input current rating (40 A) for the 24V input power shared-bus connection system.
Added
to the Tune the Axes procedure.
Updated Motor Analyzer Category Troubleshooting with rated slip-speed information.
The Certifications appendix was removed with links to the Product Certifications website added to Chapter 9 and Chapter 10.
throughout
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
11
Preface
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.
• Catalog number string 2198-H
xxx
-ERS
x
is used when there’s no need to distinguish between -ERS or -ERS2 servo drives.
Kinetix 5500 Drive Cat. No.
2198-H
xxx
-ERS
2198-H
xxx
-ERS2
Description
Kinetix 5500 drive with
hardwired
safe torque-off functionality
Kinetix 5500 drive with
integrated
safe torque-off functionality
Access the Attachments
The Microsoft Excel spreadsheet that is attached to this publication contains fault code descriptions. To use the spreadsheet file, click the Attachments link
, right-click the spreadsheet file, and save the file to your computer.
If the PDF file opens in a browser and you don't see the Attachments link , download the PDF file and reopen the file with the Adobe Acrobat Reader application.
Additional Resources
Table 1 - Additional Resources
Resource
Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001
Kinetix Linear Motion Specifications Technical Data, publication KNX-TD002
Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003
Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004
AC Line Filter Installation Instructions, publication 2198-IN003
These documents contain additional information concerning related products from Rockwell Automation.
Shunt Resistor Installation Instructions, publication 2097-IN002
Description
Product specifications for Kinetix VP (Bulletin VPL, VPF, VPH, and VPS), MP-Series™
(Bulletin MPL, MPM, MPF, and MPS), TL-Series™, and HPK-Series™ rotary motors.
Product specifications for MP-Series (Bulletin MPAS ballscrew, MPAR, and MPAI) and LDAT-Series linear actuators.
Product specifications for Kinetix Integrated Motion over the EtherNet/IP network,
Integrated Motion over sercos interface, EtherNet/IP networking, and component servo drive families.
Product specifications for Bulletin 2090 motor and interface cables, low-profile connector kits, drive power components, and other servo drive accessory items.
Provides information on how to install AC line filters designed for Kinetix 5500 and
Kinetix 5700 servo drive systems.
Provides information on how to install and wire Bulletin 2097 shunt resistors.
12
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Preface
Table 1 - Additional Resources (continued)
Resource
System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001
Kinetix Motion Control Selection Guide, publication KNX-SG001
Kinetix 5500 Drive Systems Design Guide, publication KNX-RM009
Rockwell Automation Product Selection website http://www.rockwellautomation.com/global/support/selection.page
Motion Analyzer System Sizing and Selection Tool website https://motionanalyzer.rockwellautomation.com/
Product Certifications website, rok.auto/certifications
Motor Nameplate Datasheet Entry for Custom Motor Applications Application Technique, publication 2198-AT002
Vertical Load and Holding Brake Management Application Technique, publication MOTION-AT003
Integrated Motion on the EtherNet/IP Network Reference Manual, publication MOTION-RM003
Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual, publication MOTION-UM003
GuardLogix 5570 Controllers User Manual, publication 1756-UM022
GuardLogix 5580 Controllers User Manual, publication 1756-UM543
Compact GuardLogix 5370 Controllers User Manual, publication 1769-UM022
Compact GuardLogix 5380 Controllers User Manual, publication 5069-UM001
GuardLogix 5570 and Compact GuardLogix 5370 Controller Systems Safety Reference
Manual, publication 1756-RM099
GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Reference
Manual, publication 1756-RM012
ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-UM105
Rockwell Automation Industrial Automation Glossary, publication AG-7.1
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Description
Information, examples, and techniques designed to minimize system failures caused by electrical noise.
Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements.
System design guide to select the required (drive specific) drive module, power accessory, feedback connector kit, and motor cable catalog numbers for your
Kinetix 5500 drive and Kinetix VP motor motion control system.
Online product selection and system configuration tools, including AutoCAD (DXF) drawings.
Comprehensive motion application sizing tool used for analysis, optimization, selection, and validation of your Kinetix Motion Control system.
Provides declarations of conformity, certificates, and other certification details.
Provides information on the use of nameplate data entry for custom induction motors and permanent-magnet motors that are used in applications with
Kinetix 5700 servo drives.
Provides information on vertical loads and how the servo motor holding-brake option can be used to help keep a load from falling.
Information on the AXIS_CIP_DRIVE attributes and the configuration software control modes and methods.
Information on how to configure and troubleshoot your ControlLogix® and
CompactLogix™ EtherNet/IP network modules.
Provides information on how to install, configure, program, and use ControlLogix controllers and GuardLogix® controllers in Studio 5000 Logix Designer® projects.
Provides information on how to install, configure, program, and use CompactLogix and Compact GuardLogix controllers.
Provides information on how to achieve and maintain Safety Integrity Level (SIL) and Performance Level (PL) safety application requirements for GuardLogix and
Compact GuardLogix controllers.
Provides information on how to upgrade your drive firmware by using
ControlFLASH™ software.
A glossary of industrial automation terms and abbreviations.
Provides general guidelines for installing a Rockwell Automation industrial system.
You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page
.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
13
Preface
Notes:
14
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Chapter
1
Start
Use this chapter to become familiar with the Kinetix® 5500 drive system and obtain an overview of the installation configurations.
Topic
About the Kinetix 5500 Servo Drive System
Drive Hardware and Input Power Configurations
Motor Feedback and Feedback-only Configurations
Typical Communication Configurations
Safe Torque-off Configurations
Page
About the Kinetix 5500
Servo Drive System
Table 2 - Kinetix 5500 Drive System Overview
The Kinetix 5500 servo drives are designed to provide a Kinetix Integrated
Motion solution for your drive and motor/actuator application.
Drive System
Component
Cat. No.
Description
Kinetix 5500
Servo Drives
Kinetix 5500
Capacitor Module
2198-H
2198-H
xxx xxx
-ERS
-ERS2
2198-CAPMOD-1300
200V-class (single-phase or three-phase) and 400V-class (three-phase) drives operate in standalone and multi-axis shared AC, shared DC, shared AC/DC, and shared AC/DC hybrid configurations. Modules are zero-stacked from drive-to-drive and use the shared-bus connection system to extend power in multi-axis configurations. Safe torque-off via hardwired (STO) connector.
Same power structures as 2198-H
xxx
-ERS servo drives with standalone and multi-axis bus-sharing capability. Safe torque-off via the EtherNet/IP™ network.
Use for energy storage and/or to improve performance in applications producing regenerative energy and requiring shorter duty cycles (1360 μf). Modules are zero-stacked side-by-side with servo drives and use the shared-bus connection system to extend power.
Input wiring connectors and DC bus T-connector for frame 1 and 2 servo drives.
Input wiring connectors and DC bus T-connector for frame 3 servo drives.
Shared-bus
Connector Kits
Feedback
Connector Kit
Hiperface to DSL
Converter Kit
2198-H040-
2198-H070-
x-x x-x
2198-KITCON-DSL Replacement feedback connector kit with 2-pin connector plug and grounding plate inside the connector housing.
I/O Connector Kits
Connector Sets
2198-H2DCK
(series B or later)
2198-KITCON-IOSP
2198-KITCON-IOSC
Use the 2198-H2DCK Hiperface-to-DSL feedback converter kit with MP-Series™ (Bulletin MPL, MPM, MPF, and MPS) rotary motors, MP-Series (Bulletin MPAS ballscrew, MPAR, MPAI) linear actuators, and LDAT-Series linear thrusters.
Replacement I/O connector kit (spring clamp) for I/O (IOD) connector.
Replacement I/O connector kit (screw terminal) for I/O (IOD) connector.
2198-KITCON-PWR40 Replacement connector set, 40 A, for frame 1 and frame 2 drives.
2198-KITCON-PWR70 Replacement connector set, 70 A, for frame 3 drives.
2198-KITCON-CAP1300 Replacement connector set, 40 A, for capacitor module.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
15
Chapter 1
Start
Table 2 - Kinetix 5500 Drive System Overview (continued)
Drive System
Component
Encoder Output
Module
Cat. No.
2198-ABQE
Logix 5000™
Controller Platform
Bulletin 1769
Bulletin 5069
1756-EN2T module
1756-EN2TR module
1756-EN3TR module
Description
The Allen-Bradley® encoder output module is a DIN-rail mounted EtherNet/IP network-based standalone module capable of outputting encoder pulses to a customer-supplied peripheral device (cameras, for example, used in line-scan vision systems).
Integrated Motion on the EtherNet/IP network in CompactLogix™ 5370, CompactLogix 5380, and CompactLogix 5480 controllers and Integrated Safety in Compact GuardLogix® 5370 controllers. Linear, device-level ring (DLR), and star topology is supported.
EtherNet/IP network communication modules for use with ControlLogix® 5570, ControlLogix 5580, and GuardLogix 5570 controllers. Linear, device-level ring (DLR), and star topology is supported.
Studio 5000®
Environment
Studio 5000 Logix Designer® application, version 21.00 or later, provides support for programming, commissioning, and maintaining the CompactLogix and ControlLogix controller families. Version 24.00 or later is required for 2198-H
xxx
-ERS2 servo drives.
VPL-A
xxxx,
VPL-B
xxxx
VPF-A
xxxx,
VPF-B
xxxx
VPH-A
xxxx,
VPH-B
xxxx
VPS-B
xxxx
Compatible rotary motors include 200V and 400V-class Kinetix VP (Bulletin VPL, VPF, VPH, and VPS).
Rotary Servo
Motors
Linear Actuators
Kinetix VP
MP-Series
LDAT-Series
Induction Motors N/A
Cables
Compatible linear actuators include 200V and 400V-class Kinetix VP (Bulletin VPAR), MP-Series (Bulletin MPAS ballscrew, MPAR, and MPAI) and LDAT-Series when used with the Hiperface-to-DSL feedback converter kit.
2090-CS
2090-CS
x x
M1DF-
M1DG-
xx xx
A
A
xxx xxx
Induction motors with open loop frequency control are also supported.
Bulletin 2090 flying-lead single-cable for motor power, feedback, and 24V DC brake power with Kinetix VP motors. Designed specifically for Kinetix 5500 servo drives.
Bulletin 2090 flying-lead single cable for motor power, feedback, and 24V DC brake power with Kinetix VP motors and actuators.
Designed with longer leads than 2090-CS
x
M1DF cables to accommodate Kinetix 5500 or Kinetix 5700 drive families.
2090-CFBM7DF-CEA
xxx
Bulletin 2090 motor feedback cables for MP-Series motors and actuators.
2090-CP
x
M7DF-
xx
A
xxx
Bulletin 2090 motor power/brake cables for MP-Series motors and actuators.
AC Line Filters
MP-Series
1585J-M8CBJM-
2198-DB08-F
2198-DB20-F
2198-DB42-F
2198-DBR20-F
2198-DBR40-F
2198-DBR90-F
x
Compatible rotary motors include 200V and 400V-class MP-Series (Bulletin MPL, MPM, MPF, and MPS) when used with the
Hiperface-to-DSL feedback converter kit.
Ethernet cables are available in standard lengths. Shielded cable is recommended.
Bulletin 2198 three-phase AC line filters are required to meet CE and available for use in all Kinetix 5500 drive systems. Use
2198-DB
xx
-F filters as field replacements in existing installations. Select 2198-DBR
xx
-F filters for all new systems and do not remove the servo drive ground screws.
Bulletin 2198 three-phase AC line filters are required to meet CE and available for use with all Kinetix 5500 drive systems. Select
2198-DBR
xx
-F filters for all new systems and do not remove the servo drive ground screws.
24V DC Power
Supply
External Shunt
Resistors
N/A
1606-XL
xxx
2097-R6 and 2097-R7
Bulletin 1606 24V DC power supply for control circuitry, digital inputs, safety, and motor brake.
Bulletin 2097 external passive shunt resistors for when the internal shunt capability of the drive is exceeded.
16
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Start
Chapter 1
Drive Hardware and Input
Power Configurations
Typical Kinetix 5500 systems include single-phase and three-phase standalone configurations, three-phase shared AC, shared AC/DC, shared DC, and shared AC/DC hybrid configurations.
Line
Disconnect
Device
Input
Fusing
Single-phase or
Three-phase
Input Power
Bonded Cabinet
Ground Bus
2198-DBR
xx
-F
AC Line Filter
(can be required for CE)
Standalone Configurations
In these examples, a single standalone drive is shown with and without the
Bulletin 2198 capacitor module.
Figure 1 - Typical Kinetix 5500 Standalone Installation
2198-H
xxx
-ERS
x
Drive
(top view)
Mains AC and 24V input wired to standard input connectors.
2198-H
xxx
-ERS
x
Drive (top view) with 2198-CAPMOD-1300
Capacitor Module
Mains AC input wired to standard input connector.
Shared DC (DC common bus)
Shared 24V (control power input)
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
AC Input Power
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
2198-H0
x
0-
x-x
shared-bus connection system for bussharing configurations.
2198-H
xxx
-ERS
x
Drive
(front view)
Digital Inputs to Sensors and Control String
2097-R
x
Shunt Resistor
(optional component)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
17
Chapter 1
Start
In this example, three-phase AC power and 24V control power is shared in a multi-axis configuration. All drives must have the same power rating (catalog number).
Figure 2 - Typical Shared AC Installations
Line
Disconnect
Device
Input
Fusing
Three-phase
Input Power
Bonded Cabinet
Ground Bus
2198-DBR
xx
-F
AC Line Filter
(can be required for CE)
Kinetix 5500 Servo Drives (top view)
(2198-H008-ERS drives shown)
Shared AC (mains AC input)
Shared 24V (control power input)
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
AC Input Power
Digital Inputs to Sensors and Control String
Kinetix 5500 Servo Drives (front view)
(2198-H008-ERS drives shown)
Shared-bus connection system for bus-sharing configurations.
2097-R
x
Shunt Resistor
(optional component)
IMPORTANT
In shared AC configurations, all drives must have the same power rating.
Shared AC configurations do not support Bulletin 2198 capacitor modules.
18
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Start
Chapter 1
Shared AC/DC Configurations
In this example, three-phase AC input power, 24V control power, and DC-bus power are shared in a multi-axis configuration. All drives must be the same power rating (catalog number).
Figure 3 - Typical Shared AC/DC Installations
Line
Disconnect
Device
Three-phase
Input Power
Input
Fusing
Bonded Cabinet
Ground Bus
2198-DBR
xx
-F
AC Line Filter
(can be required for CE)
Kinetix 5500 Servo Drives (top view)
(2198-H015-ERS drives shown)
2198-CAPMOD-1300 Capacitor Module
(optional component)
Shared AC (mains AC input)
Shared DC (DC common bus)
Shared 24V (control power input)
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
AC Input Power
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
Kinetix 5500 Servo Drives (front view)
(2198-H015-ERS drives shown)
Shared-bus connection system for bus-sharing configurations.
Digital Inputs to Sensors and Control String
2097-R
x
Shunt Resistor
(optional component)
IMPORTANT
In shared AC/DC configurations, all drives must have the same power rating
(catalog number).
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
19
Chapter 1
Start
Shared DC Common-bus Configurations
In this multi-axis example, the common-bus leader (sourcing) drive receives three-phase AC input power and supplies DC power to common-bus follower
(sinking) drives. The common-bus leader-drive power rating is greater than or equal to the power rating of each follower drive.
Figure 4 - Typical Shared DC Common-bus Installations
Line
Disconnect
Device
Input
Fusing
Three-phase
Input Power
Bonded Cabinet
Ground Bus
2198-DBR
xx
-F
AC Line Filter
(can be required for CE)
Kinetix 5500 Servo Drive System (top view)
Shared DC (DC common bus)
Shared 24V (control power input)
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
AC Input Power
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
Kinetix 5500 Servo Drive System (front view)
Shared-bus connection system for bus-sharing configurations.
Digital Inputs to Sensors and Control String
2097-R
x
Shunt Resistor
(optional component)
2198-H040-ERS
Common-bus Leader Drive
(
2198-H008-ERS
Common-bus
Follower Drives
2198-CAPMOD-1300 Capacitor Module
(optional component)
IMPORTANT
In shared DC common-bus configurations, the leader drive power rating must be greater than or equal to the power rating of the follower drives.
20
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Line
Disconnect
Device
Input
Fusing
Three-phase
Input Power
Bonded Cabinet
Ground Bus
2198-DBR
xx
-F
AC Line Filter
(can be required for CE)
Start
Chapter 1
Shared AC/DC Hybrid Configuration
In this multi-axis example, three-phase AC input power is supplied to two converter drives. The converter drive ratings must be the same, and greater than or equal to the power ratings of the inverter drives. This parallel converter configuration increases the DC-bus power supplied to the inverter drives.
Figure 5 - Typical Shared AC/DC Bus Hybrid Installations
Kinetix 5500 Servo Drive System (top view)
Shared AC (mains AC input)
Shared DC (DC common bus)
Shared 24V (control power input)
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
AC Input Power
Kinetix 5500 Servo Drive System (front view)
Shared-bus connection system for bus-sharing configurations.
Digital Inputs to Sensors and Control String
2097-R
x
Shunt Resistor
(optional component)
2198-H040-ERS
Common-bus (converter)
Leader Drives
2198-H008-ERS
Common-bus (inverter)
Follower Drives
2198-CAPMOD-1300 Capacitor Module
(optional component)
IMPORTANT
In shared AC/DC hybrid configuration, the converter drives must have the same power rating and must be greater than or equal to the power ratings of the inverter drives.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
21
Chapter 1
Start
Motor Feedback and
Feedback-only
Configurations
2198-H
xxx
-ERS
x
Drive
(front view)
Feedback connections are made at the 2-pin motor feedback (MF) connector.
These examples illustrate how you can use the Bulletin 2198 connector kits for making these connections. To see motor power and brake connections, refer to
.
Figure 6 - Feedback Configuration Examples
2-pin Motor Feedback
(MF) Connector
2090-CSBM1DF or 2090-CSBM1DG
Single Motor Cables
Kinetix VP Electric Cylinders
(Bulletin VPAR)
2198-KITCON-DSL Connector Kit
• Accepts DSL motor feedback from Kinetix VP
(Bulletin VPL, VPF, VPH, VPS) rotary motors and Kinetix VP electric cylinders.
• Feedback-only (DSL)
Kinetix VP Rotary Motors
(VPL-B
xxxx
motor is shown)
MP-Series Rotary Motors
(MPL-B
xxxx
motor is shown)
22
Induction Rotary Motors
(no feedback, V/Hz)
2198-H2DCK Converter Kit
Converts 15-pin Hiperface feedback into 2-pin DSL feedback for:
• MP-Series rotary motors and linear actuators
• LDAT-Series linear thrusters
• Feedback-only (absolute single-turn/multi-turn Hiperface)
Bulletin 2090 Motor Power and Feedback Cables
LDAT-S
xxxxxx-x
D
x
Linear Thrusters
MP-Series Linear Actuators
(MPAR-B3
xxxx
electric cylinder is shown)
MP-Series Linear Actuators
(MPAS-B9
xxx
ballscrew linear stage is shown)
MP-Series Linear Actuators
(MPAI-B3
xxxx
heavy-duty electric cylinder is shown)
IMPORTANT
In 2198-H2DCK converter kit applications, you can replace the 2090-
CP
x
M7DF power/brake cable with a 2090-CSBM1DF single motor cable, and reuse the 2090-CFBM7DF feedback cable. This increases the maximum cable length for 18 and 14 AWG single cables to 50 m (164 ft). 2090-CS
x
M1DF-
10A
xxx
(10 AWG) cables do not support this 50 m (164 ft) option.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Typical Communication
Configurations
Start
Chapter 1
The Kinetix 5500 drives support any Ethernet topology including linear, ring, and star by using ControlLogix, GuardLogix, or CompactLogix controllers.
These examples feature the CompactLogix 5370 programmable automation controllers (Bulletin 1769) with support for Integrated Motion over the
EtherNet/IP network.
Refer to CompactLogix Controllers Specifications Technical Data, publication
1769-TD005 , for more information on CompactLogix 5370 L1, L2, and L3 controllers.
Linear Topology
In this example, all devices are connected in linear topology. The Kinetix 5500 drives include dual-port connectivity, however, if any device becomes disconnected, all devices downstream of that device lose communication.
Devices without dual ports must include the 1783-ETAP module or be connected at the end of the line.
Figure 7 - Kinetix 5500 Linear Communication Installation
CompactLogix Controller Programming Network
00:00:BC:2E:69:F6
1 (Front)
2 (Rear)
1585J-M8CBJM-
x
Ethernet (shielded) Cable
MOD
NET
2198-ABQE
Encoder Output Module OUTPUT-A OUTPUT-B
CompactLogix 5370 Controller
Studio 5000 Logix Designer
Application
Kinetix 5500 Servo Drive System
1585J-M8CBJM-OM15
0.15 m (6 in.) Ethernet cable for drive-to-drive connections.
842E-CM Integrated
Motion Encoder
PanelView™ Plus
Display Terminal
1734-AENTR POINT I/O™
EtherNet/IP Adapter
0 0 2
Link 1
Activity/
Status
1734-AENTR
POINT I O
Module
Status
Network
Activity
Network
Status
Point Bus
Status
System
Power
Field
Power
Link 2
Activity/
Status
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
23
Chapter 1
Start
Ring Topology
In this example, the devices are connected by using ring topology. If only one device in the ring is disconnected, the rest of the devices continue to communicate. For ring topology to work correctly, a device level ring (DLR) supervisor is required (for example, the Bulletin 1783 ETAP device). DLR is an ODVA standard. For more information, refer to the EtherNet/IP
Embedded Switch Technology Application Guide, publication ENET-AP005 .
Devices without dual ports, for example the display terminal, require a
1783-ETAP module to complete the network ring.
Figure 8 - Kinetix 5500 Ring Communication Installation
CompactLogix Controller Programming Network
CompactLogix 5370 Controller Studio 5000 Logix Designer
Application
00:00:BC:2E:69:F6
1 (Front)
2 (Rear)
1783-ETAP
Module
1585J-M8CBJM-
x
Ethernet
(shielded) Cable
Kinetix 5500 Servo Drive System
PanelView Plus
Display Terminal
0 0 2
Link 1
Activity/
Status
1734-AENTR
POINT I O
Module
Status
Network
Activity
Network
Status
Point Bus
Status
System
Power
Field
Power
1734-AENTR POINT I/O
EtherNet/IP Adapter
Link 2
Activity/
Status
MOD
NET
2198-ABQE
Encoder Output Module OUTPUT-A OUTPUT-B
842E-CM Integrated
Motion Encoder
1585J-M8CBJM-OM15
0.15 m (6 in.) Ethernet cable for drive-to-drive connections.
24
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Start
Chapter 1
Star Topology
In this example, the devices are connected by using star topology. Each device is connected directly to the switch.
Kinetix 5500 drives have dual ports, so linear topology is maintained from drive-to-drive, but Kinetix 5500 drives and other devices operate independently. The loss of one device does not impact the operation of other devices.
Figure 9 - Kinetix 5500 Star Communication Installation
CompactLogix Controller Programming Network
00:00:BC:2E:69:F6
1 (Front)
2 (Rear)
1585J-M8CBJM-
x
Ethernet (shielded) Cable
842E-CM Integrated
Motion Encoder
1783-BMS
Stratix® 5700
Switch
CompactLogix 5370 Controller
Studio 5000 Logix Designer
Application
Kinetix 5500 Servo Drive System
2198-ABQE
Encoder Output Module
MOD
NET
OUTPUT-A OUTPUT-B
1585J-M8CBJM-OM15
0.15 m (6 in.) Ethernet cable for drive-to-drive connections.
PanelView Plus
Display Terminal
1734-AENTR POINT I/O
EtherNet/IP Adapter
You can use the 842E-CM integrated motion encoder for applications requiring an external encoder for gearing or camming to the Kineitx 5700 drive. By providing auxiliary feedback directly through the EtherNet/IP network, the 842E-CM encoder helps eliminate the need for point-to-point wiring while letting customers use the encoder in a variety of network topologies. For more information, see the 842E-CM Integrated Motion on
EtherNet/IP Product Profile, publication 842ECM-PP001 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
25
Chapter 1
Start
Safe Torque-off
Configurations
Kinetix 5500 servo drives are available with safe torque-off via hardwired connections or integrated over the EtherNet/IP network. These examples illustrate the safe torque-off configuration options.
Studio 5000 Logix Designer
Application
(version 21.0 or later)
Module Definition
Configured with
Motion-only
Connection
00:00:BC:2E:69:F6
1 (Front)
2 (Rear)
Hardwired Safety Configuration
The 2198-H
xxx
-ERS drives use the safe torque-off (STO) connector for wiring external safety devices and cascading hardwired safety connections from one drive to another.
Figure 10 - Safe Torque-off (hardwired) Configuration
Any Logix 5000 Controller
(CompactLogix 5370 controller is shown)
2198-H
xxx
-ERS Servo Drives
(top view)
1585J-M8CBJM-
x
Ethernet (shielded) Cable
Safe Torque-off
(STO) Connectors
Safety
Device
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
AC Input Power
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
2198-H
xxx
-ERS Servo Drives
(front view)
Digital Inputs to Sensors and Control String
Logix5585 TM
SAFETY ON
0 0 0 0 NET
LINK
RUN FORCE SD OK
DC INPUT
DC INPUT AC OUTPUT
ControlLogix 5570 Controllers or
GuardLogix 5570 Safety Controllers
ControlLogix 5580 Controllers or
GuardLogix 5580 Safety Controllers
CompactLogix 5370 Controllers or
Compact GuardLogix 5370 Safety Controllers
CompactLogix 5380 or 5480 Controllers or
Compact GuardLogix 5380 Safety Controllers
Kinetix VP
Servo Motors
26
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Studio 5000 Logix Designer
Application
(version 24.0 or later)
Module Definition
Configured with
Motion and Safety
Connections
1783-BMS
Stratix 5700
Switch
Start
Chapter 1
Integrated Safety Configurations
The GuardLogix 5570 or Compact GuardLogix 5370 safety controller issues the safe torque-off (STO) command over the EtherNet/IP network and the
2198-H
xxx
-ERS2 integrated safety drive executes the command.
In this example, a single GuardLogix safety controller makes a Motion and
Safety connection with the 2198-H
xxx
-ERS2 integrated safety drives.
IMPORTANT
If only one controller is used in an application with Motion and Safety connections, the controller must be a GuardLogix 5570 or Compact
GuardLogix 5370 safety controller.
Figure 11 - Motion and Safety Configuration (single controller)
1585J-M8CBJM-
x
Ethernet (shielded) Cable
2
1
EtherNet/IP
LNK1LNK2 NET OK
Compact GuardLogix 5370 Controller,
Compact GuardLogix 5380 Safety Controller or
GuardLogix 5570 Controller,
GuardLogix 5580 Safety Controller
(GuardLogix 5570 Safety Controller is shown)
2198-H
xxx
-ERS2 Servo Drives
(top view)
1734-AENTR
POINT Guard I/O™
EtherNet/IP Adapter
Safety
Device
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
AC Input Power
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
Motion and Safety Connections to the Drive
Digital Inputs to Sensors and Control String
2198-H
xxx
-ERS2 Servo Drives
(front view)
Kinetix VP
Servo Motors
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
27
Chapter 1
Start
EtherNet/IP
LNK1LNK2 NET OK
2
1
Any Logix 5000 Controller
(ControlLogix 5570 controller is shown)
Motion Program
Module Definition
Configured with
Motion only
Connection
In this example, a non-safety controller makes the Motion-only connection and a separate GuardLogix safety controller makes the Safety-only connection with 2198-H
xxx
-ERS2 integrated safety drives.
IMPORTANT
If two controllers are used in an application with Motion-only and
Safety-only connections, the Safety-only connection must be a
GuardLogix 5570 or Compact GuardLogix 5370 safety controller and the
Motion-only connection must be a ControlLogix 5570 or
CompactLogix 5370 controller.
Figure 12 - Motion and Safety Configuration (multi-controller)
EtherNet/IP
LNK1LNK2 NET OK
Studio 5000 Logix Designer
Application
(version 24.0 or later)
Compact GuardLogix 5370 Controller,
Compact GuardLogix 5380 Safety Controller or
GuardLogix 5570 Controller,
GuardLogix 5580 Safety Controller
(GuardLogix 5570 Safety Controller is shown)
Safety Program
Module Definition
Configured with Safety only Connection
2
1
1783-BMS
Stratix 5700
Switch
1734-AENTR
POINT Guard I/O
EtherNet/IP Adapter
Safety
Device
2198-H
xxx
-ERS2 Servo Drives
(top view)
1585J-M8CBJM-
x
Ethernet (shielded) Cable
1606-XL
xxx
24V DC Control, Digital Inputs, and Motor Brake Power
(customer-supplied)
AC Input Power
Input
Allen-Bradley
1606-XL
Po we r S u p p l y
Motion and Safety Connections to the Drive
Digital Inputs to Sensors and Control String
2198-H
xxx
-ERS2 Servo Drives
(front view)
28
Kinetix VP
Servo Motors
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Start
Chapter 1
Catalog Number Explanation
Kinetix 5500 drive catalog numbers and performance descriptions.
Table 3 - Kinetix 5500 Servo Drive Catalog Numbers
Drive Cat. No.
(hardwired STO)
2198-H003-ERS
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
Drive Cat. No.
(integrated STO)
2198-H003-ERS2
2198-H008-ERS2
2198-H015-ERS2
2198-H025-ERS2
2198-H040-ERS2
2198-H070-ERS2
Frame Size
1
Input Voltage
Continuous Output
Power
kW
Continuous Output
Current
A 0-pk
195…264V rms, single-phase
195…264V rms, three-phase
324…528V rms, three-phase
0.2 kW
0.3 kW
0.6 kW
0.5 kW
0.8 kW
1.6 kW
1.4
3.5
2
3
195…264V rms, three-phase
324…528V rms, three-phase
1.0 kW
1.5 KW
3.2 kW
2.4 kW
5.1 kW
4.0 kW
8.3 kW
7.0 kW
14.6 kW
7.1
11.3
18.4
32.5
Capacitor Module
Cat. No.
2198-CAPMOD-1300
Table 4 - Capacitor Module Catalog Number
Frame Size
2
Rated Voltage
650V DC, nom
Kit Cat. No.
Table 5 - Shared-bus Connector Kit Catalog Numbers
Frame Size Application
2198-H040-ADP-IN Frame 1 or 2
2198-H040-A-T
2198-H040-D-T
2198-H040-P-T
2198-H040-AD-T
2198-H040-AP-T
2198-H040-DP-T
2198-H040-ADP-T
2198-H070-A-T
2198-H070-D-T
2198-H070-P-T
2198-H070-AD-T
2198-H070-AP-T
2198-H070-DP-T
2198-H070-ADP-T
Next drive is…
Frame 1 drives:
2198-H003-ERS
x
2198-H008-ERS
x
Frame 2 drives:
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
2198-H070-ADP-IN
Frame 3 drive:
2198-H070-ERS
x
Next drive is…
Frame 3 drives:
2198-H070-ERS
x x
First drive
AC sharing only
DC sharing only
Control power sharing only
AC and DC-bus sharing
AC and control power sharing
DC and control power sharing
AC, DC, and control power sharing
First drive
AC sharing only
DC sharing only
Control power sharing only
AC and DC-bus sharing
AC and control power sharing
DC and control power sharing
AC, DC, and control power sharing
Capacitance
1360 μF, min
Description
• Mains AC input wiring connector
• 24V DC input wiring connector
• DC bus T-connector
AC bus T-connector
DC bus T-connector
Control power T-connector
AC and DC bus T-connectors
AC and control power T-connectors
DC and control power T-connectors
AC, DC, and control power T-connectors
• Mains AC input wiring connector
• 24V DC input wiring connector
• DC bus T-connector
AC bus T-connector
DC bus T-connector
Control power T-connector
AC and DC bus T-connectors
AC and control power T-connectors
DC and control power T-connectors
AC, DC, and control power T-connectors
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
29
Chapter 1
Start
Agency Compliance
If this product is installed within the European Union 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 can cause damage to the filter. For grounding examples, refer to
Grounded Power Configurations on page 75
.
For more information on electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 .
To meet CE requirements, these requirements apply:
• Install an AC line filter (catalog number 2198-DBR
xx
-F) for input power as close to the Kinetix 5500 drive as possible.
• Bond drive, capacitor module, and line filter grounding screws by using a braided ground strap as shown in
.
• Use Bulletin 2090 single motor cables with Kinetix VP servo motors and actuators. Use Bulletin 2090 motor power/brake and feedback cables for other compatible Allen-Bradley motors and actuators.
• Combined motor cable length for all axes on the same DC bus must not exceed 250 m (820 ft). Drive-to-motor cables must not exceed 50 m
(164 ft); however, use of continuous-flex cable and 2198-H2DCK converter kit limits the maximum length.
Table 6 - Drive-to-Motor Maximum Cable Length
Kinetix 5500 Servo Drive
Cat. No.
Standard (non-flex) Cables
Cat. No. 2090-CS
x
M1DF/DG-
xx
AA
xx
m (ft)
Kinetix VP Servo Motors
Continuous-flex Cables
(1)
Cat. No. 2090-CSBM1DF/DG-
xx
AF
xx
Cat. No. 2090-CSBM1E1-
xx
AF
xx
m (ft)
Other Compatible Rotary Motors/Linear Actuators
(2)
Bulletin 2090 Motor/Actuator Cables
(3)
Cat. No. 2090-C
xx
M7DF
m (ft)
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
50 (164)
50 (164)
30 (98.4)
20 (65.6)
50 (164)
(1) When using 2090-CSBM1E1 cable in your continuous-flex application, the maximum cable length including the standard (non-flex) cable back to the drive, is 30 m (98.4 ft)
(2) Requires use of the 2198-H2DCK Hiperface-to-DSL (series B or later) feedback converter kit.
(3) The 20 m (65.6 ft) limitation is attributed to the 2090-CP
x
M7DF power/brake cable. In 2198-H2DCK converter kit applications, you can replace the 2090-CP
x
M7DF power/brake cable with a
2090-CSBM1DF or 2090-CSBM1DG single motor cable (and reuse the 2090-CFBM7DF feedback cable) to increase the maximum cable length to 50 m (164 ft). This applies to only 18 and 14 AWG single cables. 2090-CS
x
M1D
x
-10A
xxx
(10 AWG/M40 connector) single cables are not compatible with 2090-CPBM7DF-10A
xxx
(10 AWG/M40 connector) power/brake cables.
• Install the Kinetix 5500 system inside an approved enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure. Separate signal and power cables.
• Segregate input power wiring from control wiring and motor cables.
Refer to Appendix A on page 193 for input power wiring and drive/motor
interconnect diagrams.
30
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Chapter
2
Plan the Kinetix 5500 Drive System Installation
This chapter describes system installation guidelines used in preparation for mounting your Kinetix® 5500 drive components.
Topic
Page
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 metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry and result in damage to the components.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
31
Chapter 2
Plan the Kinetix 5500 Drive System Installation
System Design Guidelines
Use the information in this section when designing your enclosure and planning to mount your system components on the panel.
For on-line product selection and system configuration tools, including
AutoCAD (DXF) drawings of the product, refer to https://www.rockwellautomation.com/global/support/selection.page
.
System Mounting Requirements
• To comply with UL and CE requirements, the Kinetix 5500 drive systems must be enclosed in a grounded conductive enclosure offering protection as defined in standard IEC 60529 to IP20 such that they are not accessible to an operator or unskilled person. A NEMA 4X enclosure exceeds these requirements providing protection to IP66.
To maintain the functional safety rating of the Kinetix 5700 drive system, this enclosure must be appropriate for the environmental conditions of the industrial location and provide a protection class of
IP54 or higher.
• The panel that 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 in accordance with pollution degree 2 (IEC 61800-5-1) because the product is rated to protection class IP20 (IEC 60529).
• Size the drive enclosure so as not to exceed the maximum ambient temperature rating. Consider heat dissipation specifications for all drive components.
• Combined motor power cable length for all axes on the same DC bus must not exceed 250 m (820 ft). Drive-to-motor cables must not exceed
50 m (164 ft), however use of continuous-flex cable and 2198-H2DCK
converter kit limits the maximum length. Refer to Table 6
on
for specifications by frame size.
IMPORTANT
System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements.
• Use high-frequency (HF) bonding techniques to connect the modules, enclosure, machine frame, and motor housing, and to provide a lowimpedance return path for high-frequency (HF) energy and reduce electrical noise.
Bond drive, capacitor module, and line filter grounding screws by using a braided ground strap as shown in
.
Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , to better understand the concept of electrical noise reduction.
32
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
AC Line Filter Selection
An AC line filter is required to meet CE requirements. Install an AC line filter for input power as close to the 2198-H
xxx
-ERS
x
drive as possible.
IMPORTANT
AC line filters are only recommended with grounded WYE power configurations. For facility power configuration examples, see
on
Table 7 - AC Line Filter Selection
Kinetix Drive Module
Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
AC Line Filter
Cat. No.
2198-DB08-F
• 2198-DBR20-F or
• 2198-DB20-F
• 2198-DBR40-F or
• 2198-DB42-F
IMPORTANT
Use 2198-DB
xx
-F line filters only as field replacements in existing installations. Select 2198-DBR
xx
-F line filters for all new systems or to replace existing 2198-DB
xx
-F line filters. This does not apply to
2198-DB08-F line filters.
Table 8 - AC Line Filter Selection for Shared AC and Shared AC/DC and Hybrid Multi-axis Systems
Kinetix 5500 Drives
Cat. No.
Drive Voltage,
(three-phase) nom
2198-H003-ERS
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x x x
240/480V
240/480V
240/480V
240/480V
240/480V
240/480V
2
Axes
2198-DBR20-F
2198-DBR20-F
3
Axes
AC Line Filter Cat. No.
4
Axes
5
Axes
2198-DBR20-F
2198-DBR40-F
2198-DBR40-F 2198-DBR90-F –
2198-DBR90-F –
–
–
6
Axes
7
Axes
8
Axes
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
33
Chapter 2
Plan the Kinetix 5500 Drive System Installation
Transformer Selection
The servo drive does not require an isolation transformer for three-phase input power. However, a transformer can be required to match the voltage requirements of the drive to the available service.
To size a transformer for the main AC power inputs, refer to the Kinetix 5500 power specifications in the Kinetix Servo Drives Technical Data, publication
KNX-TD003 .
IMPORTANT
When using an autotransformer, make sure that the phase to neutral/ ground voltage does 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).
IMPORTANT
A line reactor must be used if the source transformer is greater than
150 KVA, max and 3% impedance, min.
EXAMPLE
Sizing a transformer to the voltage requirements of this drive:
2198-H040-ERS
x
= 8.4 kW = 12.6 KVA transformer.
Circuit Breaker/Fuse Selection
The Kinetix 5500 drives use 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) and 65,000 A (circuit breakers).
Refer to
Power Wiring Examples , on page 194
, for the wiring diagram.
ATTENTION:
Do not use circuit protection devices on the output of an AC drive as an isolating disconnect switch or motor overload device. These devices are designed to operate on sine wave voltage and the drive’s PWM waveform does not allow it to operate properly. As a result, damage to the device occurs.
34
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
Standalone Drive Systems
Drive Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
Kinetix 5500 Drives
Drive Voltage, nom Phase
240V
240/480V
240V
240/480V
240V
240/480V
240/480V
240/480V
240/480V
Single-phase
Three-phase
Single-phase
Three-phase
Single-phase
Three-phase
Three-phase
Three-phase
Three-phase
UL Applications
Bussmann Fuses
Cat. No.
Molded Case CB
Cat. No.
KTK-R-2
KTK-R-3
KTK-R-5
KTK-R-7
140U-D6D2-B10
140U-D6D3-B20
140U-D6D2-B20
140U-D6D3-B60
KTK-R-10
KTK-R-15
KTK-R-20
KTK-R-25
LPJ-35SP
140U-D6D2-B80
140U-D6D3-C12
140U-D6D3-C20
140U-D6D3-C25
140G-G6C3-C40
Shared DC (common-bus) Drive Systems
20
25
10
16
35
6
6
2
4
IEC (non-UL) Applications
DIN gG Fuses
Amps (max)
Molded Case CB
Cat. No.
140U-D6D2-B10
140U-D6D3-B20
140U-D6D2-B20
140U-D6D3-B60
140U-D6D2-B80
140U-D6D3-C12
140U-D6D3-C20
140U-D6D3-C25
140G-G6C3-C40
Kinetix 5500 Drives
Cat. No.
Drive Voltage,
(three-phase) nom
2198-H003-ERS
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x x x
240/480V
240/480V
240/480V
240/480V
240/480V
240/480V
Bussmann Fuses
Cat. No.
KTK-R-10
KTK-R-10
KTK-R-15
KTK-R-20
KTK-R-25
LPJ-35SP
UL Applications
Molded Case CB
Cat. No.
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C20
140U-D6D3-C25
140G-G6C3-C40
Kinetix 5500 Drives
Cat. No.
2198-H003-ERS
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x x x
Drive Voltage,
(three-phase) nom
240/480V
240/480V
240/480V
240/480V
240/480V
240/480V
2 Axes
KTK-R-15
KTK-R-15
KTK-R-20
KTK-R-30
LPJ-35SP
LPJ-60SP
25
35
16
20
DIN gG Fuses
Amps (max)
10
10
IEC (non-UL) Applications
Molded Case CB
Cat. No.
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C20
140U-D6D3-C25
140G-G6C3-C40
Shared AC Drive Systems
Table 9 - Input Power UL Circuit-protection Specifications
Bussmann Fuses
Cat. No.
3 Axes 4 Axes
KTK-R-25
LPJ-45SP
–
–
–
–
5 Axes
Molded Case CB
Cat. No.
3 Axes 4 Axes 5 Axes 2 Axes
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C15 140U-D6D3-C20 –
140U-D6D3-C25 140U-D6D3-C30 –
140G-G6C3-C40 140G-G6C3-C50 –
140G-G6C3-C60 –
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
35
Chapter 2
Plan the Kinetix 5500 Drive System Installation
Kinetix 5500 Drives
Cat. No.
2198-H003-ERS
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x x x
Drive Voltage,
(three-phase) nom
240/480V
240/480V
240/480V
240/480V
240/480V
240/480V
32
35
63
16
20
2 Axes
16
Table 10 - Input Power IEC (non-UL) Circuit-protection Specifications
50
–
3 Axes
DIN gG Fuses
Amps (max)
4 Axes
25 –
–
5 Axes
Molded Case CB
Cat. No.
3 Axes 4 Axes 5 Axes 2 Axes
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C15 140U-D6D3-C20 –
140U-D6D3-C25 140U-D6D3-C30 –
140G-G6C3-C40 140G-G6C3-C50 –
140G-G6C3-C60 –
Shared AC/DC and Hybrid Systems
Table 11 - Input Power UL Circuit-protection Specifications
Kinetix 5500
Drives Cat. No.
2198-H003-ERS
2198-H008-ERS
x x
Drive Voltage,
(three-phase) nom
240/480V
240/480V
2 Axes
KTK-R-10
KTK-R-15
2198-H015-ERS
x
240/480V
2198-H025-ERS
x
240/480V
2198-H040-ERS
x
240/480V
2198-H070-ERS
x
240/480V
KTK-R-20
KTK-R-30
3 Axes
LPJ-50SP –
Bussmann Fuse
4 Axes
Cat. No.
5 Axes
–
–
KTK-R-30 LPJ-45SP LPJ-50SP –
6 Axes
KTK-R-20
7 Axes
KTK-R-15
8 Axes 2 Axes
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C20
140U-D6D3-C30
140G-G6C3-C50
3 Axes 4 Axes
140U-D6D3-C20
140U-D6D3-C30
140G-G6C3-C50
–
Molded Case CB
Cat. No.
5 Axes
–
–
–
6 Axes 7 Axes 8 Axes
140U-D6D3-C20
Table 12 - Input Power IEC (non-UL) Circuit-protection Specifications
Kinetix 5500
Drives Cat. No.
2198-H003-ERS
x
240/480V
2198-H008-ERS
x
240/480V
2198-H015-ERS
x
240/480V
2198-H025-ERS
x
240/480V
2198-H040-ERS
x
Drive Voltage,
(three-phase) nom
DIN gG Fuses
Amps (max)
2 Axes 3 Axes 4 Axes 5 Axes 6 Axes 7 Axes 8 Axes 2 Axes
16
240/480V
2198-H070-ERS
x
240/480V
20
32
10
16
32
50
50
–
–
–
–
20
140U-D6D3-C15
140U-D6D3-C15
140U-D6D3-C15 140U-D6D3-C20 –
140U-D6D3-C20 140U-D6D3-C30 –
140U-D6D3-C30
140G-G6C3-C50
3 Axes
Molded Case CB
4 Axes
140G-G6C3-C50
–
Cat. No.
5 Axes
–
6 Axes 7 Axes 8 Axes
140U-D6D3-C20
36
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
24V Control Power Evaluation
The Kinetix 5500 drive system requires 24V DC input for its control circuitry.
Due to the 24V shared-bus connection system and the 24V current requirements of the Kinetix 5500 drives, a thorough evaluation of control power is required prior to implementation. Consider the following when sizing such a system:
• Verify that the 24V DC power supply is capable of supplying the 24V current requirements of your Kinetix 5500 drive system. See
Power Current Calculations on page 224 to determine the 24V current
requirements.
For systems with a high 24V current demand, consider installing a separate 24V power supply for each bus group or change the bus group configuration to more evenly divide the 24V current demand.
• Verify that the wiring being used is capable of supplying the
Kinetix 5500 drive system with a voltage within the 24V input-voltage range; 24V ±10% (21.6…26.4V DC). Consider the following:
– Mount the 24V power supply as close to the Kinetix 5500 drive system as possible to minimize input voltage drop.
– Install larger gauge wire, up to 2.5 mm
2
(14 AWG) for 24V control power when using the CP connectors included with the module; or use the 24V shared-bus connection system to lower the DC wire resistance with up to 10 mm
2
(6 AWG) and result in a lower voltage drop.
IMPORTANT
The 24V current demand, wire gauge, and wire length all impact the voltage drop across the wiring being used.
Contactor Selection
You can use an AC three-phase contactor to supply AC input power to the
Kinetix 5500 drive. Follow these guidelines when selecting a contactor for your drive system.
• Make sure the contactor is capable of supporting a higher amp rating than the input fuse/circuit breaker you selected from the tables in
Circuit Breaker/Fuse Selection on page 34
• Select a contactor with a voltage rating and SCCR rating appropriate for your drive installation
• Do not cycle power to the contactor more than once per minute to help prevent damage to the Kinetix 5500 drive
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
37
Chapter 2
Plan the Kinetix 5500 Drive System Installation
Passive Shunt Considerations
The Kinetix 5500 drives all include an internal shunt that is wired to the shunt resistor (RC) connector at the factory. Bulletin 2097-R
x
external passive shunts are available to provide additional shunt capacity for applications where the internal shunt capacity is exceeded.
IMPORTANT
Keep the internal shunt wires connected unless you have an external passive shunt to connect.
Table 13 - Bulletin 2097 Passive Shunt Options
Kinetix 5500 Drives
Cat. No.
Internal Shunt Specifications
Ω W
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
100
60
40
30
50
75
(1) Shunt resistor selection is based on the needs of your actual hardware configuration.
X
–
X
X
–
External Shunt Resistor
(1)
Compatibility
Cat. No.
2097-R7
X
2097-R6
–
–
–
–
X
X
Catalog numbers 2097-R6 and 2097-R7 are shunt resistors without an enclosure.
Figure 13 - External Passive Shunts
2097-R6 and 2097-R7
Shunt Resistors
External Shunt Module Specifications
Shunt Module
Cat. No.
2097-R6
2097-R7
Resistance
Ω
75
150
Continuous Power
W
150
80
Weight, approx
kg (lb)
0.3 (0.7)
0.2 (0.4)
How the Bulletin 2097-R
x
shunts connect to Kinetix 5500 drives is explained
in External Passive-shunt Resistor Connections on page 105 and illustrated
with interconnect diagrams in Shunt Resistor Wiring Example on page 198 .
38
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
Enclosure Selection
This example is provided to assist you in sizing an enclosure for your
Kinetix 5500 drive system. You need heat dissipation data from all components
planned for your enclosure to calculate the enclosure size (refer to Table 14 ).
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 =
0.38Q
1.8T - 1.1
A =
4.08Q
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 (ft
2)
.
The exterior surface of all six sides of an enclosure is calculated as
A = 2dw + 2dh + 2wh
Where d (depth), w (width), and h (height) are in meters.
A = (2dw + 2dh + 2wh) /144
If the maximum ambient rating of the Kinetix 5500 drive system is 50 °C
(122 °F) and if the maximum environmental temperature is 20 °C (68 °F), then
T=30. In this example, the total heat dissipation is 416 W (sum of all components in enclosure). So, in the equation below, T=30 and Q=416.
A =
0.38 (416)
1.8 (30) - 1.1
= 2.99 m
2
In this example, the enclosure must have an exterior surface of at least 2.99 m
2
.
If any portion of the enclosure is not able to transfer heat, do not include that value in the calculation.
Because the minimum cabinet depth to house the Kinetix 5500 system
(selected for this example) is 300 mm (11.8 in.), the cabinet needs to be approximately 1500 x 700 x 300 mm (59.0 x 27.6 x 11.8 in.) HxWxD.
1.5 x (0.300 x 0.70) + 1.5 x (0.300 x 2.0) + 1.5 x (0.70 x 2.0) = 3.31 m
2
Because this cabinet size is considerably larger than what is necessary to house the system components, it can be more efficient to provide a means of cooling in a smaller cabinet. Contact your cabinet manufacturer for options available to cool your cabinet.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
39
Chapter 2
Plan the Kinetix 5500 Drive System Installation
Kinetix 5500 Drive
Cat. No.
Frame
Size
20%
Table 14 - Power Dissipation Specifications
40%
Usage as % of Rated Power Output
(watts)
60% 80%
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
1
2
3
12
40
64
25
80
128
37
120
192
50
160
256
100%
62
200
320
Minimum Clearance Requirements
This section provides information to assist you in sizing your cabinet and positioning your Kinetix 5500 drive:
• Additional clearance is required for cables and wires or the shared-bus connection system connected to the top of the drive.
• Additional clearance is required if other devices are installed above and/ or below the drive and have clearance requirements of their own.
• Additional clearance left and right of the drive is required when mounted adjacent to noise sensitive equipment or clean wire ways.
• The recommended minimum cabinet depth is 300 mm (11.81 in.).
Figure 14 - Minimum Clearance Requirements
40 mm (1.57 in.) clearance above drive for airflow and installation.
Kinetix 5500
Servo Drive
Clearance left of the drive is not required.
Clearance right of the drive is not required.
40 mm (1.57 in.) clearance below drive for airflow and installation.
Refer to the Kinetix Servo Drives
Technical Data, publication KNX-TD003 , for Kinetix 5500 drive dimensions.
IMPORTANT
Mount the drive in an upright position as shown. Do not mount the drive on its side.
40
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
In multi-axis shared-bus configurations, drives must be spaced by aligning the zero-stack tab and cutout.
Figure 15 - Multi-axis Shared-bus Clearance Requirements
Shared-bus connection system for bus-sharing configurations is not shown for clarity.
Zero-stack Tab and
Cutout Aligned
Electrical Noise Reduction
This section outlines best practices that minimize the possibility of noiserelated failures as they apply specifically to Kinetix 5500 system installations.
For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to 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 power rail and the subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance return path for high-frequency energy.
IMPORTANT
To improve the bond between the power rail and subpanel, construct your subpanel out of zinc plated (paint-free) steel.
Improper bonding of metal surfaces blocks the direct return path and allows high-frequency energy to travel elsewhere in the cabinet. Excessive highfrequency energy can effect the operation of other microprocessor controlled equipment.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
41
Chapter 2
Plan the Kinetix 5500 Drive System Installation
Subpanel
Star Washer
Nut
These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.
Figure 16 - 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
Subpanel
Mounting Bracket or
Ground Bus
Welded Stud
Welded Stud
Use a wire brush to remove paint from threads to maximize ground connection.
Use plated panels or scrape paint on front of panel.
Flat Washer
Nut
Star Washer
Scrape Paint
Flat Washer
If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole.
Bolt-mounting a Ground Bus or Chassis to the Back-panel
Subpanel
Tapped Hole
Bolt
Ground Bus or
Mounting Bracket
Nut
Flat Washer
Nut
Star Washer
Flat Washer
Star Washer
Scrape paint on both sides of panel and use star washers.
Star Washer
If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole.
42
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
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 do not necessarily share a common low impedance path. This difference in impedance can affect networks and other devices that span multiple panels:
• Bond the top and bottom of each subpanel to the cabinet by using
25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid. As a rule, the wider and shorter the braid is, the better the bond.
• Scrape the paint from around each fastener to maximize metal-to-metal contact.
Figure 17 - Multiple Subpanels and Cabinet Recommendations
Paint removed from cabinet.
Wire Braid
25.4 mm (1.0 in.) by
6.35 mm (0.25 in.)
Wire Braid
25.4 mm (1.0 in.) by
6.35 mm (0.25 in.)
Cabinet ground bus bonded to the subpanel.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
43
Chapter 2
Plan the Kinetix 5500 Drive System Installation
D
Dirty Wireway
D
Circuit
Breakers
D
Establishing Noise Zones
Observe these guidelines when routing cables used in the Kinetix 5500 system:
• The clean zone (C) is right of the drive system and includes the digital inputs wiring and Ethernet cable (gray wireway).
• The dirty zone (D) is above and below the drive system (black wireways) and includes the circuit breakers, 24V DC power supply, safety, and motor cables.
• The very dirty zone (VD) is limited to where the AC line (EMC) filter
VAC output jumpers over to the drive (or first drive in multi-axis systems). Shielded cable is required only if the very dirty cables enter a wireway.
Figure 18 - Noise Zones
Clean Wireway
Very Dirty Filter/AC Input Connections
Segregated (not in wireway)
(1)
C
(1)
VD
Kinetix 5500 Servo Drive System
24V DC
Power Supply
24V Input
Safety Cable
(2198-H
xxx
-ERS drives only)
AC Line Filter
(can be required for CE)
(1)
C
D
Route single motor cables in shielded cable.
Single Motor Cables
(2)
Module Status
Route registration and communication signals in shielded cables.
(1) When space to the right of the drive does not permit 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 .
(2) When 2198-H2DCK converter kit is used, feedback cable routes in the clean wireway.
44
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
Cable Categories for Kinetix 5500 Systems
Wire/Cable
These tables indicate the zoning requirements of cables connecting to the
Kinetix 5500 drive components.
Table 15 - Kinetix 5500 Drive
Connector
L1, L2, L3 (shielded cable)
L1, L2, L3 (unshielded cable)
DC-/DC+ (DC bus)
DC+/SH (shunt)
U, V, W (motor power)
Motor feedback
Motor brake
U, V, W (motor power)
Motor feedback
(1)
Motor brake
24V DC
Safety enable for safe torque-off (hardwired)
(2)
Registration input
Dedicated digital inputs (other than registration inputs)
Kinetix VP motors/ actuators
MP-Series™ motors/ actuators
IPD
IOD
Ethernet
PORT1
PORT2
(1) When the 2198-H2DCK converter kit is used, the feedback cable routes in the clean wireway.
(2) STO connector applies to only 2198-H
xxx
-ERS (hardwired) servo drives.
BC
MP
MF
BC
DC
RC
MP
MF
CP
STO
Table 16 - Capacitor Module
–
–
–
–
Zone
X
–
Very
Dirty
Dirty Clean
X
–
–
–
Bus-bar only, no wiring connector.
– X –
–
–
X
X
–
X
X
–
X
X
X
X –
–
X
–
–
–
–
X
– – X
–
–
–
–
–
–
–
–
–
–
Ferrite
Sleeve
Method
Shielded
Cable
X
–
X
–
X
X
X
X
–
X
–
X
–
X
Wire/Cable
DC-/DC+ (DC bus)
24V DC
Module status
Connector
DC
CP
MS
Zone
Very
Dirty
Dirty Clean
Bus-bar only, no wiring connector.
–
–
X
X
–
–
–
–
Ferrite
Sleeve
Method
Shielded
Cable
–
–
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
45
Chapter 2
Plan the Kinetix 5500 Drive System Installation
Noise Reduction Guidelines for Drive Accessories
Refer to this section when mounting an AC (EMC) line filter or external passive-shunt resistor for guidelines designed to reduce system failures caused by excessive electrical noise.
AC Line Filters
Observe these guidelines when mounting your AC (EMC) line filter (refer to
for an example):
• Mount the AC line filter on the same panel as the Kinetix 5500 drive and as close to the drive as possible.
• Good HF bonding to the panel is critical. For painted panels, refer to the examples on
• Segregate input and output wiring as far as possible.
IMPORTANT
CE test certification applies to only the AC line filter used with a single drive or the line filter used in multi-axis drive configurations. Sharing a line filter with more than one multi-axis drive configuration can perform satisfactorily, but the customer takes legal responsibility.
46
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Plan the Kinetix 5500 Drive System Installation
Chapter 2
External Passive Shunt Resistor
Observe these guidelines when mounting your Bulletin 2097 external passive-shunt resistor outside of the enclosure:
• Mount shunt resistor and wiring in the very dirty zone or in an external shielded enclosure.
• Mount resistors in a shielded and ventilated enclosure outside of the cabinet.
• Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.
Figure 19 - External Shunt Resistor Outside the Enclosure
Customer-supplied
Metal Enclosure
Shunt Power Wiring Methods:
Twisted pair in conduit (1st choice).
Twisted pair, two twists per foot (min) (2nd choice).
150 mm (6.0 in.) clearance (min) on all four sides of the shunt resistor.
Metal Conduit (where required by local code)
Dirty Wireway
D
D
Enclosure
Clean Wireway
C
D
Very Dirty Connections Segregated
(not in wireway)
VD
VD
24V DC
Power Supply
Kinetix 5500 Servo Drive System
Circuit
Breaker
Safety Cable
(2198-H
xxx
-ERS drives only)
No sensitive equipment within
150 mm (6.0 in.).
AC Line Filter
(can be required for CE)
Ethernet and I/O Cables
D
Route single motor cables in shielded cable.
Single Motor Cable
Module Status
Route registration and communication signals in shielded cables.
C
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
47
Chapter 2
Plan the Kinetix 5500 Drive System Installation
D
Dirty Wireway
Circuit
Breaker
D
When mounting your Bulletin 2097 passive-shunt resistor inside the enclosure, follow these additional guidelines:
• Mount metal-clad modules anywhere in the dirty zone, but as close to the Kinetix 5500 drive as possible.
• Route shunt power wires with other very dirty wires.
• 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.
Figure 20 - External Shunt Resistor Inside the Enclosure
D
Enclosure
150 mm (6.0 in.) clearance (min) on all four sides of the shunt resistor.
Very Dirty Connections Segregated
(not in wireway)
24V DC
Power Supply
VD
Shunt Power Wiring Methods:
Twisted pair in conduit (1st choice).
Twisted pair, two twists per foot (min) (2nd choice).
VD
Kinetix 5500 Servo Drive System
Clean Wireway
C
Safety Cable
(2198-H
xxx
-ERS drives only)
AC Line Filter
(can be required for CE)
No sensitive equipment within
150 mm (6.0 in.).
Ethernet and I/O Cables
D
Route single motor cables in shielded cable.
Single Motor Cable
Module Status
Route registration and communication signals in shielded cables.
C
48
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Mount the Kinetix 5500 Drive System
Chapter
3
This chapter provides the system installation procedures for mounting your
Kinetix® 5500 drives to the system panel.
Topic
Page
This procedure assumes you have prepared your panel and understand how to bond your system. For installation instructions regarding equipment and accessories not included here, refer to the instructions that came with those products.
SHOCK HAZARD:
To avoid hazard of electrical shock, perform all mounting and wiring of the Kinetix 5500 drives prior to applying power. Once power is applied, connector terminals can 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 metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry and result in damage to the components.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
49
Chapter 3
Mount the Kinetix 5500 Drive System
Determine Mounting Order
Mount drives in order (left to right) according to power rating (highest to lowest) starting with the highest power rating. If power rating is unknown, position drives (highest to lowest) from left to right based on amp rating.
Zero-stack Tab and Cutout
Engaging the zero-stack tab and cutout from drive-to-drive makes efficient use of panel space for installations with multiple drives.
IMPORTANT
Engaging the zero-stack tab and cutout from drive-to-drive is required for shared-bus multi-axis drive systems. This is done to make sure the drive connectors are spaced properly to accept the shared-bus connection system.
Figure 21 - Zero-stack Tab and Cutout Example
Zero-stack Tab and Cutout Engaged
2198-H
xxx
-ERS
x
Drives
(front view)
2198-H
xxx
-ERS
x
Drive System
(front view)
For the zero-stack feature to engage properly (when more than one frame size exists in the drive system) frame 3 drives must mount left of frame 1 or 2 drives, and frame 2 drives must mount left of frame 1 drives.
Capacitor modules can mount to the right of any frame size, but are always rightmost in any drive configuration.
IMPORTANT
Mount drives in descending order, left to right, according to frame size with capacitor modules always mounted on the far right.
Figure 22 - Shared-bus Connection System Example
Shared-bus Connection System
(required in shared-bus configurations)
50
Frame 3
Drive
Frame 2
Drives
Frame 1
Drives
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
2198-CAPMOD-1300 Capacitor Module
(optional component)
Mount the Kinetix 5500 Drive System
Chapter 3
Shared-bus Connection System
The shared-bus connection system is used to extend the mains AC input, 24V control input, and the DC bus power from drive-to-drive in shared-bus multiaxis configurations.
IMPORTANT
When the shared-bus connection system is used, the zero-stack tab and cutout must be engaged between adjacent drives.
Input Wiring
(AC input wiring is shown)
Input Wiring Connector
(1)
(mains AC input shown)
Zero-stack Tab and Cutout Engaged
The connection system is comprised of three components:
• Input wiring connectors that plug into the leftmost drive and receive input wiring for mains AC and 24V DC.
• AC bus, DC bus, and 24V DC T-connectors that plug into the drives downstream from the first where AC, DC, and/or 24V control power is shared. DC bus T-connectors also plug into the first drive where DC bus power is shared.
• Bus bars that connect between drives to extend the mains AC bus, DC bus, and 24V DC control power from drive-to-drive.
Figure 23 - Connection System Example
Bus-bar Connectors
(2)
(AC bus-bars shown)
AC T-connectors
DC Bus T-connector
(3)
DC Bus Connector Latch
2198-H
xxx
-ERS
x
Drive System (top view)
Frame 2 drives are shown.
Drive with largest amp rating must be leftmost drive.
(1) Due to the higher amp rating of frame 3 drives, input wiring connectors for frame 3 drives (catalog number 2198-H070-ADP-IN) are slightly larger than connectors for frame 1 and 2 drives (catalog number 2198-H040-ADP-IN).
(2) Due to the extra width of frame 3 drives, bus-bar connectors between frame 3 drives are slightly longer (85 mm) than connectors between frame 3, frame 2, and frame 1 drives (55 mm).
(3) DC bus T-connectors latch on both sides when inserted into the drive. To remove the DC bus T-connector, at least one latch must be pried away with a non-conductive probe.
The three components assemble from left to right across the drive system.
1.
Attach wiring to input wiring connectors.
2.
Insert input wiring connectors and T-connectors into the appropriate drive connectors.
3.
Insert bus-bars to connect between wiring connectors and T-connectors.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
51
Chapter 3
Mount the Kinetix 5500 Drive System
Single-axis Configurations
The following restrictions exist for standalone (single-axis) configurations:
• Standalone (single-axis) drives can be mounted to the panel individually or by using the zero-stack tab and cutout (refer to
)
• The shared-bus connection system does not apply and must not be used
For a single-axis example configuration, refer to
Standalone Installation on page 17
.
Multi-axis Configurations
Each multi-axis configuration has restrictions that apply:
• The shared-bus connection system must be used. Do not attach discrete wires from drive-to-drive.
• The maximum number of drives in Shared AC bus power-sharing groups cannot exceed 5.
• The maximum number of drives in any other bus power-sharing group cannot exceed 8.
For a multi-axis example configuration, refer to Typical Shared AC/DC Bus
Hybrid Installations on page 21
.
52
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Drill-hole Patterns
Mount the Kinetix 5500 Drive System
Chapter 3
Hole patterns for drives mounted in zero-stack or shared-bus configuration are provided for mounting your drives to the panel. Drives with the highest power rating are always mounted to the left of any drive with a lower power rating in shared-bus configurations:
• Frame 1 drives can be followed by only another frame 1 drive.
• Frame 2 drives can be followed by frame 1 drives or another frame 2 drive.
• Frame 3 drives can be followed by frame 1, frame 2, or another frame 3 drive.
• Mount Bulletin 2198 capacitor modules in the rightmost position.
– Capacitor modules have the same hole pattern as frame 2 drives.
– Only Shared DC, Shared AC/DC, and Shared AC/DC, hybrid configurations are compatible with Bulletin 2198 capacitor modules.
Table 17 - Hole Pattern Overview
Frame Size Frame Size Patterns Drive Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
Frame 1
Frame 2
2198-H070-ERS
x
Frame 3
Page
As many as eight frame 1 drives
As many as 8 frame 2 drives
One frame 2 drive followed by as many as seven frame 1 drives
As many as 8 frame 3 drives
One frame 3 drive followed by as many as seven frame 1 drives
One frame 3 drive followed by as many as seven frame 2 drives
Table 18 - Capacitor Module Support
Drive Cat. No.
Standalone
Three-phase Operation
Shared DC Shared AC/DC
Shared AC/DC
Hybrid
Number of capacitor modules connected, max
2198-H003-ERS
x
(1)
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
1
2
0
N/A
0
1
3
2
4
3 4
(1) Catalog number 2198-H003-ERS and any drive in standalone single-phase operation is not compatible with the Kinetix 5500 capacitor module.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
53
Chapter 3
Mount the Kinetix 5500 Drive System
193.68
Frame 1
Standalone Drive
243.84
These hole patterns apply to standalone drives.
Figure 24 - Frame 1, Frame 2, and Frame 3 Standalone Hole Patterns
Frame 2
Standalone Drive
Frame 3
Standalone Drive
273.70
4.51
5.00
34.00
8x
ØM4 (#8-32)
0
0
0
Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.
0
0
0
52.50
54
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Mount the Kinetix 5500 Drive System
Chapter 3
These hole patterns apply when all drives in the system are frame 1 or frame 2.
There is 50 mm (2.0 in.) between mounting holes (A-to-A and B-to-B).
Figure 25 - Frame 1 and Frame 2 Hole Patterns
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
55
Chapter 3
Mount the Kinetix 5500 Drive System
This hole pattern applies when transitioning from frame 2 drives to frame 1 drives. To mount additional frame 1 drives to the right of Axis 2 in this figure,
refer to the frame 1 hole pattern in Figure 25 .
Figure 26 - Frame 2 to Frame 1 Hole Pattern
Axis 1
(frame 2)
Axis 2
(frame 1)
4x
ØM4 (#8-32)
243.84
243.83
5.00
57.00
Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.
50.15
0
0
52.50
56
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Mount the Kinetix 5500 Drive System
Chapter 3
This hole pattern applies when all drives in the system are frame 3 drives. There is 85.20 mm (3.4 in.) between mounting holes, as shown.
Figure 27 - Frame 3 Hole Pattern
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
57
Chapter 3
Mount the Kinetix 5500 Drive System
This hole pattern applies when transitioning from frame 3 drives to frame 1 drives. To mount additional frame 1 drives to the right of Axis 2 in this figure,
refer to the frame 1 hole pattern in Figure 25 .
Figure 28 - Frame 3 to Frame 1 Hole Pattern
Axis 1
(frame 3)
Axis 2
(frame 1)
6x
ØM4 (#8-32)
273.70
272.23
34.00
97.20
Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.
78.55
0
0 52.50
92.70
58
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Mount the Kinetix 5500 Drive System
Chapter 3
This hole pattern applies when transitioning from frame 3 drives to frame 2 drives. To mount additional frame 2 drives to the right of Axis 2 in this figure,
refer to the frame 2 hole pattern in Figure 25 .
Figure 29 - Frame 3 to Frame 2 Hole Pattern
Axis 1
(frame 3)
Axis 2
(frame 2)
6x
ØM4 (#8-32)
273.70
272.24
34.00
100.00
Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding.
0
28.40
0
52.50
95.00
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
59
Chapter 3
Mount the Kinetix 5500 Drive System
Mount Your Kinetix 5500
Drive
This procedure assumes you have prepared your panel and understand how to bond your system. For installation instructions regarding other equipment and accessories, refer to the instructions that came with those products.
Follow these steps to mount your Kinetix 5500 drives to the panel.
1.
Lay out the hole pattern for each Kinetix 5500 drive in the enclosure.
Refer to
Establishing Noise Zones on page 44 for panel layout
recommendations.
IMPORTANT
To improve the bond between the Kinetix 5500 drive and subpanel, construct your subpanel out of zinc plated (paint-free) steel.
2.
Drill holes in the panel for mounting your drive system.
Hole patterns, by frame size, are shown in
beginning on
3.
Loosely attach the mounting hardware to the panel.
The recommended mounting hardware is M4 (#8-32) steel bolts.
Observe bonding techniques as described in
4.
Attach the leftmost drive to the cabinet panel.
2
1
Kinetix 5500 Servo Drives
(frame 1 drives shown)
Top Screws
(bottom screws not shown)
Zero-stack Tab and Cutout Engaged
5.
Attach additional drives (if any) just to the right of the previous drive by using the same method, but also making sure the zero-stack tabs and cutouts are engaged.
Zero-stack mounting is required based on configuration, refer to the
Zero-stack Tab and Cutout Example on page 50 .
6.
Tighten all mounting fasteners.
Apply 2.0 N•m (17.7 lb•in) maximum torque to each fastener.
60
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Chapter
4
Connector Data and Feature Descriptions
This chapter illustrates drive connectors and indicators, including connector pinouts, and provides descriptions for Kinetix® 5500 drive features.
Topic
Understand Control Signal Specifications
Safe Torque-off Safety Features
Page
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
61
Chapter 4
Connector Data and Feature Descriptions
Kinetix 5500 Connector Data
Use these illustrations to identify the connectors and indicators for the
Kinetix 5500 drive modules.
Figure 30 - Kinetix 5500 Drive Features and Indicators
7
Kinetix 5500 Drive, Front View
(2198-H003-ERS
x
drive is shown)
7
9
8
10
2
1
17
Kinetix 5500, Top View
(2198-H003-ERS drive is shown)
11
2
1
6
5
4
3
U
V
W
2
1
13
12
14
15
2
1
L3
L2
L1
+
–
18
19
20
21
Shared-bus AC Input
Wiring Connector
2
1
Protective
Knock-out
Shared-bus 24V Input
Wiring Connector
Kinetix 5500, Top View
(2198-H
xxx
-ERS2 drives)
16
Item
1
2
5
6
3
4
7
Description
Motor cable shield clamp
Converter kit mounting hole
(1)
(under cover)
Motor feedback (MF) connector
Digital inputs (IOD) connector
Ethernet (PORT1) RJ45 connector
Ethernet (PORT2) RJ45 connector
Zero-stack mounting tab/cutout
Item
8
9
10
11
12
13
14
Description
Module status indicator
Network status indicator
LCD display
Navigation pushbuttons
Link speed status indicators
Link/Activity status indicators
Motor power (MP) connector
Item
15
16
17
18
19
20
21
Description
Motor brake (BC) connector
Ground terminal
(1) Protective knock-out covers the 2198-H2DCK Hiperface-to-DSL feedback converter kit mounting hole. Remove knock-out for use with the converter kit.
(2) DC bus connector ships with protective knock-out cover that can be removed for use in shared-bus configurations.
(3) Protective knock-out cover is removed on 2198-H
xxx
-ERS (hardwired STO) drives.
Shunt resistor (RC) connector
AC mains input power (IPD) connector
DC bus (DC) connector (under cover)
(2)
24V control input power (CP) connector
Safe torque-off (STO) connector
(3)
(does not apply to 2198-H
xxx
-ERS2 drives)
62
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connector Data and Feature Descriptions
Chapter 4
Figure 31 - Capacitor Module Features and Indicators
Kinetix 5500 Capacitor Module
Top View
3
2
1
2
5
4
Kinetix 5500 Capacitor Module
Front View
1
4
5
2
3
Item
1
Description
Ground screw (green)
Module status (MS) connector (relay output)
Module status indicator
DC bus (DC) connector (under cover)
(1) (2)
24V control input power (CP) connector
(1) The DC-bus connector ships with a protective knock-out cover that can be removed for use in shared-bus configurations.
(2) The shared-bus connector set for the capacitor module, catalog number 2198-KITCON-CAP1300, is included for connection to the upstream drive. Replacement kits are also available.
Module Status Connector Pinout
Description MS Pin
1
2
Module status output
Signal
MS
MS
Safe Torque-off Connector Pinout
For the hardwired safe torque-off (STO) connector pinouts, feature
descriptions, and wiring information, refer to Chapter 9 beginning on page 169
.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
63
Chapter 4
Connector Data and Feature Descriptions
Input Power Connector Pinouts
L3
L2
L1
Table 19 - Mains Input Power Connector
IPD Pin Description
Chassis ground
Three-phase input power
Table 20 - 24V Input Power Connector
CP Pin
1
2
Description
24V power supply, customer supplied
24V common
Signal
24V+
24V-
DC Bus and Shunt Resistor Connector Pinouts
Table 21 - DC Bus Power Connector
Description DC Pin
1
2
DC bus connections
Signal
DC-
DC+
Table 22 - Shunt Resistor Connector
Description
2
1
RC Pin
1
2
Shunt connections (frames 2 and 3)
Shunt connections (frame 1)
Signal
DC+
SH
SH
DC+
Signal
L3
L2
L1
64
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connector Data and Feature Descriptions
Chapter 4
Digital Inputs Connector Pinouts
The Kinetix 5500 drive has two configurable digital inputs and 5 configurable functions to choose from in the Logix Designer application. Digital input 1 can be configured as a dual-function (home/registration) input.
Table 23 - Digital Inputs Connector
2
3
IOD Pin Description
1 24V current-sinking fast input #1. This is a dual-function input.
4
I/O common for customer-supplied 24V supply.
24V current-sinking fast input #2.
I/O cable shield termination point.
Signal
IN1
COM
IN2
(1)
SHLD
(1) This signal has dual-functionality. You can use IN1 (IOD-1) as Registration 1 or Home input when Home/Registration 1 is configured.
Table 24 - Configurable Functions
Default Configuration
(1)
Digital input1= Home/Registration 1
Digital input2 = Registration 2
Description
Unassigned
Home
Registration 1
Registration 2
Positive overtravel
Negative overtravel
Home/Registration 1
(1) Studio 5000 Logix Designer,® version 27 or later, is required to change from the default configuration.
Figure 32 - Pin Orientation for Digital Inputs (IOD) Connector
Pin 1 IN1
COM
IN2
SHLD
Ethernet Communication Connector Pinout
6
7
4
5
8
2
3
Pin
1
Description
Transmit+
Transmit-
Receive+
Reserved
Reserved
Receive-
Reserved
Reserved
–
–
RD-
–
–
Signal
TD+
TD-
RD+
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
1 8
65
Chapter 4
Connector Data and Feature Descriptions
Motor Power, Brake, and Feedback Connector Pinouts
Table 25 - Motor Power Connector
Description
V
W
MP Pin
U
Three-phase motor power
Chassis ground
V
W
Signal
U
Color
Brown
Black
Blue
Green
ATTENTION:
To avoid damage to the Kinetix 5500 DC-bus power supply and
inverter, make sure the motor power signals are wired correctly. Refer to MP
on
page 88 for motor power connector wiring examples.
IMPORTANT
Drive-to-motor power cables must not exceed 50 m (164 ft), depending on overall system design.
System performance was tested at this cable length. These limitations also apply when meeting CE requirements.
Table 26 - Motor Brake Connector
Description BC Pin
1
2
Motor brake connections
Signal
MBRK+
MBRK-
Motor Feedback Connector Pinout
Description MF Pin
1
2
Bidirectional data and power for digital encoder interface
SHIELD
Cable shield and grounding plate (internal to 2198-KITCON-DSL connector kit) termination point
Cable shield and shield clamp (internal to 2198-H2DCK converter kit) termination point
Signal
D+
D-
SHIELD
Figure 33 - Pin Orientation for Motor Feedback (MF) Connector
Pin 1
Pin 2
66
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connector Data and Feature Descriptions
Chapter 4
Understand Control Signal
Specifications
This section provides a description of the Kinetix 5500 digital inputs, Ethernet communication, power and relay specifications, encoder feedback specifications, and safe torque-off features.
Digital Inputs
Two digital inputs are available for the machine interface on the IOD connector. Digital inputs require a 24V DC @ 15 mA supply. These are sinking inputs that require a sourcing device. A common and cable shield connection is provided on the IOD connector for digital inputs.
The Registration 1 input is capable of dual functionality. You can also use this as the Home input. Configuration for dual functionality is not needed.
IMPORTANT
To improve registration input EMC performance, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 .
Function
Home/Reg1
Registration 1
Registration 2
Positive overtravel
Negative overtravel
Table 27 - Understand Digital Input Functions
Description
An active state indicates to a homing sequence that the referencing sensor has been seen. Typically, a transition of this signal is used to establish a reference position for the machine axis.
An inactive-to-active transition (also known as a positive transition) or active-to-inactive transition (also known as a negative transition) is used to latch position values for use in registration moves.
The positive/negative limit switch (normally closed contact) inputs for each axis require 24V DC (nominal).
Default Behavior
The function is always inactive. You can enable in the Logix
Designer application.
Table 28 - Digital Input Specifications
Attribute
Type
Dedicated functions
Input current (with 24V applied)
On-state input voltage
Off-state input voltage
Pulse reject filtering (registration functions)
Pulse reject filtering (home input function) debounce filter
Propagation delay (registration functions)
Registration accuracy
Registration repeatability
Windowed registration invalid-to-valid event delay
Value
Active high, single-ended, current sinking (EN 61131-2 Type 1)
Registration 1, Home, Registration 2, Positive overtravel, Negative overtravel
12 mA, typical
15…30V @ 15 mA, max
-1.0…5.0V
12.0 μs
20 ms, nom
0 (delay compensated)
±3 μs
700 ns
125 μs, min
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
67
Chapter 4
Connector Data and Feature Descriptions
Figure 34 - Digital Input Circuitry
IOD-1 or IOD-3
IN
x
INPUT
COM
IOD-2
Kinetix 5500 Drive
24V DC
Ethernet Communication Specifications
The PORT1 and PORT2 (RJ45) Ethernet connectors are provided for communication with the Logix 5000™ controller.
Attribute
Communication
Cyclic update period
Embedded switch features
Value
The drive auto-negotiates speed and duplex modes. These modes can be forced through the Logix Designer application. 100BASE-TX, full duplex is recommended for maximum performance.
1.0 ms, min
Three-port, cut-through, time correction on IEEE-1588 packets, limited filtering, quality of service with four priority levels
Auto MDI/MDIX crossover detection/ correction
Port-to-port time synchronization variation
Cabling
Yes
100 ns, max
CAT5e shielded, 100 m (328 ft) max
Motor Brake Circuit
The brake option is a spring-set holding brake that releases when voltage is applied to the brake coil in the motor. The customer-supplied 24V power supply drives the brake output through a solid-state relay. The solid-state brake driver circuit provides the following:
• Brake current-overload protection
• Brake over-voltage protection
Two connections (BC-1 and BC-2) are required for the motor brake output.
Connections are rated for 2.0 A @ +24V (refer to Figure 35
).
68
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connector Data and Feature Descriptions
Chapter 4
Figure 35 - Motor Brake Circuit
INT PWR 24V PWR
Control
Board
MBRK+ (BC-1)
Kinetix 5500
Servo Drive
ISP772
Inductive
Energy
Clamp
MBRK– (BC-2)
24V COM
IMPORTANT
Motor parking-brake switching frequency must not exceed
10 cycles/min.
Control of the solid-state relay to release the motor brake is configurable in the
Logix Designer application (refer to Configure SPM Motor Closed-loop
Control Axis Properties beginning on page 138
). An active signal releases the motor brake. Turn-on and turn-off delays are specified by the
MechanicalBrakeEngageDelay and MechanicalBrakeReleaseDelay settings.
IMPORTANT
Holding brakes that are available on Allen-Bradley® rotary motors are designed to hold a motor shaft at 0 rpm for up to the rated brakeholding torque, not to stop the rotation of the motor shaft, or be used as a safety device.
You must command the servo drive to 0 rpm and engage the brake only after verifying that the motor shaft is at 0 rpm.
These steps provide one method you can use to control a brake.
1.
Wire the mechanical brake according to the appropriate interconnect
diagram in Appendix A beginning on page 193 .
2.
Enter the MechanicalBrakeEngageDelay and Mechanical
BrakeReleaseDelay times in the Logix Designer application.
Refer to Axis Properties>Parameter List. The delay times must be from the appropriate motor family brake specifications table in the Kinetix
Rotary Motion Specifications Technical Data, publication
KNX-TD001 .
3.
Use the drive stop-action default setting (Current Decel & Disable).
Refer to Axis Properties>Actions>Stop Action in the Logix Designer application.
4.
Use the motion instruction Motion Axis Stop (MAS) to decelerate the servo motor to 0 rpm.
5.
Use the motion instruction Motion Servo Off (MSF) to engage the brake and disable drive.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
69
Chapter 4
Connector Data and Feature Descriptions
Feedback Specifications
Control Power
The Kinetix 5500 drive requires 24V DC input power for control circuitry.
IMPORTANT
SELV and PELV rated power supplies must be used to energize external safety devices connected to the Kinetix 5500 safety inputs.
The National Electrical Code and local electrical codes take precedence over the values and methods provided. Implementation of these codes is the responsibility of the machine builder.
Table 29 - Control Power Input Power Specifications
Attribute
Input voltage
Control power AC input current
Nom @ 24V DC
(1)
Inrush, max
(1) Plus BC connector (MBRK+) current.
Frame 1
21.6…26.4V DC
400 mA
2.0 A
Frame 2
800 mA
3.0 A
Frame 3
1.3 A
3.0 A
The Kinetix 5500 drive accepts motor feedback signals from Stegmann
Hiperface digital-servo-link (DSL) encoders on the motor feedback (MF) connector.
TIP
Auto-configuration in the Logix Designer application of intelligent absolute, high-resolution encoders is possible with only Allen-Bradley motors.
The Kinetix 5500 drives support Kinetix VP motors with Stegmann Hiperface digital-servo-link (DSL) encoders by using the 2-pin (MF) feedback connector. You can also use the MF connector for feedback-only applications.
Other Allen-Bradley motors and actuators with Stegmann Hiperface singleturn or multi-turn high-resolution absolute encoders are also accepted, but only when using drive firmware revision 2.002 or later, and the 2198-H2DCK
Hiperface-to-DSL (series B or later) feedback converter kit.
Table 30 - Stegmann Hiperface DSL Specifications
Attribute
Protocol
Memory support
Hiperface data communication
Value
Hiperface DSL
Programmed with Allen-Bradley motor data
9.375 Mbits/s
70
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connector Data and Feature Descriptions
Chapter 4
Encoder Type
Stegmann Hiperface (DSL)
-M
Stegmann Hiperface
-V
Stegmann Hiperface (magnetic scale) -
x
D
x
Cat. No.
Designator
-P
-W
-Q
Absolute Position Feature
The absolute position feature of the drive tracks the position of the motor, within the multi-turn retention limits, while the drive is powered off. The absolute position feature is available with only multi-turn encoders.
Table 31 - Absolute Position Retention Limits
Motor Cat. No. Actuator Cat. No.
Retention Limits
Turns (rotary) mm (linear)
VPL-A/B
xxxxx
-P
VPF-A/B
xxxxx
-P
VPS-B
xxxxx
-P
VPL-A/B
xxxxx
-W,
VPF-A/B
xxxxx
-W
VPH-A/B
xxxxx
-W
VPL-A/B
xxxxx
-Q
VPF-A/B
xxxxx
-Q
VPH-A/B
xxxxx
-Q
MPL-A/B
xxxxx
-M
MPM-A/B
xxxxx
-M
MPF-A/B
xxxxx
-M
MPS-A/B
xxxxx
-M
VPAR-A/B
xxxxx
-P
VPAR-B
xxxxx
-W
VPAR-B
xxxxx
-Q
MPAR-A/B3
xxxx
-M
MPAI-A/B
xxxxx
M
4096 (±2048)
4096 (±2048)
512 (±256)
2048 (±1024)
–
–
–
–
MPL-A/B
xxxxx
-V
–
MPAS-A/B
xxxx
1-V05, MPAS-A/B
xxxx
2-V20
MPAR-A/B1
xxxx
-V, MPAR-A/B2
xxxx
-V
MPAI-A/B
xxxxx
V
LDAT-S
xxxxxx
-
x
D
x
4096 (±2048)
–
–
960 (37.8)
Figure 36 - Absolute Position Limits (measured in turns)
4096 Turns
2048 Turns
512 Turns
-2048 -1024
-512 -256 -128
-64 0
Position at Power Down
+64
+128
+256
+512 +1024 +2048
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
71
Chapter 4
Connector Data and Feature Descriptions
Safe Torque-off Safety
Features
Kinetix 5500 servo drives have safe torque-off (STO) capability and can safely turn off the inverter power transistors in response to a monitored digital input, according to Category 0 Stop behavior.
Servo Drives with Hardwired Safety
2198-H
xxx
-ERS (hardwired) servo drives support parallel input terminals for cascading to adjacent drives over duplex wiring. For applications that do not require the STO safety function you must install jumper wires to bypass the safe torque-off feature.
Refer to Chapter 9 on page 169 for the STO connector pinout, installation,
and wiring information.
Servo Drives with Integrated Safety
For 2198-H
xxx
-ERS2 (integrated safety) servo drives, the GuardLogix® 5570 or Compact GuardLogix 5570 safety controller issues the STO command via the EtherNet/IP™ network and the 2198-H
xxx
-ERS2 servo drives execute the command.
Refer to Chapter 10 on page 177 for integrated safety drive specifications,
configuring motion and safety connections, motion direct commands, and the
STO bypass feature.
72
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter
5
This chapter provides procedures for wiring your Kinetix® 5500 system components and making cable connections.
Topic
Determine the Input Power Configuration
Remove the Ground Screws in Select Power Configurations
Wire the Digital Input Connectors
Wire Kinetix VP Motors and Actuators
Wire Other Allen-Bradley Motors and Actuators
External Passive-shunt Resistor Connections
Page
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
73
Chapter 5
Connect the Kinetix 5500 Drive System
Basic Wiring Requirements
This section contains basic wiring information for the Kinetix 5500 drives.
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 metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry and result in damage to components.
SHOCK HAZARD:
To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2198 drive modules prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use.
IMPORTANT
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.
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 devices can be induced into I/O communication, or other sensitive low voltage signals.
This can cause system faults and communication anomalies.
The Bulletin 2090 single motor cable contains the power, brake, and feedback wires, but is properly shielded to protect the noise-sensitive feedback signals.
Refer to
Electrical Noise Reduction on page 41 for examples of routing high
and low voltage cables in wireways. Refer to the System Design for Control of
Electrical Noise Reference Manual, publication GMC-RM001 , for more information.
74
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Determine the Input Power
Configuration
Before wiring input power to your Kinetix 5500 system, you must determine the type of input power within your facility. The drive is designed to operate in both grounded and ungrounded environments.
ATTENTION:
Ungrounded, corner-grounded, and impedance-grounded input power configurations are permitted, but you must remove the ground
screws. Refer to Ground Screw Settings on page 78 for a ground screw
summary.
Grounded Power Configurations
The grounded (WYE) power configuration lets you ground your three-phase power at a neutral point. This type of grounded power configuration is preferred.
Figure 37 - Grounded Power Configuration (WYE Secondary)
Kinetix 5500 Servo Drive
(top view)
2
1
Transformer (WYE) Secondary
L3
Transformer
L2
L1
Three-phase
(1)
AC Line Filter
(can be required for CE)
L3
L2
L1
Three-phase
Input VAC
Circuit
Protection
Phase Ground
Bonded Cabinet Ground
Connect to
Ground Stud
2
1
Ground Grid or
Power Distribution Ground
(1) When using 2198-DB
xx
-F line filter, the AC ground jumper is installed and the DC ground jumper is installed. When using
2198-DBR
xx
-F line filter, the AC ground jumper is installed and the DC ground jumper is installed.
The Kinetix 5500 drive has factory-installed ground screws for grounded (wye) power distribution.
Refer to
Power Wiring Examples beginning on page 194 for input power
interconnect diagrams.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
75
Chapter 5
Connect the Kinetix 5500 Drive System
Figure 38 - Impedance-grounded Power Configuration (WYE Secondary)
Kinetix 5500 Servo Drive
(top view)
2
1
Transformer (WYE) Secondary
L3
Transformer
L2
L1
AC Screw
(1)
DC Screw
Three-phase
Input VAC
Circuit
Protection
Kinetix 5500 Servo Drive
(top view)
L3
L2
L1
2
1
Phase Ground
Bonded Cabinet Ground
Connect to
Ground Stud
Ground Grid or
Power Distribution Ground
(1) The AC ground jumper is removed and the DC ground jumper is removed. See Figure 42
on
for access to ground screws.
Figure 39 - Corner-grounded Power Configuration (Delta Secondary)
2
1
Transformer (Delta) Secondary
Transformer
L3
AC Screw
(1)
DC Screw
L3
L2
L1
Circuit
Protection
L2
L1
2
1
Bonded Cabinet Ground
Connect to
Ground Stud
Ground Grid or
Power Distribution Ground
(1) The AC ground jumper is removed and the DC ground jumper is removed. See Figure 42
on
for access to ground screws.
Refer to
Power Wiring Examples beginning on page 194 for input power
interconnect diagrams.
76
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Figure 40 - Grounded Power Configuration (single-phase input)
Kinetix 5500 Servo Drive
(top view)
2
1
Transformer (WYE) Secondary
Transformer
L3
L2
L1
Three-phase
(1)
AC Line Filter
(can be required for CE)
L3
L2
L1
Three-phase
Input VAC
Circuit
Protection
Phase Ground
Bonded Cabinet Ground
Connect to
Ground Stud
2
1
Ground Grid or
Power Distribution Ground
(1) When using 2198-DB
xx
-F line filter, the AC ground jumper is installed and the DC ground jumper is installed. When using
2198-DBR
xx
-F line filter, the AC ground jumper is installed and the DC ground jumper is installed.
IMPORTANT
To reduce leakage current in single-phase AC input operation, remove the
AC ground screw (refer to Figure 42 on page 79
).
Install the AC ground screw only if higher EMC performance is required.
Refer to
Power Wiring Examples beginning on page 194 for input power
interconnect diagrams.
Ungrounded Power Configurations
The ungrounded power configuration ( Figure 41
), corner-grounded
), and impedance-grounded (
Figure 38 ) power configurations do
not provide a neutral ground point.
IMPORTANT
If you determine that you have ungrounded, corner-grounded, or impedance-grounded power distribution in your facility, you must remove the ground screws in each of your drives that receive input power.
Refer to
Remove the Ground Screws in Select Power Configurations on page 79 for more information.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
77
Chapter 5
Connect the Kinetix 5500 Drive System
Figure 41 - Ungrounded Power Configuration
Kinetix 5500 Servo Drive
(top view)
2
1
Three-phase
Input VAC
Chassis Ground
Transformer (Delta) Secondary
Transformer
L3
L2
L1
L3
L2
L1
AC Screw
DC Screw
(1)
Circuit
Protection
Bonded Cabinet Ground
Connect to
Ground Stud
2
1
Ground Grid or
Power Distribution Ground
(1) The AC ground jumper is removed and the DC ground jumper is removed. See Figure 42
on
for access to ground screws.
ATTENTION:
Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground.
Refer to
Power Wiring Examples beginning on page 194 for input power
interconnect diagrams.
Ground Screw Settings
Determine the ground screw setting for your Kinetix 5500 servo drives.
Table 32 - Ground Screw Settings
Ground Configuration
Grounded (wye)
• AC fed ungrounded
• Corner grounded
• Impedance grounded
Single-phase input power
Example Diagram
Ground Screw Setting
Both screws installed (default setting)
Both screws removed
AC screw removed
(1)
(1) Removing the AC ground screw to minimize leakage current in single-phase operation can affect EMC performance.
ATTENTION:
To help prevent damage to the servo drive, you must set the ground screws according to the example diagrams that are summarized in
78
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Remove the Ground Screws in Select Power
Configurations
Removing the ground screws involves gaining access, opening the sliding door, and removing the screws.
IMPORTANT
If you have grounded-wye power distribution, you do not need to remove
the ground screws. Go to Ground the Drive System on page 80
.
Removing the ground screws in multi-axis configurations is best done when each drive is removed from the panel and placed on its side on a solid surface.
ATTENTION:
Because the unit no longer maintains line-to-neutral voltage protection, the risk of equipment damage exists when you remove the ground screws.
ATTENTION:
To avoid personal injury, the ground screws access door must be kept closed when power is applied. If power was present and then removed, wait at least 5 minutes for the DC-bus voltage to dissipate and verify that no DC-bus voltage exists before accessing the ground screws.
Figure 42 - Remove the Ground Screws
Ground Screws
Access Door
Kinetix 5500 Drive
(side view)
AC Screw
DC Screw
Lift door to meet arrow at left.
Ground screws installed for grounded power configuration
(screws installed is default setting).
• Remove both screws for ungrounded, corner-grounded, and impedance-grounded power for three-phase operation
• Remove only the AC screw for single-phase operation
ATTENTION:
Risk of equipment damage exists. The drive ground configuration must be accurately determined. Leave the ground screws installed for grounded power configurations (default). Remove the screws for ungrounded, corner-grounded, and impedance-grounded power configurations.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
79
Chapter 5
Connect the Kinetix 5500 Drive System
Ground the Drive System
All equipment and components of a machine or process system must have a common earth ground point connected to chassis. A grounded system provides a ground path for protection against electrical shock. Grounding your drives and panels minimize the shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.
ATTENTION:
The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system.
For CE grounding requirements, refer to
Agency Compliance on page 30 .
Ground the System Subpanel
Ground Kinetix 5500 drives and 2198-CAPMOD-1300 capacitor modules to a bonded cabinet ground bus with a braided ground strap. Keep the braided ground strap as short as possible for optimum bonding.
Figure 43 - Connecting the Ground Terminal
Kinetix 5500
Servo Drive
(standalone)
Kinetix 5500
Servo Drives
(shared-bus)
80
1
2
3
Braided Ground Straps
12 mm (0.5 in.) by 0.8 mm (0.03 in.)
Keep straps as short as possible.
4
2
3
Item
1
4
Description
Ground screw (green) 2.0 N•m (17.7 lb•in), max
Braided ground strap (customer supplied)
Ground grid or power distribution ground
Bonded cabinet ground bus (customer supplied)
Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , for more information.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Ground Multiple Subpanels
In this figure, the chassis ground is extended to multiple subpanels.
Figure 44 - Subpanels Connected to a Single Ground Point
Follow NEC and applicable local codes.
Bonded Ground Bus
Ground Grid or Power
Distribution Ground
High-frequency (HF) bonding is not illustrated. For HF bonding information, refer to
on
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
81
Chapter 5
Connect the Kinetix 5500 Drive System
Wiring Requirements
Wires must 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.
Refer to
Power Wiring Examples on page 194 for interconnect diagrams.
IMPORTANT
The National Electrical Code and local electrical codes take precedence over the values and methods provided.
Table 33 - Power and I/O Wiring Requirements
Kinetix 5500 Drive
Cat. No.
Description
Pin
Connects to Terminals
Signal
Wire Size
mm
2
(AWG)
Strip Length
mm (in.)
Torque Value
N•m (lb•in)
2198-H003-ERS
x
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
2198-H003-ERS
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x x x x x x
Mains input power
(1)
(single-axis IPD connector)
Motor power
L3
L2
L1
CP-1
CP-2
BC-1
BC-2
DC-1
DC-2
RC-1
RC-2
RC-1
RC-2
ST0-1
ST0-2
ST0-3
ST0-4
ST0-5
IOD-1
IOD-2
IOD-3
IOD-4
U
V
W
L3
L2
L1
U
V
W
1.5…4
(16…12)
1.5…6
(16…10)
Motor power cable depends on motor/ drive combination.
0.75…2.5
(4)
(18…14)
2.5…6
(14…10)
0.5…2.5
(20…14)
8.0 (0.31)
10.0 (0.39)
7.0 (0.28)
10.0 (0.39)
0.5…0.6
(4.4…5.3)
0.5…0.6
(4.4…5.3)
0.5…0.8
(4.4…7.1)
2198-
xxxx
-ERS
x
(single-axis CP connector)
Brake power
DC Bus power
Shunt resistor
(frame 2 and 3)
Shunt resistor
(frame 1)
Safety
(2)
Digital inputs
DC+
SH
SH
DC+
SB+
SB-
S1
SC
S2
IN1
(3)
COM
IN2
SHLD
24V+
24V-
MBRK+
MBRK-
DC-
DC+
N/A
N/A
(5)
0.5…4.0
(20…12)
0.2…1.5
(24…16)
0.2…1.5
(24…16)
7.0 (0.28)
N/A
(6)
8.0 (0.31)
10.0 (0.39)
10.0 (0.39)
0.22…0.25
(1.9…2.2)
N/A
0.5…0.6
(4.4…5.3)
N/A
N/A
(7)
(1) The wire size, strip length, and torque specifications shown here apply to the single-axis connector that ships with the drive. For the shared-bus connector specifications, refer to
on
(CP connector) and Table 37 on page 86
(IPD connector).
(2) These signals and the safe torque-off (STO) connector apply to only the 2198-H
xxx
-ERS drives.
(3) This signal has dual-functionality. You can use IN1 (IOD-1) as registration or Home input.
(4) Building your own cables or using third-party cables is not an option. Use single motor cable catalog number 2090-CS
x
M1DF-
xx
AA
xx
. Refer to the Kinetix Motion Accessories
Specifications Technical Data, publication KNX-TD004 , for cable specifications.
(5) Motor brake wires are part of the 2090-CSBM1DF/DG-
xx
AA
xx
motor cable.
(6) DC bus connections are always made from drive-to-drive over the bus-bar connection system. These terminals do not receive discrete wires.
(7) This connector uses spring tension to hold wires in place.
82
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Wiring Guidelines
Connect the Kinetix 5500 Drive System
Chapter 5
ATTENTION:
To avoid personal injury and/or equipment damage, observe the following:
• 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.
• Use motor power connectors for connection purposes only. Do not use them to turn the unit on and off.
• Ground shielded power cables to prevent potentially high voltages on the shield.
Use these guidelines as a reference when wiring the power connectors on your
Kinetix 5500 drive.
IMPORTANT
For connector locations of the Kinetix 5500 drives, refer to Kinetix 5500
.
When removing insulation from wires and tightening screws to secure the
wires, refer to the table on page 82
for strip lengths and torque values.
IMPORTANT
To improve system performance, run wires and cables in the wireways as
established in Establishing Noise Zones on page 44
.
Follow these steps when wiring the connectors for your Kinetix 5500 drive.
1.
Prepare the wires for attachment to each connector plug by removing insulation equal to the recommended strip length.
IMPORTANT
Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.
2.
Route the cable/wires to your Kinetix 5500 drive.
3.
Insert wires into connector plugs.
Refer to connector pinout tables in Chapter 4 or the interconnect
.
4.
Tighten the connector screws.
5.
Gently pull on each wire to make sure it does not come out of its terminal; reinsert and tighten any loose wires.
6.
Insert the connector plug into the drive connector.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
83
Chapter 5
Connect the Kinetix 5500 Drive System
Wire the Power Connectors
This section provides examples and guidelines to assist you in making connections to the input power connectors.
Refer to
Power Wiring Examples on page 194 for an interconnect diagram.
24V (CP) Connector Plug
Wire the 24V Control Power Input Connector
The 24V power (CP) connector requires 24V DC input for the control circuitry. The single-axis connector plug is included with the drive, shared-bus connector kits are purchased separately.
Figure 45 - CP Connector Wiring - Single Axis
Kinetix 5500 Drive
Top View
2
1
24V
-
24V+
Remo
Bus Only
84
24V DC Input
Wiring Connector
24V
-
24V+
Table 34 - Single-axis CP Connector Wiring Specifications
Drive Module
Cat. No.
CP Pin
2198-H
xxx
-ERS
x
2198-CAPMOD-1300
CP-1
CP-2
Signal
24V+
24V-
Recommended
Wire Size
mm
2
(AWG)
Strip Length
mm (in.)
0.5…2.5
(20…14)
7.0 (0.28)
Torque Value
N•m (lb•in)
0.22…0.25
(1.9…2.2)
Figure 46 - CP Connector Wiring - Shared Bus
Kinetix 5500 Drives
Top View
Drive Cat. No.
Table 35 - Shared-bus CP Connector Wiring Specifications
CP Pin Signal
Input Current, max
A rms
Recommended
Wire Size
mm
2
(AWG)
2198-H
xxx
-ERS
x
2198-CAPMOD-1300
CP-1
CP-2
24V+
24V-
40 10 (6)
Strip Length
mm (in.)
11.0 (0.43)
Torque Value
N•m (lb•in)
1.7…1.8
(15.0…15.9)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Wire the Input Power Connector
The input power (IPD) connector requires 195…528V AC (single-phase or three-phase) for mains input power. The single-axis connector plug is included with the drive, shared-bus connector kits are purchased separately.
ATTENTION:
Make sure the input power connections are correct when wiring the IPD connector plug or input wiring connector and that the plug/ connector is fully engaged in the drive connector. Incorrect wiring/polarity or loose wiring can cause explosion or damage to equipment.
Figure 47 - IPD Connector Wiring - Single Axis
Kinetix 5500 Drive
Top View
Input Power (IPD)
Connector Plug
L3
L2
L1 r DC
Remo
Bus O
Kinetix 5500 Drive
Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
Table 36 - Single-axis IPD Connector Wiring Specifications
Pin Signal
Recommended
Wire Size
mm
2
(AWG)
Strip Length
mm (in.)
L3
L2
L1
L3
L2
L1
1.5…4
(16…12)
1.5…6
(16…10)
8.0 (0.31)
10.0 (0.39)
Torque Value
N•m (lb•in)
0.5…0.6
(4.4…5.3)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
85
Chapter 5
Connect the Kinetix 5500 Drive System
Figure 48 - IPD Connector Wiring - Shared Bus
Mains AC Input
Wiring Connector
L3
L2
L1
Kinetix 5500 Drives
Top View
Kinetix 5500 Drive
Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
Table 37 - Shared Bus IPD Connector Wiring Specifications
Pin Signal
Input Current, max
A rms
Recommended
Wire Size
mm
2
(AWG)
Strip Length
mm (in.)
L3
L2
L1
L3
L2
L1
52
13.3…3.3
(6…12)
13.3 (6)
11.0 (0.43)
Torque Value
N•m (lb•in)
1.7…1.8
(15.0…15.9)
Wire the Digital Input
Connectors
This section provides guidelines to assist you in making digital input connections.
Wire the Safe Torque-off Connector
For the hardwired safe torque-off (STO) connector pinouts, feature
descriptions, and wiring information, refer to Chapter 9 beginning on page 169
.
86
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Wire the Digital Inputs Connector
The digital inputs (IOD) connector uses spring tension to hold wires in place.
Figure 49 - IOD Connector Wiring
Kinetix 5500 Servo Drive
(front view)
1
IN1
COM
IN2
SHLD
Digital Inputs (IOD) Connector Plug
Table 38 - Digital Inputs (IOD) Connector Specifications
Drive Cat. No.
DC Pin Signal
Recommended
Wire Size
mm
2
(AWG)
Strip Length
mm (in.)
2198-H
xxx
-ERS
x
IOD-1
IOD-2
IOD-3
IOD-4
IN1
(1)
COM
IN2
SHLD
0.2…1.5
(24…16)
10.0 (0.39)
(1) This signal has dual-functionality. You can use IN1 (IOD-1) as registration or Home input.
(2) This connector uses spring tension to hold wires in place.
Torque Value
N•m (lb•in)
N/A
(2)
Wire Kinetix VP Motors and
Actuators
Kinetix 5500 drives and Kinetix VP motor/actuator combinations use single motor-cable technology with motor power, feedback, and brake wires (when specified) housed in a single cable. Feedback wires are shielded separately and provide a shield braid for grounding in the connector kit.
IMPORTANT
Due to the unique characteristics of single cable technology, designed for and tested with Kinetix 5500 drives and Kinetix VP motors, you cannot build your own cables or use third-party cables.
Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004 , for cable specifications.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
87
Chapter 5
Connect the Kinetix 5500 Drive System
Table 39 - Single Cable Catalog Numbers
Motor
Cat. No.
Feedback Kit
Cat. No.
Motor Cable Cat. No.
(with brake wires)
VPL-A/B
xxxx
VPF-A/B
xxxx
VPH-A/B
xxxx
VPS-B
xxxxx
VPAR-A/B
xxxx
2198-KITCON-DSL
(included with each servo drive)
2090-CSBM1DF-
xx
AA
xx
(standard) cables
2090-CSBM1DF-
xx
AF
xx
(continuous-flex) cables
2090-CSBM1DG-
xx
AA
xx
(standard) cables
2090-CSBM1DG-
xx
AF
xx
(continuous-flex) cables
Motor Cable Cat. No.
(without brake wires)
Feedback Connections
2090-CSWM1DF-
xx
AA
xx
(standard) cables
2090-CSWM1DG-
xx
AA
xx
(standard) cables
Flying-lead feedback conductors. Cables are designed specifically for Kinetix 5500 drives.
Flying-lead feedback conductors. Leads are longer to accommodate Kinetix 5500 or Kinetix 5700 drives. Extra service loops are required with Kinetix 5500 drives.
Maximum Cable Lengths
Combined motor cable length for all axes on the same DC bus must not exceed 250 m (820 ft). The maximum drive-to-motor cable length for
Kinetix 5500 drives and motor/actuator combinations with 2090-CS
x
M1D
x
cables is 50 m (164 ft) for most drives with standard (non-flex) cables. See
for additional cable length details.
Motor Power Connections
Refer to
Kinetix 5500 Servo Drive and Rotary Motor Wiring Examples
on
for an interconnect diagram.
Figure 50 - MP Connector Wiring
Kinetix 5500 Servo Drive
(front view)
U
V
W
Motor Power (MP) Connector Plug
Motor Cable
Shield Clamp
88
WARNING:
Make sure the motor power connections are correct when wiring the MP connector plug and that the plug is fully engaged in the module connector. Incorrect wiring/polarity or loose wiring can cause an explosion or damage to equipment.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Table 40 - Motor Power (MP) Connector Specifications
Drive Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
Pin
U
V
W
Signal/Wire Color
U
V
W
Brown
Black
Blue
Green/Yellow
Recommended Wire Size
(1)
mm
2
(AWG)
Motor power cable depends on motor/drive combination.
Strip Length
mm (in.)
8.0 (0.31)
Torque Value
N•m (lb•in)
0.5…0.6
(4.4…5.3)
2198-H070-ERS
x
0.75…2.5
(18…14) max
2.5…6
(14…10) max
10.0 (0.39)
0.5…0.8
(4.4…7.1)
(1) Building your own cables or using third-party cables is not an option. Use 2090-CS
x
M1DF/DG single motor cables. Refer to the Kinetix Motion Accessories
Specifications Technical Data, publication KNX-TD004 , for cable specifications.
Motor Brake Connections
Figure 51 - BC Connector Wiring
Kinetix 5500 Servo Drive
(front view)
2
1
MBRK-
MBRK+
Motor Brake (BC) Connector Plug
Motor Cable
Shield Clamp
Table 41 - Motor Brake (BC) Connector Specifications
Drive Cat. No.
Pin
Signal/
Wire Color
Recommended
(1)
Wire Size
(AWG)
Strip Length
mm (in.)
2198-H
xxx
-ERS
x
BC-1
BC-2
MBRK+/Black
MBRK-/White
(1) Motor brake wires are part of the 2090-CSBM1DF/DG motor cable.
Torque Value
N•m (lb•in)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
89
Chapter 5
Connect the Kinetix 5500 Drive System
Motor Feedback Connections
Single motor-cable feedback connections are made by using the 2198-
KITCON-DSL feedback connector kit (included with each servo drive).
• 2090-CS
x
M1DF cables have flying-lead conductors designed specifically for Kinetix 5500 servo drives.
• 2090-CS
x
M1DG cables also have flying-lead feedback conductors.
Leads are longer than 2090-CS
x
M1DF cables to accommodate
Kinetix 5500 or Kinetix 5700 servo drives. However, because the leads are longer, extra service loops are required with Kinetix 5500 drives.
IMPORTANT
When using the 2198-KITCON-DSL feedback connector kit, the ambient temperature for the Kinetix 5500 drive enclosure is 0…50 °C (32…122 °F).
Figure 52 - MF Connector Wiring
Motor Feedback
Connector Kit
Motor Cable
Shield Clamp
2090-CSBM1DF-18AA
xx
Motor Cable
Kinetix 5500 Servo Drive
(front view)
Refer to Kinetix 5500 Feedback Connector
Kit Installation Instructions, publication
2198-IN002 , for connector kit specifications.
Mounting Screws (2)
2198-KITCON-DSL
Feedback Connector Kit
Exposed Shield
Cover
Cover Screws (2)
Connector
Housing
Feedback Cable
(EPWR+, EPWR-)
Internal
Grounding Plate
IMPORTANT
Cable preparation and positioning that provides a high-frequency bond between the shield braid and grounding plate is required to optimize system performance.
Table 42 - Motor Feedback (MF) Connector Specifications
Drive Cat. No.
Pin
2198-H
xxx
-ERS
x
MF-1
MF-2
Signal/
Wire Color
D+/Blue
D-/White/Blue
Wire Size
AWG
22
Strip Length
mm (in.)
Cover Screw
Torque Value
N•m (lb•in)
10.0 (0.39) 0.4 (3.5)
IMPORTANT
The feedback bundle in 2090-CS
x
M1DF-18AA
xx
motor cables (typically used with frame 1 drives) route around the shield clamp (as shown in
The feedback bundle in 14 and 10 AWG cables (typically used with frame 2 and 3 drives) route with the power and brake wires inside the cable shield.
90
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Apply the Single Motor-cable Shield Clamp
Factory-supplied 2090-Series single motor cables are shielded, and the braided cable shield must terminate at the drive during installation. A small portion of the cable jacket has been removed to expose the shield braid. The exposed area must be clamped (with the clamp provided) at the bottom front of the drive.
SHOCK HAZARD:
To avoid hazard of electrical shock, make sure shielded power cables are grounded according to recommendations.
TIP
Cables for Kinetix VP motors (catalog numbers 2090-CB
x
M1DF-18AA
xx
) do not route the feedback bundle under the shield clamp. The same cables with 14 or
10 AWG conductors have the feedback bundle within the cable shield braid.
This procedure assumes you have completed wiring your motor power, brake, and feedback connectors and are ready to apply the cable shield clamp.
Follow these steps to apply the motor cable shield clamp.
1.
Loosen the left-side (retention) clamp screw and remove the right-side screw.
18 AWG Cable Installation
Kinetix 5500 Servo Drives,
Frame 1 or 2, Front View
(frame 1 is shown)
2198-KITCON-DSL
Motor Feedback
Connector Kit
Motor Power
(MP) Connector
Motor Cable
Shield Clamp
Retention Screw
(loosen, do not remove)
Feedback cable routed around the shield clamp.
Motor Brake
(BC) Connector
Exposed shield braid under clamp.
Shield Clamp Screws (2)
2.0 N•m (17.7 lb•in), max
2090-CSBM1DF-18AA
xx
Single Motor Cable
When the drive/motor combination calls for 18 AWG cable, the feedback cable routes around the motor cable shield clamp.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
91
Chapter 5
Connect the Kinetix 5500 Drive System
Kinetix 5500 Servo Drives,
Frame 2 or 3, Front View
(frame 2 is shown)
2198-KITCON-DSL
Motor Feedback
Connector Kit
Feedback cable routed within the shield braid.
Motor Cable
Shield Clamp
14 and 10 AWG Cable Installation
Motor Power
(MP) Connector
Motor Brake
(BC) Connector
Retention Screw
(loosen, do not remove)
Clamp features apply to all frame sizes.
Exposed shield braid under clamp.
Shield Clamp Screws (2)
Servo Drive
Retention
Screw
Shield Clamp
Clamp Screws
2.0 N•m (17.7 lb•in)
Torque clamp screws to
2.0 N•m (17.7 lb•in), max
2090-CSBM1DF-14AA
xx
Single Motor Cable
When the drive/motor combination calls for 14 or 10 AWG cable, the feedback cable routes along with the power and brake wiring.
2.
Position the exposed portion of the cable shield directly in line with the clamp.
IMPORTANT
Loosen the retention screw, if needed, until you can start threading both clamp screws with the cable shield under the clamp.
3.
Tighten each screw a few turns at a time until the maximum torque value of 2.0 N•m (17.7 lb•in) is achieved.
4.
Repeat
for each drive in multi-axis configurations.
Wire Other Allen-Bradley
Motors and Actuators
Kinetix 5500 drives are also compatible with many other Allen-Bradley® motors and actuators, however the 2198-H2DCK Hiperface-to-DSL feedback converter kit is required for converting the 15-pin Hiperface feedback signals to 2-pin DSL feedback signals.
Follow these guidelines when 2090-CP
x
M7DF (power/brake) cables and
2090-CFBM7DF (feedback) cables are used in a new installation or reused in an existing installation with Kinetix 5500 servo drives. MP-Series™ servo motors and actuators have separate connectors for 2090-CP
x
M7DF power/ brake cables and 2090-CFBM7DF feedback cables.
92
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
IMPORTANT
To configure these additional motors and actuators (see Table 44 ) with
your Kinetix 5500 servo drive, you must have drive firmware 2.002 or
to determine if you need to install the
Kinetix 5500 Add-on Profile.
Table 43 - AOP Installation Requirement
Drive Firmware Revision Logix Designer Application Version Kinetix 5500 AOP Needed?
2.002 or later
21.00
21.03 or later
(1)
Yes
No
(1) If you are planning to use drive firmware revision 4.001 or later, see
.
Install the Kinetix 5500 Add-On Profile
Add-On profiles (AOP) are available for download at the Custom Downloads
Add-On Profiles website: https://download.rockwellautomation.com/esd/ download.aspx?downloadid=addonprofiles
Follow these steps to download the Kinetix 5500 Add-On profile.
1.
Login to the Custom Download Add-On Profiles website.
The Custom Download Files dialog box opens.
2.
Check AOP for 2198-Hxxx CIP Motion Kinetix5500.
3.
Click Download Now and accept the user license agreement.
If prompted to install the Download Manager, allow the installation.
4.
Click the Add-On Profile icon and follow the download instructions.
5.
Extract the AOP zip file and run Setup.
To access AOP downloads by using the Product Compatibility Download
Center (PCDC), see
Install the Kinetix 5500 Add-On Profile on page 114 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
93
Chapter 5
Connect the Kinetix 5500 Drive System
Motor Power and Brake Connections
The motors and actuators in Table 44 have separate power/brake and feedback
cables. The motor power/brake cable attaches to the cable clamp on the drive and the power/brake conductors attach to the MP and BC connectors, respectively.
Table 44 - Current Motor Power Cable Compatibility
Motor/Actuator Cat. No.
(1)
Motor Power Cat. No.
(2)
(with brake wires)
Motor Power Cat. No.
(without brake wires)
MPL-A/B15
xxx
-
xx
7
x
AA, MPL-A/B2
xxx
-
xx
7
x
AA,
MPL-A/B3
xxx
-
xx
7
x
AA, MPL-A/B4
xxx
-
xx
7
x
AA,
MPL-A/B45
xxx
-
xx
7
x
AA, MPL-A/B5
xxx
-
xx
7
x
AA,
MPL-B6
xxx
-
xx
7
x
AA
MPM-A/B
xxxx,
MPF-A/B
xxxx,
MPS-A/B
xxxx
MPAS-A/B
xxxx
1-V05S
x
A, MPAS-A/B
xxxx
2-V20S
x
A
MPAI-A/B
xxxx,
MPAR-A/B3
xxx,
MPAR-A/B1
xxx
and MPAR-A/B2
xxx
(series B)
LDAT-S
xxxxxx-x
D
x
2090-CPBM7DF-
(standard) or
2090-CPBM7DF-
(continuous-flex)
xx xx
AA
AF
xx xx
2090-CPWM7DF-
(standard) or
2090-CPWM7DF-
(continuous-flex)
xx xx
N/A
(1) The 2198-H2DCK (series B or later) feedback converter kit is required.
(2) Refer to the Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004 , for cable specifications.
AA
AF
xx xx
Refer to Motor Power Connections on page 88
and
Motor Brake Connections on page 89
for the MP and BC connector specifications.
Table 45 - Legacy Motor Power Cables
Motor Cable
Standard
Continuous-flex
Description
Power/brake, threaded
Power-only, bayonet
Power/brake, threaded
Power-only, threaded
Power-only, bayonet
Motor Power Cat. No.
2090-XXNPMF-
xx
S
xx
2090-XXNPMP-
xx
S
xx
2090-CPBM4DF-
xx
AF
xx
2090-CPWM4DF-
xx
AF
xx
2090-XXTPMP-
xx
S
xx
Table 46 - Induction Motor Power Cable Specifications
Voltage Rating Cable Manufacturer
Belden
Lapp Group
SAB
Cable Series
29500-29507
ÖLFEX VFD XL
VFD XLPE TR
600V
Temperature Rating
90 °C (194 °F)
94
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Motor Power/Brake Cable Series Change
MP-Series Motors and Actuators
Dimensions are in mm (in.)
MP-Series Motors and Actuators
Motor power and brake conductors on 2090-CPBM7DF (series A) cables have the following dimensions from the factory. If your cable is reused from an existing application, the actual conductor lengths could be slightly different.
Figure 53 - 2090-CPBM7DF (series A) Power/brake Cable Dimensions
102 (4.0)
Dimensions are in mm (in.)
Edge of
Heat Shrink
Power Conductors
150 (5.9)
Overall Cable Shield
Brake
Conductors
Brake Shield (remove)
635 (25)
To reuse your existing (series A) Bulletin 2090 cables with Kinetix 5500 drives, some preparation is necessary so that the cable shield, conductor, and strip lengths are correct. Follow these cable preparation guidelines:
• Trim the shield flush so that no strands can short to adjacent terminals.
• Measure the conductor lengths and include a service loop.
• Remove just enough insulation to provide the proper strip length.
Motor power and brake conductors on 2090-CPBM7DF (series B) 12 and 10
AWG standard (non-flex) cables provide drive-end shield braid and conductor preparation modified for compatibility with multiple Kinetix servo drive families, including Kinetix 5500 drives.
Figure 54 - 2090-CPBM7DF (series B, 10 or 12 AWG) Power/brake Cable Dimensions
305 (12.0)
234 (9.20)
15.0 (0.59)
71 (2.80)
12.7 (0.50)
5.0 (0.20)
Power Conductors
Overall Cable Shield
Heat Shrink
5.0 (0.20)
Brake
Conductors
8.0 (0.31)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
95
Chapter 5
Connect the Kinetix 5500 Drive System
96
Maximum Cable Lengths
Combined motor cable length for all axes on the same DC bus must not exceed 250 m (820 ft). The maximum drive-to-motor cable length for
Kinetix 5500 drives and motor/actuator combinations with 2090-C
xx
M7DF cables is 20 m (65.6 ft); however, you can replace the existing motor power/ brake cable with a 2090-CSBM1DF or 2090-CSBM1DG single motor cable to extend the length up to 50 m (164 ft).
IMPORTANT
The option to replace 2090-CPBM7DF power/brake cables with
2090-CSBM1DF/DG single cables applies to only 18 and 14 AWG single cables. 2090-CS
x
M1D
x
-10A
xxx
(10 AWG/M40 connector) single cables are not compatible with 2090-CPBM7DF-10A
xxx
(10 AWG/M40 connector) power/brake cables.
When replacing your existing motor power/brake cable with a
2090-CSBM1DF/DG single motor cable, only the motor power and brake conductors are used. Cut off the feedback conductors in the single motor cable and reuse the existing 2090-Series feedback cable.
Motor Power/Brake Cable Preparation
2090-CPBM7DF (series B) cables are available with 12 and 10 AWG motorpower conductor sizes. So, 14 AWG cables used on frame 3 drives, which are physically taller, require preparation.
Cable Preparation for Frame 1 and Frame 2 Drives
For frame 1 and frame 2 drives, the 2090-CPBM7DF (16 and 14 AWG) power conductor length, 102 mm (4.0 in.), is sufficiently long to reach the MP connector plug and provide adequate stress relief.
The brake conductor length, 635 mm (25 in.), is much longer than necessary.
We recommend that you measure 163 mm (6.4 in.) from the edge of the cable jacket (that is covered by heat shrink) and trim off the rest.
Refer to
and on
page 99 for a typical installation example. For strip
lengths and torque values, refer to Table 40 on page 89 .
Cable Preparation for Frame 3 Drives
2090-CPBM7DF (series B) 12 and 10 AWG cables are designed for use with
Kinetix 5500 drives and do not require any modifications.
For frame 3 drives, 2090-CPBM7DF (14 AWG) cables, and 12 and 10 AWG
(series A) cables, the overall length of the cable preparation area needs to be increased for the motor power conductors to reach the MP connector and also provide a proper service loop.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Follow these steps to prepare your existing 14 AWG cables, and 12 and
10 AWG (series A) cables.
1.
Remove a total of 325 mm (12.8 in.) of cable jacket from your existing cable.
This exposes additional cable shield.
2.
Remove all but 63.5 mm (2.5 in.) of the shield.
3.
Cover 12.5 mm (0.5 in.) of the shield ends and an equal length of the conductors with 25 mm (1.0 in.) of electrical tape or heat shrink.
Do the same on the other side of the cable shield. This keeps the shield ends from fraying and holds the conductors together.
4.
Cut the brake conductors back to 163 mm (6.4 in.) and trim the shield braid at the base of the jacket.
The shield braid covering the brake conductors is not needed.
5.
Remove the specified length of insulation from the end of each wire.
This example applies to existing 2090-CPBM7DF (14 AWG) cables, and 12 and 10 AWG (series A) cables. If you are using a 2090-CSBM1DF/DG single motor cable, you can remove the shield braid covering the brake conductors.
Figure 55 - Power/brake Cable (14, 12, and 10 AWG)
325 (12.8)
262 (10.3)
Dimensions are in mm (in.)
8.0 (0.31) Frame 1 and 2 drives
10.0 (0.39) Frame 3 drives
Electrical Tape or Heat Shrink
Motor Conductors
51.0 (2.0)
25.0 (1.0)
155 (6.1)
284 (11.2)
221 (8.7)
(1) The overall shield braid covering the brake conductors can be removed.
Brake
Conductors
(1)
7.0 (0.28)
Refer to
and on
page 99 for a typical installation example. For strip
lengths and torque values, refer to Table 40 on page 89 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
97
Chapter 5
Connect the Kinetix 5500 Drive System
Apply the Motor Power/brake Shield Clamp
The power/brake cable shield attaches to the drive cable clamp. A clamp spacer is included with the 2198-H2DCK feedback converter kit for cable diameters that are too small for a tight fit within the drive clamp alone.
SHOCK HAZARD:
To avoid hazard of electrical shock, make sure shielded power cables are grounded according to recommendations.
Follow these steps to apply the motor power/brake shield clamp.
1.
Route the conductors with service loops to provide stress relief to the motor power and brake conductors.
2.
Make sure the cable clamp tightens around the cable shield and provides a good bond between the cable shield and the drive chassis.
IMPORTANT
Loosen the retention screw, if needed, until you can start threading both clamp screws with the cable shield under the clamp.
3.
Tighten each screw, a few turns at a time, until the maximum torque value of 2.0 N•m (17.7 lb•in) is achieved.
IMPORTANT
If the power/brake cable shield has a loose fit inside the shield clamp, insert the clamp spacer between the shield clamp and the drive to reduce the clamp diameter. When the clamp screws are tight, 2.0 N•m
(17.7 lb•in), the result must be a high-frequency bond between the cable shield and the drive chassis.
Refer to
for a cable-clamp attachment illustration.
98
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Figure 56 - Cable Clamp Attachment
Connect the Kinetix 5500 Drive System
Chapter 5
Service Loops
Clamp Spacer Added
(small diameter cable)
Clamp Compressed
Around Shield
(no spacer required)
Retention Screw
(loosen, do not remove)
Clamp features apply to all frame sizes.
Frame 1
Servo Drive
Frame 2
Servo Drive
Servo Drive
Frame 3
Servo Drive
Retention
Screw
Clamp Spacer (if needed)
(1)
Shield Clamp
Clamp Screws
2.0 N•m (17.7 lb•in)
Insert the clamp spacer when the cable diameter is smaller than the drive clamp alone.
(1) The clamp spacer is included with the Hiperface-to-DSL feedback converter kit, catalog number 2198-H2DCK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
99
Chapter 5
Connect the Kinetix 5500 Drive System
100
Motor Feedback Connections
The feedback cable attaches to the 2198-H2DCK converter kit and is wired to the 10-pin connector. Bulletin 2090 feedback cables require preparation to make sure the shield clamp attaches properly and conductors route smoothly to the 10-pin connector terminals.
IMPORTANT
When using the 2198-H2DCK feedback connector kit and Bulletin 2090
feedback cables listed in Table 47
or
Table 48 , the ambient temperature
for the Kinetix 5500 drive enclosure is derated to 0…40 °C (32…104 °F).
All of the current and legacy feedback cables listed below are compatible with the 2198-H2DCK (series B or later) converter kit.
IMPORTANT
Only Allen-Bradley motors and actuators with single-turn or multi-turn high-resolution absolute encoders are compatible.
Table 47 - Motor Feedback Cable Compatibility
Motor/Actuator Family
MP-Series electric cylinders
Motor/Actuator
(1)
Cat. No.
MPL-A/B15
xxx-
V/E
x
7
x
AA
MPL-A/B2
xxx-
V/E
x
7
x
AA
MP-Series low-inertia motors
MP-Series medium-inertia motors MPM-A/B
xxxx-
S/M
MP-Series food-grade motors MPF-A/B
xxxx-
S/M
MP-Series stainless-steel motors
MPL-A/B3
xxx
-S/M
x
7
x
AA
MPL-A/B4
xxx
-S/M
x
7
x
AA
MPL-A/B45
xxx
-S/M
x
7
x
AA
MPL-A/B5
xxx
-S/M
x
7
x
AA
MPL-B6
xxx
-S/M
x
7
x
AA
MP-Series integrated linear stages
MPS-A/B
xxxxx-
S/M
MPAS-A/B
xxxx
1-V05S
x
A
MPAS-A/B
xxxx
2-V20S
x
A
MPAR-A/B1
xxxx-
V and MPAR-A/B2
xxxx-
V
(series B)
MPAR-A/B3
xxxx-
M
MP-Series heavy-duty electric cylinders
LDAT-Series linear thrusters
MPAI-A/B
LDAT-S
xxxxx xxxxxx-x
M3
D
x
(1) The 2198-H2DCK (series B or later) feedback converter kit is required.
Table 48 - Legacy Motor Feedback Cables
Motor Cable
Standard
Continuous-flex
Feedback Cable
Cat. No.
2090-CFBM7DF-CEAA
xx
2090-CFBM7DD-CEAA
xx
2090-CFBM7DF-CERA
xx
(standard) or
2090-CFBM7DF-CEAF
xx
2090-CFBM7DD-CEAF
xx
2090-CFBM7DF-CDAF
xx
(continuous-flex)
Description Feedback Cable Cat. No.
Encoder feedback, threaded
2090-XXNFMF-S
xx
2090-UXNFBMF-S
xx
2090-UXNFBMP-S
xx
Encoder feedback, bayonet
2090-XXNFMP-S
xx
Encoder feedback, bayonet 2090-XXTFMP-S
xx
Encoder feedback, threaded 2090-CFBM4DF-CDAF
xx
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
10-pin
Connector
Figure 57 - 2198-H2DCK Converter Kit Pinout
Terminal Signal Wire Color
Strip Length
mm (in.)
Torque Value
N•m (lb•in)
1 SIN+ Black
2 SIN– White/Black
3 COS+
4 COS–
5 DATA+
Red
White/Red
Green
5.0 (0.2)
0.22…0.25
(1.9…2.2)
11
14
7
10
EPWR_9V
(2)
Orange
DATA– White/Green
TS
White/Orange
Gray
(1) The ECOM and TS- connections are tied together and connect to the cable shield.
(2) The converter kit generates 5V and 9V from a 12V supply coming from the drive. The 5V supply is used by 5V encoders in 230V motors. The 9V supply is used by 9V encoders in 460V motors.
Motor Feedback Cable Preparation
Follow these steps to prepare feedback cables.
1.
Remove 115 mm (4.5 in.) of cable jacket and 103 mm (4.0 in.) of cable shield.
IMPORTANT
This length of wire is needed to provide a service loop for the longest wires terminated at the 10-pin connector. However, most wires need to be trimmed shorter, depending on the terminal they are assigned to.
2.
Determine the length for each of the 10 wires and trim as necessary.
3.
Remove 5.0 mm (0.2 in.) of insulation from the end of each wire.
Dimensions are in mm (in.)
5.0 (0.2)
Cable Jacket
Cable Shield
12.0 (0.5)
103 (4.0)
115 (4.5)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
101
Chapter 5
Connect the Kinetix 5500 Drive System
Apply the Converter Kit Shield Clamp
Follow these steps to apply the converter kit shield clamp.
1.
Apply the shield clamp to the 12 mm (0.5 in.) of exposed cable shield to achieve a high-frequency bond between the shield braid and clamp.
IMPORTANT
Cable preparation and positioning that provides a highfrequency bond between the shield braid and clamp is required to optimize system performance.
Also, make sure that the cable is positioned where the cover clamps onto the jacket for added stress relief.
Apply 0.30 N•m (2.6 lb•in) torque to each screw.
Shield Clamp
Cable Positioned Where Cover Clamps
Onto the Cable Jacket
2.
Route and insert each wire to its assigned terminal.
Include a service loop, as shown in
Figure 58 , and refer to the connector
.
3.
Tighten each terminal screw.
Apply 0.22…0.25 N•m (1.9…2.2 lb•in) torque to each screw.
4.
Gently pull on each wire to make sure it does not come out of its terminal; reinsert and tighten any loose wires.
5.
Attach the tie wrap for added stress relief.
102
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Connect the Kinetix 5500 Drive System
Chapter 5
Table 49 - 2090-CFBM7DF-CEA
xxx
Feedback Cables
Rotary Motors
Linear Actuators
9
10
5
6
3
4
1
2
11
12
13
MPL-B15
xxx
…MPL-B2
xxx
-V/E
x
4/7
x
AA
MPL-B3
xxx
…MPL-B6
xxx
-M/S
x
7
x
AA
MPL-A5
xxx
-M/S
x
7
x
AA
MPM-A165
xxx
…MPM-A215
xxx
MPM-B
xxxxx-
M/S
MPF-B
xxx
-M/S
MPF-A5
xxx
-M/S
MPS-B
xxx
-M/S
MPAS-B
xxxxx
-V
xx
S
x
A
MPAR-B
xxxx,
MPAI-B
xxxx
LDAT-S
xxxxxx-x
D
x
Sin+
Sin-
Cos+
Cos-
Data+
Data-
Reserved
ECOM
EPWR_9V
ECOM
TS
MPL-A15
MPL-A3
MPL-A4
MPL-A45
MPS-A5
MPAS-A
MPAR-A
Sin+
Sin-
Cos+
Cos-
Data+
Data-
EPWR_5V
ECOM
Reserved
ECOM
TS
(1) The ECOM and TS- connections are tied together and connect to the cable shield.
xxx xxx xxx xxx
MPM-A115
MPF/MPS-A3
MPF/MPS-A4
MPF/MPS-A45
xxx
…MPL-A2
-M/S
-M/S
-M/S
xxx xxxxx xxxx,
…MPM-A130
xx xx
-V
xx
-M/S
x x xx
7
7
x
S
x x
7
-M/S
-M/S
x
AA
AA
x
-M/S
A
MPAI-A
AA
xxx xxxx
-V/E
x
4/7
xxxx
M/S
AA
2198-H2DCK
Converter Kit Pin
5
10
14
6
(1)
3
4
1
2
7
6
11
A mounting bracket is included with the 2198-H2DCK converter kit to secure the kit to the drive. Install the mounting bracket in the mounting position specific to the frame size of your drive.
Figure 58 - Wire the 2198-H2DCK Feedback Converter Kit
Mounting Screws (2)
2
1
Mounting Bracket
Frame 1 Mounting Position
(catalog numbers 2198-H003 ERS
x
and 2198-H008-ERS
x
)
Converter Kit Mounting Hole with Protective Cover Removed
(frame 1 drive example shown)
Frame 2 Mounting Position
(catalog numbers 2198-H015-ERS
x,
2198-H025-ERS, and 2198-H040-ERS
x
)
Frame 3 Mounting Position
(catalog number 2198-H070-ERS
x
)
Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006 , for converter kit specifications.
Exposed Shield Aligned in the Cable Channel
10-pin
Connector
Service Loops
Tie Wrap for Stress Relief and Wire Management
Clamp Screws (2)
1. Place exposed cable shield in the channel.
2. Place the shield clamp over the exposed shield.
3. Tighten screws, torque
0.3 N•m (2.6 lb•in).
Shield Clamp
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
103
Chapter 5
Connect the Kinetix 5500 Drive System
Capacitor Module
Connections
Follow these guidelines when wiring the 2198-CAPMOD-1300 capacitor module:
• Wire output (MS) connections to the Logix 5000™ controller
(optional).
• Refer to
wiring example on
• Refer to
Kinetix 5500 Capacitor Module Status Indicators on page 159
for troubleshooting the module status indicator and relay output.
• Refer to the installation instructions provided with your Bulletin 2198 capacitor module, publication 2198-IN004 .
IMPORTANT
To improve system performance, run wires and cables in the wireways as established in
. Connections to the DC-bus must be made with the shared-bus connection system.
Figure 59 - MS Connector Wiring
2198-CAPMOD-1300
Capacitor Module
2
1
Module Status
(MS) Connector Plug
Table 50 - Capacitor Module Connector Specifications
Connector
Description
Module Status
PELV/SELV
24V power (plug)
DC-bus power
Pin
MS-1
MS-2
CP-1
CP-2
Bus-bar
Signal
MS
MS
24V+
24V-
DC-
DC+
Recommended
Wire Size
mm
2
(AWG)
0.14…1.5
(28…16)
0.5…2.5
(20…14)
N/A
(1)
Strip Length
mm (in.)
7.0 (0.28)
7.0 (0.28)
N/A
(1)
Torque Value
N•m (lb•in)
0.22…0.25
(1.9…2.2)
0.22…0.25
(1.9…2.2)
N/A
(1)
(1)
DC bus connections are always made from one drive module to another over the shared-bus connection system. These terminals do not receive discrete wires.
104
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
External Passive-shunt
Resistor Connections
Connect the Kinetix 5500 Drive System
Chapter 5
Follow these guidelines when wiring your 2097-R
x
shunt resistor:
• Refer to
External Passive Shunt Resistor on page 47 for noise zone
considerations.
• Refer to
on
.
• Refer to the installation instructions provided with your Bulletin 2097 shunt resistor, publication 2097-IN002 .
IMPORTANT
To improve system performance, run wires and cables in the wireways as
.
Figure 60 - RC Connector Wiring
Kinetix 5500 Drive
Top View
2
1
Remo
Bus Only
Table 51 - Shunt Resistor (RC) Connector Specifications
Drive Cat. No.
Pin Signal
Recommended
Wire Size
mm
2
(AWG)
Strip Length
mm (in.)
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
RC-1
RC-2
RC-1
RC-2
SH
DC+
DC+
SH
0.5…4.0
(20…12)
8.0 (0.31)
Torque Value
N•m (lb•in)
0.5…0.6
(4.4…5.3)
IMPORTANT
You must disconnect the internal shunt wires at the RC connector before connecting the Bulletin 2097 shunt resistor wires.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
105
Chapter 5
Connect the Kinetix 5500 Drive System
Ethernet Cable Connections
This procedure assumes you have your Logix 5000 controller and Kinetix 5500 drive modules mounted and are ready to connect the network cables.
The EtherNet/IP™ network is connected by using the PORT 1 and PORT 2
to locate the Ethernet connectors on your
Kinetix 5500 drive. Refer to Figure 61
to locate the connectors on your
Logix 5000 controller.
Shielded Ethernet cable is required and available in several standard lengths.
Ethernet cable lengths connecting drive-to-drive, drive-to-controller, or driveto-switch must not exceed 100 m (328 ft).Refer to the Kinetix Motion
Accessories Specifications Technical Data, publication KNX-TD004 , for more information.
Figure 61 - ControlLogix and CompactLogix Ethernet Port Locations
ControlLogix® 5570 Controller with
Bulletin 1756 EtherNet/IP Communication Module
LNK1LNK2 NET OK
CompactLogix™ 5370 Controller,
Compact GuardLogix® 5370 Controller
(CompactLogix 5370 controller is shown)
ControlLogix Ethernet Ports
The 1756-EN2T modules have only one port,
1756-EN2TR and 1756-EN3TR modules have two.
ControlLogix 5580 and
GuardLogix 5580 Controller
Logix5585 TM
SAFETY ON
0 0 0 0
NET
LINK
RUN FORCE SD OK
Front Views
00:00:BC:2E:69:F6
1 (Front)
2 (Rear)
Front View
CompactLogix 5380 Controller, or
Compact GuardLogix 5380 Controller
(CompactLogix 5380 controller is shown)
Front View
1 GB Ethernet Port
Port 1, Front
Port 2, Rear
Bottom View
These Logix 5000 controllers accept linear, ring (DLR), and star network configurations. Refer to
Typical Communication Configurations on page 23
for linear, ring, and star configuration examples.
IMPORTANT
When using an external Ethernet switch for routing traffic between the controller and the drive, switches with IEEE-1588 time synchronization capabilities (boundary or transparent clock) must be used to make sure switch delays are compensated.
106
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Chapter
6
Configure and Start the Kinetix 5500 Drive
System
This chapter provides procedures for configuring your Kinetix® 5500 drive system with a Logix 5000™ controller.
Topic
Understand the Kinetix 5500 Display
Configure the Logix 5000 Controller
Configure Feedback-only Axis Properties
Configure Induction-motor Frequency-control Axis Properties
Configure SPM Motor Closed-loop Control Axis Properties
Apply Power to the Kinetix 5500 Drive
Understand Bus-sharing Group Configuration
TIP
Before you begin, make sure you know the catalog number for each drive component, the Logix module and /or controller, and the servo motor used in your motion control application.
Page
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
107
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Understand the Kinetix 5500
Display
The Kinetix 5500 drive has two status indicators and an LCD status display.
The indicators and display are used to monitor the system status, set network parameters, and troubleshoot faults. Four navigation buttons are directly below the display and are used to select items from a soft menu.
Figure 62 - Kinetix 5500 Drive LCD Display and Status Indicators
PRECHARGE
192.168.1.1
DC BUS: 0.3V
Status Indicators (see page 156
)
PRECHARAGE
192.168.1.1
DC BUS: 0.3V
Soft Menu
This is the Home screen. The setup selections are tied to the two Setup (left-side) buttons and the menu selections are tied to the two Menu (right-side) buttons.
Navigation Buttons
PRECHARAGE
192.168.1.1
DC BUS: 0.3V
Each soft menu item is executed by pressing the navigation button directly below the item, as shown in this example.
MAIN MENU
MODULE INFO
MOTOR INFO
Setup
Menu
The soft menu provides a changing selection that corresponds to the current screen. Use the navigation buttons to perform the following.
Press to go back. Pressing enough times results in the Home screen.
Pressing either arrow moves the selection to the next (or previous) item. When changing values, pressing the up arrow increments the highlighted value. Values rollover after reaching the end of the list.
Press to select values to change, moving from right to left. Values rollover when reaching the end of the list.
Press to select a menu item.
Press to return to the Home screen.
?
Press to display the fault help (possible solutions in troubleshooting tables).
(1)
(1) Refer to the Kinetix 5500 Fault Codes.xlsx file to review the troubleshooting tables. See Access the Attachments on page 13 for information on accessing the Kinetix 5500 Fault Codes.xlsx file.
108
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
Menu Screens
The menu screens provide information about the drives, motors, diagnostics, and the fault log. Parameters cannot be updated in the menu screens. Press one of the menu buttons to access the menu.
You can use the soft menu items and navigation buttons to view the information.
MAIN MENU
MODULE INFO
MOTOR INFO
Menu/Sub Menu
Selections
Drive Info
Attributes Description Example Values
Motor Info
Diagnostics>
Drive Diagnostics
Diagnostics>
Motor Diagnostics
Diagnostics>
Encoder Diagnostics
Fault Log
Catalog number
Firmware revision
Hardware revision
Serial number
Model number
Serial number
Bus diagnostics
Converter diagnostics
Inverter diagnostics
2198-H
xxx
-ERS
x
FW REV: 1.1.450167
HW REV: 1.1
SERIAL#: xxxxxxxxxxx
MODEL: VPL-B1306F
SERIAL#: xxxxxxxxxxx
BUS VOLT: 0.0V
BUS CUR: 0.0A
CONV UTIL: 0.7%
CONV TEMP: 31.7C
INV UTIL: 0.0%
INV TEMP: 31.7C
SPEED:0.0 RPM
MTR CUR:0.0A RMS
MTR UTIL:0.0%
MTR TEMP:0.00C
Motor speed
Motor current
Motor utilization
Motor temperature
Serial number
Resolution
Number of turns
Encoder temperature
Supply voltage
Link quality
SERIAL#xxxxxxxxxxx
RESOLUTION: 262144
NO OF TURNS: 1
ENC TEMP:33.7C
SUPP VOLT:11.3V
The link quality attribute indicates how noisy a communication link is and also indicates if there is a communication link already established at the drive end. The LINK QUAL value must always be 100%. Persistent values below 100% indicates a poor feedback ground connection.
LINK QUAL: 100.0%
Remote signal strength indicator
Accumulated position errors
Similar to Link Quality, RSSI reports the quality of link as seen at the motor end by the encoder. Maintain the RSSI value between 80 and 100%. Persistent values below 80% indicates a poor feedback ground connection.
This is an aggregated number of errors in the primary position feedback channel of DSL feedback.
RSSI: 100.0%
POS ERRORS: 1
Channel position errors This is an aggregated number of errors on a secondary communication channel of the DSL feedback.
Fault text Fault code as listed in the Kinetix 5500 Fault Codes.xlsx file.
(1)
FLT S20 - CONV OVERLOAD FL
CHNL ERRORS: 5
Fault details
Fault help
The problem as reported in the Kinetix 5500 Fault Codes.xlsx file.
The Possible Solution as reported in the Kinetix 5500 Fault Codes.xlsx file.
The converter thermal model indicates that the temperature has exceeded the factory set capacity rating of 110%.
• Reduce the number of drives in the same bus group
• Reduce duty-cycle of commanded motion
(1) See Access the Attachments on page 13 for information on accessing the Kinetix 5500 Fault Codes.xlsx file.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
109
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Setup Screens
The setup screens provide the means of changing drive settings, for example, the IP address. Press one of the setup buttons to access the setup screens.
You can use the soft menu items and navigation buttons to view the information and make changes.
SETTINGS
NETWORK
DISPLAY
Press to validate your changes:
• If the change is invalid, the value doesn’t change.
• If the change is valid, an asterisk appears next to the changed attribute.
STATIC IP
IP ADDRESS*
SUBNET MASK
IMPORTANT
You must cycle control power to make network configuration changes persistent. In this example, the IP address was changed. The change takes affect and the asterisk disappears after control power is cycled.
Display configuration changes take effect immediately.
110
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
Table 52 - Navigating the Settings Menu
Settings Menu Selections
Protected Mode
Network
Display
Safety
Web
(1)
Sub Menu Selections
Reset
Network Config
Flash Update
Device Config
->Static IP
DHCP
(2)
Backlight Timeout
Cyclic Data Select
Contrast
Reset Ownership
Enabled
->Disabled
(3)
CONV TEMP
SHUNT UTIL
INV UTIL
INV TEMP
MOTOR UTIL
SPEED
OUT PWR
OUT FREQ
Attributes
ENABLED
DISABLED
ENABLED
DISABLED
ENABLED
DISABLED
ENABLED
DISABLED
IP address
Subnet mask
Gateway
On
Off
30 sec…NEVER
(NEVER=no timeout period, the backlight is always on)
CONV UTIL
OUT CUR
-10…+10
Are you sure?
Default
ENABLED
ENABLED
ENABLED
ENABLED
192.168.1.1
255.255.255.000
192.168.001.001
0
Description
When Enabled (default), identity object or safety resets are not possible when a controller connection is open.
When Enabled (default), network configuration changes are not possible when a controller connection is open.
When Enabled (default), firmware updates are not possible when a controller connection is open.
When Enabled (default), only attribute writes are possible when a controller connection is open.
Indicates current IP address
Indicates current subnet mask
Indicates current gateway
Turns DHCP on
Turns DHCP off
Sets backlight timeout period of the display
DC bus voltage
Converter utilization in percent
Converter temperature in °C
Shunt utilization in percent
Inverter utilization in percent
Inverter temperature in °C
Motor utilization in percent
RPM
Output power in watts
Output frequency in hertz
Output current in amps
Contrast setting of the display
Resets safety ownership (reset fails after 30 seconds)
Enables the web server
Disables the web server
(1) The Safety menu applies to only 2198-H
xxx
-ERS2 drives.
(2) An arrow (->) appears in front of the chosen attribute indicating that this attribute is currently configured. This is also the factory default setting.
(3) The DC bus voltage is one of several cyclic data attributes. You can select any of the Cyclic Data Select attributes to be displayed on the Home screen.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
111
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Startup Sequence
On initial powerup, the drive performs a self test. Upon successful completion, the drive firmware revision is displayed.
Kinetix 55 then…
SELF-TEST
FW REV: 1.1.33
75% until Kinetix 5500 is spelled out… until the test is complete…
Kinetix 5500
SELF-TEST
FW REV: 1.1.33
100%
Next, the axis state, the IP address, and the default cyclic data attribute (in this example
DC bus voltage) appears. In addition, the setup and menu soft keys are displayed.
This is the Home screen.
PRECHARAGE
192.168.1.1
DC BUS: 0.3V
<-- Axis State
<-- IP Address
<-- Cyclic Data Attribute
In this example PRECHARGE is the axis state attribute.
lists the other axis states and their descriptions.
Table 53 - Axis States on the Home Screen
Axis State
STANDBY
CONNECTING
CONFIGURING
SYNCING
STOPPED
PRECHARGE
STARTING
Description
The drive is waiting to receive configuration information from the controller.
The drive is trying to establish communication with the EtherNet/IP™ controller.
The drive is receiving configuration information from the controller.
The drive is waiting for a successful Group Sync service.
The drive is fully configured, but the control loops are not enabled.
The drive is ready for mains input power.
The drive is enabled and checking various conditions before entering the RUNNING or TESTING state. For example, the drive checks the Brake Release delay time during the STARTING state.
RUNNING
TESTING
STOPPING
• The drive is enabled, configured with an active control mode, and actively tracking a command.
• The drive is configured for No Control and is fully operational.
The drive is actively executing a test procedure, for example, a hookup test.
The drive is decelerating to a stop as the result of a disable.
ABORTING The drive is decelerating to a stop as the result of a fault or an abort request.
MAJOR FAULTED The drive is faulted due to an existing or past fault condition.
START INHIBITED The drive has an active condition that inhibits it from being enabled.
SHUTDOWN The drive has been shut down.
112
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure the Drive
Configure and Start the Kinetix 5500 Drive System
Chapter 6
You can include the drive in your Studio 5000 Logix Designer® application by adding it to a configured EtherNet/IP module or controller under the I/O configuration tree. After setting network parameters, you can view the drive status information in Studio 5000® environment and use it in your Logix
Designer application.
Set the Network Parameters
You must program network parameters by using the LCD display.
1.
From the LCD display, select SETUP>NETWORK and choose between STATIC IP and DHCP.
The default setting is STATIC IP.
2.
If STATIC IP, then press to configure the following parameters:
• IP address
• Gateway
• Subnet mask
Settings are stored in nonvolatile memory. IP addressing can also be changed through the Module Configuration dialog box in RSLinx® software. Changes to the IP addressing take effect after power is cycled. The drive is factory programmed to static IP address of 192.168.1.1.
Refer to
Setup Screens on page 110 for help setting the network parameters.
Studio 5000 Logix Designer
For help using the Studio 5000 Logix Designer application as it applies to configuring the ControlLogix® or CompactLogix™ controllers, refer to
Additional Resources on page 12 .
Version History
Each release of the Studio 5000 Logix Designer application makes possible the configuration of additional Allen-Bradley® motors, actuators, and drive features not available in previous versions.
IMPORTANT
To configure these additional drive features with your Kinetix 5500 servo drive, you must have drive firmware 4.001 or later. Refer to
determine if you need to install the Kinetix 5500/5700 Add-on Profile.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
113
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Table 54 - AOP Installation Requirement
Drive Firmware Revision Logix Designer Application Version Kinetix 5500/5700 AOP Needed?
26.00 or 27.00
4.001
Yes
28.00 or later No
5.001
7.001 or later
(1)
26.00, 27.00, or 28.00
29.00 or later
29.00 or later
Yes
No
No
(1) Drive firmware 7.001 enhancements are available only with the Studio 5000 Logix Designer, version 29.00 or later, firmware update. The AOP for firmware 7.001 is not available.
Install the Kinetix 5500 Add-On Profile
Download Add-On profiles (AOP) from the Product Compatibility
Download Center (PCDC) website: http://compatibility.rockwellautomation.com/Pages/home.aspx
.
Follow these steps to download the Kinetix 5500 Add-On profile.
1.
Go to the Product Compatibility Download Center.
The Compatibility & Downloads webpage appears.
2.
Click Download.
114
3.
Enter Kinetix 5500 in the Search PCDC window.
4.
Click the appropriate firmware revision and follow prompts to download.
5.
Extract the AOP zip file and run Setup.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure the Logix 5000
Controller
Configure and Start the Kinetix 5500 Drive System
Chapter 6
These procedures assume that you have wired your Kinetix 5500 drive system.
In this example, the GuardLogix® 5570 safety controller, ControlLogix 1756-
EN2T communication module, and CompactLogix 5370 controller dialog boxes are shown.
Follow these steps to configure the controller.
1.
Apply power to your controller and open your Logix Designer application.
2.
From the Create menu, choose New Project.
The New Project dialog box appears.
IMPORTANT
If you are configuring a 2198-H
xxx
-ERS2 (integrated) servo drive in a safety application, you must use a GuardLogix safety controller.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
115
Chapter 6
Configure and Start the Kinetix 5500 Drive System
In this example, the typical dialog boxes for 1756-EN
x
T EtherNet/IP modules and CompactLogix 5370 controllers with embedded Ethernet are shown.
Follow these steps to configure your Logix 5000 controller.
1.
Expand the Logix 5000 controller family and select your controller.
2.
Type the file Name.
3.
Click Next.
The New Project dialog box appears.
116
4.
From the Revision pull-down menu, choose your software revision.
5.
Click Finish.
The new controller appears in the Controller Organizer under the
I/O Configuration folder.
Controller Organizer with
CompactLogix 5380 controller.
Controller Organizer with
GuardLogix 5580 controller.
6.
Configure the Logix 5000 controller.
Your new Logix 5000 controller appears under the I/O Configuration folder in the Controller Organizer.
In this example, a GuardLogix
5580 controller with 1756-EN2T communication module is used.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
7.
From the Edit menu, choose Controller Properties.
The Controller Properties dialog box appears.
8.
Click the Date/Time tab.
9.
Check Enable Time Synchronization.
The motion modules set their clocks to the module you assign as the
Grandmaster.
IMPORTANT
Check Enable Time Synchronization for all controllers that participate in CIP Sync™. The overall CIP Sync network automatically promotes a Grandmaster clock, unless the priority is set in the
Advanced tab.
10.
Click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
117
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Configure the Kinetix 5500 Drive
IMPORTANT
To configure 2198-H
xxx
-ERS (hardwired safety) drives, you must be using the Logix Designer application, version 21.00 or later.
To configure 2198-H
xxx
-ERS2 (integrated safety) drives, you must be using the Logix Designer application, version 24.00 or later.
Use this table to determine where to begin your drive configuration.
Drive Cat. No.
2198-H
xxx
-ERS
2198-H
xxx
-ERS2
Start Here
Configure Drive with Hardwired Safety Connections
Configure Drive with Integrated Safety Connections
Page
Configure Drive with Hardwired Safety Connections
Follow these steps to configure Kinetix 5500 drives with hardwired safety.
1.
Below the controller you just created, right-click Ethernet and choose
New Module.
The Select Module Type dialog box appears.
Enter 2198 here to further limit your search.
118
2.
By using the filters, check Motion and Allen-Bradley, and select your
2198-H
xxx
-ERS servo drive as appropriate for your actual hardware configuration.
3.
Click Create.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
The New Module dialog box appears.
4.
Configure the new drive.
a. Type the drive Name.
b. Select an Ethernet Address option.
In this example, the Private Network address is selected.
c. Enter the address of your 2198-H
xxx
-ERS drive.
In this example, the last octet of the address is 1.
d. Under Module Definition click Change.
Depending on the Module Definition revision selection, alternate product features can be selected.
5.
Click OK to close the New Module dialog box.
Your 2198-H
xxx
-ERS servo drive appears in the Controller Organizer under the Ethernet controller in the
I/O Configuration folder.
6.
Click Close to close the Select Module Type dialog box.
7.
Jump to Continue Drive Configuration on page 124
to continue with your drive configuration.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
119
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Configure Drive with Integrated Safety Connections
Follow these steps to configure Kinetix 5500 drives with integrated safety.
1.
Below the controller you just created, right-click Ethernet and choose
New Module.
The Select Module Type dialog box appears.
2.
By using the filters, check Motion and Allen-Bradley, and select your
2198-H
xxx
-ERS2 servo drive as appropriate for your actual hardware configuration.
3.
Click Create.
The New Module dialog box appears.
120
4.
Configure the new drive.
a. Type the drive Name.
b. Select an Ethernet Address option.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
In this example, the Private Network address is selected.
c. Enter the address of your 2198-H
xxx
-ERS2 servo drive.
In this example, the last octet of the address is 2.
d. Under Module Definition click Change.
The Module Definition dialog box appears.
Connection Mode
Motion only
Motion and Safety
Safety only
Controller Needed
ControlLogix 5570 and 5580
GuardLogix 5570, or CompactLogix 5370
GuardLogix 5570 or Compact GuardLogix 5370
GuardLogix 5570 or Compact GuardLogix 5370
N/A
N/A e. From the Connection pull-down menu, choose the Connection mode for your motion application.
Description
Drive Cat. No. 2198-H
xxx
-ERS
Only hardwired safe torque-off connections are possible.
Description
Drive Cat. No. 2198-H
xxx
-ERS2
Motion is managed by this controller.
Safety is managed by another controller that has a
Safety-only connection to the drive.
Motion and Safety are managed by this controller.
Safety is managed by this controller.
Motion is managed by another controller that has a
Motion-only connection to the drive.
TIP
When ‘Safety’ appears in the Connection mode, integrated safety is implied.
The Safety Network Number (SNN) field populates automatically when the Connection mode includes an integrated Motion and Safety or Safety-only connection. For a detailed explanation of the safety network number, refer to the GuardLogix Controller Systems Safety
Reference Manual, publication 1756-RM099 .
5.
Click OK to close the Module Definition dialog box.
6.
Click OK to close the New Module dialog box.
Your 2198-H
xxx
-ERS2 servo drive appears in the Controller
Organizer under the Ethernet controller in the
I/O Configuration folder.
7.
Right-click the drive you just created in the Controller Organizer and choose Properties.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
121
Chapter 6
Configure and Start the Kinetix 5500 Drive System
The Module Properties dialog box appears.
8.
Click the Drive Safety tab.
9.
From the Restart Type pull-down menu, choose Manual or Automatic depending on your specific application.
• Manual restart indicates a transition from 0 to 1 on the SO.Reset tag is required to allow torque after the SO.SafeTorqueOff tag has transitioned from 0 to 1.
• Automatic restart indicates torque will be allowed only by transitioning the SO.SafeTorqueOff tag from 0 to 1. The SO.Reset tag is used only for resetting safety faults.
10.
Click Apply.
11.
Click the Safety tab.
122
The connection between the owner and the 2198-H
xxx
-ERS2 servo drive is based on the following:
• Servo drive catalog number must be 2198-H
xxx
-ERS2 (integrated)
• Servo drive safety network number
• GuardLogix slot number
• GuardLogix safety network number
• Path from the GuardLogix controller to the 2198-H
xxx
-ERS2 drive
• Configuration signature
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
If any differences are detected, the connection between the GuardLogix controller and the 2198-H
xxx
-ERS2 drive is lost, and the yellow yield icon appears in the controller project tree after you download the program.
12.
Click Advanced.
The Advanced Connection Reaction Time Limit Configuration dialog box appears.
Analyze each safety channel to determine the appropriate settings. The smallest Input RPI allowed is 6 ms. Selecting small RPI values consumes network bandwidth and can cause nuisance trips because other devices cannot get access to the network.
13.
Click OK.
For more information about the Advanced Connection Reaction Time Limit
Configuration, refer to the GuardLogix 5570 Controllers User Manual, publication 1756-UM022 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
123
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Continue Drive Configuration
After you’ve established your Kinetix 5500 drive in the Logix Designer application, the remaining configuration steps are the same regardless of the drive catalog number.
1.
Right-click the 2198-H
xxx
-ERS
x
servo drive you just created and choose Properties.
The Module Properties dialog box appears.
2.
Click the Associated Axes tab.
3.
Click New Axis.
The New Tag dialog box appears.
124
4.
Type the axis Name.
AXIS_CIP_DRIVE is the default Data Type.
5.
Click Create.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
The axis (Axis_1 in this example) appears in the
Controller Organizer under Motion Groups>
Ungrouped Axes and is assigned as Axis 1.
TIP
You can configure an axis as Feedback Only. Refer to Configure Feedbackonly Axis Properties
on
for more information.
6.
Click Apply.
7.
Click the Digital Input tab.
8.
From the Axis pull-down menu, choose an axis to configure.
9.
From the Digital Input pull-down menus, choose a digital input assignment appropriate for your application. Refer to
10.
Click Apply.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
125
Chapter 6
Configure and Start the Kinetix 5500 Drive System
11.
Click the Power tab.
IMPORTANT
Single-phase operation is possible only when Module Properties>Power tab>Bus Configuration is configured as Standalone.
IMPORTANT
The Logix Designer application enforces shared-bus configuration rules for Kinetix 5500 drives, except for shared AC configurations.
126
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
12.
From the pull-down menus, choose the power options appropriate for your actual hardware configuration.
ATTENTION:
To avoid damage to equipment, make sure the AC input voltage configured in the Logix Designer application matches the actual hardware being configured.
Attribute
Voltage
AC Input Phasing
Bus Configuration
(1) (2)
Menu
400-480 VAC
200-240 VAC
• Three Phase
• Single Phase
Standalone
Shared AC/DC
Shared DC
Description
324…528 AC rms input voltage
195…264 AC rms input voltage
Input power phasing. Kinetix 5500 drives with single-phase operation is limited to 2198-H003-
ERS
x
, 2198-H008-ERS
x
, and 2198-H015-ERS
x
.
Applies to single-axis drives and drives with
Shared AC input configurations.
Applies to converter drives with Shared AC/DC and Shared AC/DC Hybrid input configurations.
Applies to inverter drives with Shared DC input
(common-bus) configurations.
Applies to standalone bus configurations.
Bus Sharing Group
(3)
Standalone
• Group1
• Group2
• Group3…
Applies to any bus-sharing configuration
(4)
.
Shunt Regulator Action
Shunt Regulator Resistor Type
Disabled
Shunt Regulator
Internal
External
Disables the internal shunt resistor and external shunt option.
Enables the internal and external shunt options.
Enables the internal shunt (external shunt option is disabled).
Enables the external shunt (internal shunt option is disabled).
External Shunt
(5)
• None
• 2097-R6
• 2097-R7
Selects external shunt option. Only the shunt model intended for the drive model is shown.
(1) Refer to
for more information on single-axis and multi-axis configurations.
(2) Bus Configuration selection is not applicable to all EtherNet/IP drives.
(4) All drives physically connected to the same shared-bus connection system must be part of the same Bus Sharing
Group in the Logix Designer application.
(5) Refer to the Kinetix Servo Drives Specifications Technical Data, publication KNX-TD003 , for more information on the
Bulletin 2097 external shunt resistors.
13.
Click OK.
14.
Repeat
for each 2198-H
xxx
-ERS
x
servo drive.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
127
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Configure the Motion Group
Follow these steps to configure the motion group.
1.
In the Controller Organizer, right-click Motion Groups and choose
New Motion Group.
The New Tag dialog box appears.
128
2.
Type the new motion group Name.
3.
Click Create.
Your new motion group appears in the Controller
Organizer under the Motion Groups folder.
4.
Right-click the new motion group and choose
Properties.
The Motion Group Properties dialog box appears.
5.
Click the Axis Assignment tab and move your axes (created earlier) from
Unassigned to Assigned.
6.
Click the Attribute tab and edit the default values as appropriate for your application.
7.
Click OK.
Your axis moves to the new motion group.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
Configure Feedback-only Axis
Properties
Follow these steps to configure feedback-only axis properties.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the General category.
The General dialog box appears.
3.
From the Axis Configuration pull-down menu, choose Feedback Only.
4.
From the Feedback Configuration pull-down menu, choose Master
Feedback.
5.
From the Module pull-down menu, choose the drive to associate with your Feedback Only axis.
The Module Type and Power Structure fields populate with the chosen drive catalog number.
6.
Click Apply.
7.
Select the Master Feedback Category.
The Master Feedback Device Specification appears.
8.
From the Type pull-down menu, choose a feedback device type.
9.
Review other categories in the Controller Organizer and make changes as needed for your application.
10.
Click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
129
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Configure Induction-motor
Frequency-control Axis
Properties
Follow these steps to configure induction-motor axis properties for various frequency control methods.
General and Motor Categories
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the General category.
The General dialog box appears.
3.
From the Axis Configuration pull-down menu, choose Frequency
Control.
4.
From the Feedback Configuration pull-down menu, choose No
Feedback.
5.
From the Module pull-down menu, choose the drive to associate with your Frequency Control (induction motor) axis.
The Module Type and Power Structure fields populate with the chosen drive catalog number.
6.
Click Apply.
130
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
7.
Select the Motor category.
Configure and Start the Kinetix 5500 Drive System
Chapter 6
8.
From the Data Source pull-down menu, choose Nameplate Datasheet.
This is the default setting.
9.
From the Motor Type pull-down menu, choose Rotary Induction.
10.
From the motor nameplate or datasheet, enter the phase-to-phase values for your motor.
See Motor Category on page 242
for a motor performance datasheet example.
11.
Click Apply.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
131
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Basic Volts/Hertz Method
1.
Configure the General tab and Motor tab as shown in
.
2.
Select the Frequency Control category.
3.
From the Frequency Control Method pull-down menu, select Basic
Volts/Hertz.
4.
Enter the Basic Volts/Hertz attribute values appropriate for your application.
Default values are shown.
5.
Click Apply.
6.
Select the Parameter List category.
132
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
The Motion Axis Parameters dialog box appears.
7.
From the Parameter Group pull-down menu, choose Frequency
Control.
8.
Set the FluxUp, SkipSpeed, VelocityDroop, and CurrentVectorLimit attributes appropriate for your application.
See the corresponding section in Appendix D, beginning on page 227
, for information and configuration examples regarding all of these topics.
9.
Click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
133
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Sensorless Vector Method
1.
Configure the General tab and Motor tab as shown in
.
2.
Select the Frequency Control category.
3.
From the Frequency Control Method pull-down menu, select Sensorless
Vector.
4.
Enter the Basic Volts/Hertz attribute values appropriate for your application.
Default values are shown.
5.
Click Apply.
6.
Select the Parameter List category.
7.
The Motion Axis Parameters dialog box appears.
134
8.
From the Parameter Group pull-down menu, choose Frequency
Control.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
9.
Set the FluxUp, SkipSpeed, VelocityDroop, MaximumFrequency,
MaximumVoltage, and CurrentVectorLimit attributes appropriate for your application.
See the corresponding section in Appendix D, beginning on page 227
, for information and configuration examples regarding all of these topics.
10.
Click Apply.
11.
Select the Motor>Model category.
Motor model attributes are automatically estimated from the
Nameplate/Datasheet parameters. For improved performance, motor tests can be run.
12.
Select the Motor>Analyzer category.
13.
The Analyze Motor to Determine Motor Model dialog box opens.
14.
Click one of the motor test tabs.
In this example, Calculate Model is chosen. See
Autotune Procedure on page 244 for information about each of the
tests.
15.
Click Start.
16.
Click Accept Test Results.
17.
Click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
135
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Fan/Pump Volts/Hertz Method
1.
Configure the General tab and Motor tab as shown in
.
2.
Select the Frequency Control category.
3.
From the Frequency Control Method pull-down menu, select Fan/
Pump Volts/Hertz.
4.
Enter the Basic Volts/Hertz attribute values appropriate for your application.
Default values are shown.
5.
Click Apply.
6.
Select the Parameter List category.
136
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
The Motion Axis Parameters dialog box appears.
7.
From the Parameter Group pull-down menu, choose Frequency
Control.
8.
Set the FluxUp, SkipSpeed, VelocityDroop, RunBoost,
MaximumFrequency, MaximumVoltage and CurrentVectorLimit attributes appropriate for your application.
See the corresponding section in Appendix D, beginning on page 227
, for information and configuration examples regarding all of these topics.
9.
Click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
137
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Configure SPM Motor Closedloop Control Axis Properties
Kinetix 5500 drives accept Hiperface and Hiperface DSL feedback from surface permanent magnet (SPM) motors when the appropriate feedback
connector kit is used. Table 55 lists the compatible Allen-Bradley motors and
actuators.
Feedback Type
Hiperface
Hiperface DSL
Table 55 - Motor Feedback Compatibility
High-resolution single-turn and multi-turn, absolute
Description
Feedback
Connector
Applies to Allen-Bradley Bulletin MPL, MPM, MPF, MPS (-M/S or -V/E) rotary motors and Bulletin MPAS (ballscrew), MPAR, MPAI linear actuators, and
LDAT-Series (-
x
D
x
) linear thrusters, wired to the 2198-H2DCK converter kit.
2-pin motor feedback (MF)
Applies to Allen-Bradley Bulletin VPL, VPF, VPH, and VPS rotary motors wired to the 2198-KITCON-DSL connector kit.
IMPORTANT
Unprogrammed Smart feedback devices (Hiperface Sin/Cos and Hiperface
DSL) are not supported. Unprogrammed as load or feedback-only feedback types are supported. Contact your local distributor or Rockwell Automation sales representative for support options.
Follow these steps to configure surface permanent-magnet (SPM) motor closed-loop axis properties.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the General category.
The General and Associated Module dialog box appears.
138
3.
From the General pull-down menus, change configuration settings as needed for your application.
IMPORTANT
Frequency Control is not supported for permanent magnet motors.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
4.
From the Associated Module>Module pull-down menu, choose your
Kinetix 5500 drive.
The drive catalog number populates the Module Type and Power
Structure fields.
5.
Click Apply.
6.
Select the Motor category.
The Motor Device Specification dialog box appears.
7.
From the Data Source pull-down menu, choose Catalog Number.
8.
Click Change Catalog.
The Change Catalog Number dialog box appears.
9.
Select the motor catalog number appropriate for your application.
To verify the motor catalog number, refer to the motor name plate.
10.
Click OK to close the Change Catalog Number dialog box.
11.
Click Apply.
Motor data specific to your motor appears in the Nameplate / Datasheet
- Phase to Phase parameters field.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
139
Chapter 6
Configure and Start the Kinetix 5500 Drive System
12.
Select the Scaling category and edit the default values as appropriate for your application.
13.
Click Apply, if you make changes.
14.
Select the Load category and edit the default values as appropriate for your application.
140
15.
Click Apply, if you make changes.
16.
Select the Actions category.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
The Actions to Take Upon Conditions dialog box appears.
From this dialog box you can program actions for the drive module to
take. Refer to Logix 5000 Controller and Drive Behavior on page 161
for more information.
17.
Select the Exceptions category.
The Action to Take Upon Exception Condition dialog box appears.
From this dialog box you can change the action for exceptions (faults).
Refer to
Logix 5000 Controller and Drive Behavior on page 161
for more information.
TIP
In the Logix Designer application, version 32 and later, Disable replaced StopDrive as the default Action.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
141
Chapter 6
Configure and Start the Kinetix 5500 Drive System
18.
Select the Parameter List category.
The Motion Axis Parameters dialog box appears.
Download the Program
From this dialog box you can set brake engage and release delay times for servo motors. For recommended motor brake delay times, refer to the
Kinetix Rotary Motion Specifications Technical Data, publication
KNX-TD001 .
19.
Click OK.
20.
Repeat
for each servo motor axis.
After completing the Logix Designer application and saving the file you must download your program to the Logix 5000 processor.
142
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Apply Power to the
Kinetix 5500 Drive
Configure and Start the Kinetix 5500 Drive System
Chapter 6
This procedure assumes that you have wired and configured your Kinetix 5500 system and your Logix 5000 controller.
SHOCK HAZARD:
To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2198 servo drives prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use.
Follow these steps to apply power to the Kinetix 5500 system.
1.
Disconnect the load to the motor.
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.
2.
Apply 24V DC control power.
The LCD display begins the startup sequence. Refer to Startup
. If the startup sequence does not begin, check the
24V control power connections.
3.
When the startup sequence completes, verify that the two status indicators are steady green and the axis state is PRECHARGE.
If the axis state does not reach PRECHARGE and the two status
indicators are not solid green, refer to Kinetix 5500 Drive Status
IMPORTANT
Apply control power before applying three-phase AC power. This makes sure the shunt is enabled, which can prevent nuisance faults or Bus Overvoltage faults.
4.
Apply mains input power and monitor the DC BUS voltage on the
LCD display.
If the DC BUS does not reach the expected voltage level, check the three-phase input power connections. Also, it can take as many as 1.8 seconds after input power is applied before the drive can accept motion commands.
5.
Verify that the axis state changes to STOPPED.
If the axis state does not change to STOPPED, refer to Fault Code
.
Applying Power after Changing Input Voltage Range
This step applies to any drive or multi-axis drive configuration.
ATTENTION:
To avoid damage to equipment when the configured input voltage range of the drive or drives changes from 230V AC to 460V AC or from 460V AC to
230V AC, the bus voltage needs to bleed down below 50V DC before the new configured input voltage is applied.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
143
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Understand Bus-sharing
Group Configuration
When configuring Module Properties>Power tab for each Kinetix 5500 servo drive, you can breakout drives from one or more servo systems into multiple bus-sharing (power) groups.
A drive that faults in Group 1 does not affect the operation of Group 2, even though all of the drives in Groups 1 and 2 are in the same Motion group in the
Logix Designer application.
Figure 63 - 25 Bus-sharing Groups Are Possible
IMPORTANT
Bus-sharing groups do not apply to drives with a Bus Configuration of
Standalone. When Standalone is configured as the Bus Configuration,
Standalone (dimmed) is also configured as the Bus Sharing Group.
Figure 64 - Standalone Bus Configuration
144
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
Bus-sharing Group Example
In this example, twelve axes are needed to support the motion application. All twelve axes are configured in the same Motion group in the Logix Designer application.
However, the twelve axes of motion are also configured as two bus-sharing groups and one standalone drive in Module Properties>Power tab. By creating two bus-sharing groups, a converter drive that faults in Group 1 only disables
Group 1 drives, and has no effect on the drive operation of Group 2 or the
Standalone drive.
CompactLogix Controller Programming Network
Figure 65 - Bus-sharing Group Example
Three-phase and
24V Input Power
1585J-M8CBJM-
x
Ethernet (shielded) Cable
CompactLogix 5370 Controller
Logix Designer
Application
Kinetix 5500 Servo Drive System
Group 1 (shared AC/DC hybrid)
Logix Designer Application
Controller Organizer
Module Properties>Power Tab
Bus Sharing Group 1
Axis_01
Axis_02
Axis_03
Axis_04
Axis_05
Axis_06
2198-H040-ERS
Leader Drives
x
Common-bus (converter)
2198-H003-ERS
x
Common-bus (inverter)
Follower Drives
Three-phase and
24V Input Power
Kinetix 5500 Servo Drive System
Group 2 (shared-DC common-bus)
Standalone
Axis_12
Bus Sharing Group 2
Axis_07
Axis_08
Axis_09
Axis_10
Axis_11
1585J-M8CBJM-
x
Ethernet (shielded) Cable
Kinetix 5500 Servo Drive
Standalone
Three-phase and
24V Input Power
2198-H040-ERS
Common-bus Leader Drive
x
2198-H003-ERS
x
Common-bus
Follower Drives
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
145
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Configure Bus-sharing Groups
Group 1 is a shared AC/DC hybrid configuration. The Bus Configuration for the first two converter drives is Shared AC/DC. The Bus Configuration for the inverter drives is Shared DC.
ATTENTION:
To avoid damage to equipment, all modules physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application.
Figure 66 - Group 1 Converter Drives Configuration
Figure 67 - Group 1 Inverter Drives Configuration
146
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
Group 2 is a shared DC (common-bus) configuration. The Bus Configuration for the leader drive is Shared AC/DC. The Bus Configuration for the follower drives is Shared DC.
Figure 68 - Group 2 Leader Drive Configuration
Figure 69 - Group 2 Follower Drives Configuration
Figure 70 - Standalone Drive Configuration
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
147
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Test and Tune the Axes
This procedure assumes that you have configured your Kinetix 5500 drive, your Logix 5000 controller, and applied power to the system.
IMPORTANT
Before proceeding with testing and tuning your axes, verify that the MOD
and NET status indicators are operating as described in Kinetix 5500 Drive
.
For help using the Logix Designer application as it applies to testing and tuning your axes with ControlLogix EtherNet/IP modules or CompactLogix 5370
controllers, refer to Additional Resources on page 12
.
Test the Axes
Follow these steps to test the axes.
1.
Verify the load was removed from each axis.
ATTENTION:
To avoid personal injury or damage to equipment, you must remove the load from each axis as uncontrolled motion can occur when an axis with an integral motor brake is released during the test.
2.
In your Motion Group folder, right-click an axis and choose Properties.
The Axis Properties dialog box appears.
3.
Click the Hookup Tests category.
148
4.
In the Test Distance field, enter the desired test distance.
The Position Units are defined in the Axis Properties>Scaling tab.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
5.
Click the desired test to verify connections.
Hookup Test
Marker
Definitions
Verifies marker detection capability as you manually rotate the motor shaft. The test completes when the drive either detects the marker or when the motor moves the distance specified in the Test Distance field. If the marker remains undetected and the test completes successfully, it means the motor moved the full test distance. If the marker remains undetected and the test fails, the motor did not move the full test distance. Run this test after running the Motor Feedback and Motor and Feedback tests.
Commutation
Motor Feedback
Verifies the commutation offset and commutation polarity of the motor. For Kinetix 5500 drives, this
test applies to only third-party motors. See Commutation Test
on page
.
Verifies feedback connections are wired correctly as you manually rotate the motor shaft. The test completes when the drive determines that the motor moved the full distance specified in the Test
Distance field. Run this test before the Motor and Feedback Test to verify that the feedback can be read properly.
Motor and Feedback
Verifies motor power and feedback connections are wired correctly as the drive commands the motor to rotate. Because the drive is rotating the motor, this test requires full bus power to run. Run the Motor
Feedback test before running this test to verify that the feedback is being read correctly.
6.
Click Start.
The Logix Designer - Motor and Feedback Test dialog box appears. The
Test State is Executing. TESTING appears on the drive LCD display.
Drive LCD Display
TESTING
192.168.1.1
DC BUS: 218.3V
When the test completes successfully, the Test State changes from
Executing to Passed.
7.
Click OK.
This dialog box appears asking if the direction was correct.
8.
Click Yes.
9.
Click Accept Test Results.
10.
If the test fails, this dialog box appears.
a. Click OK.
b. Verify the DC bus voltage.
c. Verify unit values entered in the
Scaling category.
d. Verify the motor power and feedback wiring.
e. Return to
step 6 and run the test again.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
149
Chapter 6
Configure and Start the Kinetix 5500 Drive System
Tune the Axes
Choose the tuning procedure best suited for your motor type.
Motor Type
Permanent magnet (PM)
Induction
Go directly to
Tune Induction Motors on page 153
Tune Permanent Magnet Motors
The load observer feature provides high-performance motion control without having to manually tune your axis. Using load observer with a default set of gains can yield high-performance right out of the box. Most of the time, there is no need to perform an auto-tune procedure or further optimize gain settings.
Follow these steps to configure the drive for high-performance by using the load observer feature.
1.
Verify that the load is connected.
Re-attach the load if it was disconnected for the Hookup Test.
ATTENTION:
If the drive has not been enabled before (new installation), verify that you have safeguards in place to safely remove power from the drive in the event of an unstable situation where the drive can produce undesired motion.
2.
Click the Autotune tab in the Axis Properties dialog box.
a. From the pull-down menus for Application Type, Loop Response, and Load Coupling, choose Custom, Medium, and Rigid settings, respectively.
b. Verify that only the Velocity Feedforward box is checked.
150
Uncheck Torque Low Pass Filter (that is checked by default).
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
3.
Click the Load category in the Axis Properties dialog box.
a. Check Use Load Ratio.
b. Set the Load Ratio = 0.
4.
Click the Observer category in the Axis Properties dialog box.
a. From the Configuration pull-down menu, choose Load Observer with Velocity Estimate if the axis is configured for Position Loop control.
Choose Load Observer Only if the axis is configured for Velocity
Loop control.
Load Observer is not available for Torque Loop control.
b. Click Apply and click Yes to update all dependent attributes.
The Load Observer Bandwidth and other gains are set automatically.
4
1
4
1
1
K pp
K vp
K op
T bw
0 0 0
K pi
K vi
K oi
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
151
Chapter 6
Configure and Start the Kinetix 5500 Drive System
5.
Click the Compliance category in the Axis Properties dialog box.
a. From the Adaptive Tuning Configuration pull-down menu, choose
Tracking Notch.
b. Click Apply.
6.
Enable the drive for a few seconds with an MSO instruction or motion direct command, followed by an MSF instruction or motion direct command, to make sure that no audible squealing noise is present.
IMPORTANT
If an audible squealing noise is heard, go to Axis Properties>Load>
Compliance category and set the Torque Notch Filter Frequency field
(Hz) to remove the noise. Refer to Motion System Tuning
Application Techniques, publication MOTION-AT005 (Compensating for High Frequency Resonances), for information on how to set the
Torque Notch Filter Frequency field.
7.
Repeat
for each axis.
152
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Configure and Start the Kinetix 5500 Drive System
Chapter 6
Tune Induction Motors
IMPORTANT
The Automatic FluxUpControl setting is recommended for best Autotune results.
Follow these steps to tune the induction motor axes.
1.
Verify the load is removed from the axis being tuned.
ATTENTION:
To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then reattach the load and perform the tuning procedure again to provide an accurate operational response.
2.
Select the Autotune category.
3.
Type values for Travel Limit and Speed.
In this example, Travel Limit = 50.0 and Speed = 2.0. The actual value of programmed units depend on your application.
4.
From the Direction pull-down menu, choose a setting appropriate for your application.
Forward Uni-directional is default.
5.
Edit other fields as appropriate for your application.
6.
Click Start.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
153
Chapter 6
Configure and Start the Kinetix 5500 Drive System
The Logix Designer - Autotune dialog box appears. When the test completes, the Test State changes from Executing to Success.
154
Tuned values populate the Loop and Load parameter tables. Actual bandwidth values (Hz) depend on your application and can require adjustment once motor and load are connected.
7.
Click Accept Tuned Values.
8.
Click OK to close the Logix Designer - Autotune dialog box.
9.
Click OK to close the Axis Properties dialog box.
10.
If the test fails, this dialog box appears.
a. Click OK.
b. Make an adjustment to motor velocity.
c. Refer to the controller user manual for more information.
d. Return to
step 6 and run the test again.
11.
Repeat
for each axis.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Safety Precautions
Chapter
7
Troubleshoot the Kinetix 5500 Drive System
This chapter provides troubleshooting tables and related information for your
Kinetix® 5500 servo drives.
Topic
Logix 5000 Controller and Drive Behavior
Page
Observe the following safety precautions when troubleshooting your
Kinetix 5500 servo drive.
ATTENTION:
Capacitors on the DC bus can retain hazardous voltages after input power has been removed. Before working on the drive, measure the DC bus voltage to verify that 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.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
155
Chapter 7
Troubleshoot the Kinetix 5500 Drive System
Interpret 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, contact your Rockwell Automation sales representative for further assistance.
Display Interface
The LCD display provides fault messages and troubleshooting information by using the soft menu items and navigation buttons.
MAIN MENU
DIAGNOSTICS
FAULT LOG
Under the Main Menu, select FAULT LOG by using the up/down arrows.
?
Press to display the list of active fault codes.
Press again to display the fault details (the problem in troubleshooting tables).
Press to display the fault help (possible solutions in troubleshooting tables).
Refer to
Understand the Kinetix 5500 Display on page 108 for more
information on navigating the LCD display menu.
Fault Code Overview
The fault code tables are designed to help you determine the source of the fault or exception. When a fault condition is detected, the drive performs the appropriate fault action, the fault is displayed, and the fault is added to a persistent fault log (along with diagnostics data). The earlier faults have priority to be displayed.
The drive removes the fault text from the display when a Fault Reset service is sent from the controller and the fault is no longer active. If a fault is still active following a Fault Reset service, the fault is again posted to the display and written to the fault log.
However, there is a delay before the fault is posted again. In a Studio 5000
Logix Designer® application, this delay results as the AxisFault tag on the drive axis being cleared until the fault is posted again. During this delay, the
AxisState tag continues to indicate that the axis is faulted. Use the AxisState tag on the axis object and only to determine if an axis is faulted.
Although software overtravel fault codes do not exist, software overtravel detection for the AXIS_CIP_DRIVE axis type is determined in the
Logix 5000™ controller. For more information, see Integrated Motion on the
EtherNet/IP™ Network Reference Manual, publication MOTION-RM003 .
The drive maintains a log of the last 128 faults with time stamps and is stored in persistent memory. However, the fault log cannot be cleared on the drive.
156
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Troubleshoot the Kinetix 5500 Drive System
Chapter 7
Table 56 - Fault Code Summary
Fault Code Type
FLT S
FLT M
xx xx
(1) (2)
Description
Standard runtime axis exceptions. The exception can apply to an individual axis or to all axes.
Manufacturer-specific runtime axis exception. The exception can apply to an individual axis or to all axes.
INIT FLT S
xx
INIT FLT M
xx
Exceptions that prevent normal operation and occur during the initialization process.
NODE FLT
xx
NODE ALARM
xx
Exceptions that can prevent normal operation of the drive module and apply to the entire module and affect all axes.
Exceptions that can prevent normal operation of the drive module, but do not result in any action other than reporting the alarm to the controller.
INHIBIT S
xx
INHIBIT M
xx
ALARM S
xx
ALARM M
xx
SAFE FLT
xx
Conditions that prevent normal operation and indicate that the drive module is prevented from being enabled.
An underlying exception condition that does not result in any action other than reporting the alarm to the controller.
Exception that is generated by a fault condition that is detected in the safety function.
(1) S
xx
refers to Standard exceptions.
(2) M
xx
refers to Manufacturer-specific exceptions.
TIP
Fault codes that are triggered by conditions that fall outside factory-set limits are identified by FL at the end of the display message. For example, FLT S07 – MTR OVERLOAD FL.
Fault codes that are triggered by conditions that fall outside user-set limits are identified by UL at the end of the display message. For example, FLT S08 – MTR OVERLOAD UL.
Fault Codes
For fault code descriptions and possible solutions, see the Kinetix 5500 Fault
Codes.xlsx file attached to this publication. For more information about the
file, see Access the Attachments on page 12 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
157
Chapter 7
Troubleshoot the Kinetix 5500 Drive System
Kinetix 5500 Servo Drive
Ethernet RJ45 Connectors
Module Status
Network Status
Link Speed
Status Indicators
Link/Activity
Status Indicators
Kinetix 5500 Drive Status Indicators
The module status and network status indicators are just above the LCD status display.
IMPORTANT
Status indicators are not reliable for safety functions. Use them only for general diagnostics during commissioning or troubleshooting. Do not attempt to use status indicators to determine operational status.
Table 57 - Module Status Indicator
Condition
Steady Off
Steady Green
Flashing Green
Flashing Red
Steady Red
Flashing Green/Red
Status
No power applied to the drive.
Drive is operational. No faults or failures.
Standby (drive not configured).
Major recoverable fault. The drive detected a recoverable fault, for example, an incorrect or inconsistent configuration.
Major fault. The drive detected a non-recoverable fault.
Self-test. The drive performs self-test during powerup.
Table 58 - Network Status Indicator
Condition
Steady Off
Flashing Green
Steady Green
Flashing Red
Steady Red
Flashing Green/Red
Status
No power applied to the drive or IP address is not configured.
Drive connection is not established, but has obtained an IP address.
Drive connection is established. Normal operation.
Connection timeout. One or more of the connections, for which this drive is the target, has timed out.
Duplicate IP address. IP address specified is already in use.
Self-test. The drive performs self-test during powerup.
Table 59 - Ethernet Link Speed Status Indicator
Condition
Steady Off
Steady On
Status
10 Mbit
100 Mbit
Table 60 - Ethernet Link/Activity Status Indicator
Condition
Steady Off
Steady On
Blinking
Status
No link
Link established
Network activity
158
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Troubleshoot the Kinetix 5500 Drive System
Chapter 7
Kinetix 5500 Capacitor Module Status Indicators
Kinetix 5500 Capacitor Module
Module Status
Indicator
Module Status
(MS) Connector
The capacitor module status indicator and module status (MS) connector are on the front of the module. The module status connector is a relay output suitable for wiring to the Logix 5000 controller.
Table 61 - Module Status Indicator and Relay Output
Module Status
Indicator
Steady Green
Relay
Output
(1)
Closed
Status Resolution
Flashing Green
Flashing Red
Steady Red
Open
Open
Open
Bus is fully charged and no faults exist.
N/A
Control power is present and bus is waiting to charge up.
N/A
Recoverable fault
(precharge or overvoltage fault).
Internal, non-recoverable fault condition inside the module.
• Cycle control and bus power
• Verify that AC input meets specifications
• Cycle control and bus power
• Verify that AC input meets specifications
• Replace the module if fault persists
(1) Wiring the module status relay output to the Logix 5000 controller is optional.
General Troubleshooting
These conditions do not always result in a fault code, but can require troubleshooting to improve performance.
Condition
Axis or system is unstable.
You cannot obtain the motor acceleration/deceleration that you want.
Potential Cause
The position feedback device is incorrect or open.
Unintentionally in Torque mode.
Motor tuning limits are set too high.
Possible Resolution
Check wiring.
Check to see what primary operation mode was programmed.
Run Tune in the Logix Designer application.
Position loop gain or position controller accel/decel rate is improperly set.
Run Tune in the Logix Designer application.
Improper grounding or shielding techniques are causing noise to be transmitted into the position feedback or velocity command lines, causing erratic axis movement.
Check wiring and ground.
Motor Select limit is incorrectly set (servo motor is not matched to axis module).
• Check setups.
• Run Tune in the Logix Designer application.
Mechanical resonance.
Torque Limit limits are set too low.
Incorrect motor selected in configuration.
The system inertia is excessive.
The system friction torque is excessive.
Available current is insufficient to supply the correct accel/decel rate.
Acceleration limit is incorrect.
Velocity Limit limits are incorrect.
The motor is operating in the field-weakening range of operation.
• Notch filter or output filter can be required (refer to Axis
Properties dialog box, Output tab in the Logix Designer application).
• Enable adaptive tuning. See
for more notch filter information.
Verify that torque limits are set properly.
Select the correct motor and run Tune in the Logix Designer application again.
• Check motor size versus application need.
• Review servo system sizing.
Check motor size versus application need.
• Check motor size versus application need.
• Review servo system sizing.
Verify limit settings and correct them, as necessary.
Verify limit settings and correct them, as necessary.
Reduce the commanded acceleration or deceleration.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
159
Chapter 7
Troubleshoot the Kinetix 5500 Drive System
Condition
Motor does not respond to a command.
Presence of noise on command or motor feedback signal wires.
No rotation
Motor overheating
Abnormal noise
Potential Cause
The axis cannot be enabled until stopping time has expired.
The motor wiring is open.
The motor cable shield connection is improper.
The duty cycle is excessive.
The rotor is partially demagnetized causing excessive motor current.
Motor tuning limits are set too high.
Loose parts are present in the motor.
Possible Resolution
Disable the axis, wait for 1.5 seconds, and enable the axis.
Check the wiring.
• Check feedback connections.
• Check cable shield connections.
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 torque limits are set incorrectly.
Brake connector not wired
Recommended grounding per installation instructions have not been followed.
Line frequency can be present.
Check and correct the mechanics.
Variable frequency can be velocity feedback ripple or a disturbance caused by gear teeth or ballscrew, and so forth. The frequency can be a multiple of the motor power transmission components or ballscrew speeds resulting in velocity disturbance.
• Decouple the motor for verification.
• Check and improve mechanical performance, for example, the gearbox or ballscrew mechanism.
The motor connections are loose or open.
Foreign matter is lodged in the motor.
Check motor wiring and connections.
Remove foreign matter.
The motor load is excessive.
The bearings are worn.
The motor brake is engaged (if supplied).
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.
Check and properly set the limit.
Check and properly set the limits.
Check brake wiring
• 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.
Check coupling.
Change the command profile to reduce accel/decel or increase time.
Return the motor for repair.
Run Tune in the Logix Designer application.
• Remove the loose parts.
• Return motor for repair.
• Replace motor.
Through bolts or coupling is loose.
The bearings are worn.
Mechanical resonance.
Tighten bolts.
Return motor for repair.
Notch filter can be required (refer to Axis Properties dialog box,
Output tab in the Logix Designer application).
Erratic operation - Motor locks into position, runs without control or with reduced torque.
Motor power phases U and V, U and W, or V and W reversed.
Check and correct motor power wiring.
160
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Troubleshoot the Kinetix 5500 Drive System
Chapter 7
Logix 5000 Controller and
Drive Behavior
By using the Logix Designer application, you can configure how the
Kinetix 5500 drives respond when a drive fault/exception occurs.
TIP
The INIT FLT
xxx
faults are always generated after powerup, but before the drive is enabled, so the stopping behavior does not apply.
NODE ALARM
xxx
faults do not apply because they do not trigger stopping behavior.
The drive supports fault actions for Ignore, Alarm, Minor Fault, and Major
Fault as defined in Table 62 . The drive also supports three configurable
stopping actions as defined in
.
Refer to the drive behavior tables beginning on page 163 to see how the fault
and stopping actions apply to each of the exception fault codes.
Table 62 - Kinetix 5500 Drive Exception Action Definitions
Exception Action
Ignore
Alarm
Minor Fault
Major Fault
Definition
The drive completely ignores the exception condition. For some exceptions that are fundamental to the operation of the planner, Ignore is not an available option.
The drive sets the associated bit in the Motion Alarm Status word, but does not otherwise affect axis behavior. Like Ignore, if the exception is so fundamental to the drive, Alarm is not an available option. When an exception action is set to Alarm, the Alarm goes away by itself when the exceptional condition has cleared.
The drive latches the exception condition but the drive does not execute any exception action.
The drive latches the exception condition and executes the configured exception action.
You can configure exception behavior in the Logix Designer application from the Axis Properties dialog box, Actions category. These controller exception actions are mapped to the drive exception actions.
Table 63 - Logix Designer Exception Action Definitions
Exception Action
Ignore
Alarm
Fault Status Only
Definition
The controller completely ignores the exception condition. For some exceptions that are fundamental to the operation of the planner, Ignore is not an available option.
The controller sets the associated bit in the Motion Alarm Status word, but does not otherwise affect axis behavior. Like Ignore, if the exception is so fundamental to the drive, Alarm is not an available option. When an exception action is set to Alarm, the Alarm goes away by itself when the exceptional condition has cleared.
Like Alarm, Fault Status Only instructs the controller to set the associated bit in the Motion Fault
Status word, but does not otherwise affect axis behavior. However, unlike Alarm an explicit Fault
Reset is required to clear the fault once the exceptional condition has cleared. Like Ignore and
Alarm, if the exception is so fundamental to the drive, Fault Status Only is not an available option.
Stop Planner
StopDrive (v31 and earlier)
Disable (v32 and later)
The controller sets the associated bit in the Motion Fault Status word and instructs the Motion
Planner to perform a controlled stop of all planned motion at the configured maximum deceleration rate. An explicit Fault Reset is required to clear the fault once the exceptional condition has cleared.
If the exception is so fundamental to the drive, Stop Planner is not an available option.
When the exception occurs, the associated bit in the Fault Status word is set and the axis comes to a stop by using the stopping action defined by the drive for the particular exception that occurred.
There is no controller based configuration to specify what the stopping action is, the stopping action is device dependent.
Shutdown
When the exception occurs, the drive brings the motor to a stop by using the stopping action defined by the drive (as in Stop Drive) and the power module is disabled. An explicit Shutdown
Reset is required to restore the drive to operation.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
161
Chapter 7
Troubleshoot the Kinetix 5500 Drive System
For Kinetix 5500 drives, only selected exceptions are configurable. In the drive behavior tables, the controlling attribute is given for programmable fault actions.
Table 64 - Configurable Stopping Actions
Stopping Action
Decel and hold
Decel and disable
(1)
Disable and coast
Description
Most control
Less control
Least control
The best available stopping action is the one that maintains the most control over the motor. However, not all faults support every stopping action.
(1) When configured for Frequency Control (induction motors only), select Decel and disable only when the Current Limiting feature
is enabled. For more information on this feature, see Current Limiting for Frequency Control
on
When configured for Frequency Control (IM motors only), Decel and disable should only be selected when the Current Limiting feature has been enabled.
For more information on this feature, refer to
Only selected drive exceptions are configurable. In the drive behavior tables, the controlling attribute is given for programmable fault actions.
TIP
In the Logix Designer application, version 32 and later, Disable replaced
StopDrive as the default Action.
Figure 71 - Logix Designer Axis Properties - Actions Category
162
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Troubleshoot the Kinetix 5500 Drive System
Chapter 7
This dialog box applies to Kinetix 5500 (EtherNet/IP network) servo drives.
FLT S02 – MTR COMMUTATION
FLT S03 – MTR OVERSPEED FL
FLT S04 – MTR OVERSPEED UL
FLT S05 – MTR OVERTEMP FL
FLT S07 – MTR OVERLOAD FL
FLT S08 – MTR OVERLOAD UL
FLT S10 – INV OVERCURRENT
FLT S11 – INV OVERTEMP FL
FLT S13 – INV OVERLOAD FL
FLT S14 – INV OVERLOAD UL
FLT S15 – CONV OVERCURRENT
FLT S16 – GROUND CURRENT
FLT S18 – CONV OVERTEMP FL
FLT S20 – CONV OVERLOAD FL
FLT S21 – CONV OVERLOAD UL
FLT S23 – AC PHASE LOSS
FLT S25 – PRECHARGE FAILURE
FLT S29 – BUS OVERLOAD FL
FLT S30 – BUS OVERLOAD UL
FLT S31 – BUS REG FAILURE
FLT S33 – BUS UNDERVOLT FL
FLT S34 – BUS UNDERVOLT UL
FLT S35 – BUS OVERVOLT FL
FLT S39 – BUS POWER LEAKAGE
FLT S45 – FDBK COMM FL
(1)
FLT S47 – FDBK DEVICE FAILURE
FLT S49 – BRAKE SLIP FLT
FLT S50 – POS HW OTRAVEL
Table 65 - Drive Behavior, FLT S
xx
Fault Codes
Exception Fault Code Exception Text
Motor Commutation Fault
Motor Overspeed
Factory Limit Fault
Motor Overspeed
User Limit Fault
Motor Overtemperature
Factory Limit Fault
Motor Thermal Overload
Factory Limit Fault
Motor Thermal OverLoad
User Limit Fault
Inverter Overcurrent Fault
Inverter Overtemperature
Factory Limit Fault
Inverter Thermal Overload
Factory Limit Fault
Inverter Thermal Overload
User Limit Fault
Converter Overcurrent Fault
Ground Current
Factory Limit Fault
Converter OverTemp
Factory Limit Fault
Converter Thermal OverLoad
Factory Limit Fault
Converter Thermal Overload
User Limit Fault
AC Single Phase Loss Fault
Pre-charge Failure Fault
Bus Regulator Thermal
OverLoad
Factory Limit Fault
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Bus Regulator Thermal Overload
User Limit Fault
Bus Regulator Failure
X
X
Bus Undervoltage
Factory Limit Fault
Bus Undervoltage
User Limit Fault
Bus Overvoltage
Factory Limit Fault
Bus Power Leakage Fault
X
X
X
X
Motor Feedback Data Loss
Factory Limit Fault
Feedback Device Failure
X
X
Brake Slip Exception X
Hardware Overtravel - Positive X
X
X
Permanent
Magnet Motor
Induction Motor
Fault Action
X
X
X
X
X
X
X
X
X
–
–
X
X
X
X
X
X
X
X
X
X
X
–
–
–
X
X
X
–
X
–
–
–
X
–
–
X
–
–
–
X
X
–
–
–
–
X
–
–
X
–
–
X
X
–
–
–
X
–
–
–
X
–
–
X
–
–
–
X
X
–
–
–
–
X
–
–
X
–
–
X
X
–
–
–
X
–
–
–
X
–
–
X
–
–
–
X
X
–
–
–
–
X
–
–
X
–
–
X
X
–
–
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Best Available
Stopping Action
(applies to major faults)
Disable/Coast
Disable/Coast
Decel/Hold
Disable/Coast
Decel/Disable
Decel/Hold
Disable/Coast
Disable/Coast
Disable/Coast
Decel/Hold
Disable/Coast
Disable/Coast
Disable/Coast
Disable/Coast
Decel/Hold
Decel/Disable
Disable/Coast
Disable/Coast
Decel/Hold
Disable/Coast
Decel/Disable
Decel/Hold
Disable/Coast
Decel/Disable
Disable/Coast
Disable/Coast
Decel/Hold
Decel/Hold
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
163
Chapter 7
Troubleshoot the Kinetix 5500 Drive System
Table 65 - Drive Behavior, FLT S
xx
Fault Codes (continued)
Exception Fault Code Exception Text
Permanent
Magnet Motor
Induction Motor
Fault Action
FLT S51 – NEG HW OTRAVEL
FLT S54 – POSN ERROR
FLT S57 – UNDERTORQUE LIMIT
Hardware Overtravel - Negative
Excessive Position Error Fault
Excessive Velocity Error Fault
Overtorque Limit Fault
Undertorque Limit Fault
(1) Does not apply to induction motors in frequency control mode.
X
X
X
X
X
Table 66 - Drive Behavior, FLT M
xx
Fault Codes
Exception Fault Code Exception Text
X
–
–
–
–
X
X
X
X
X
Permanent
Magnet Motor
Induction Motor
Fault Action
X
X
X
X
X
FLT M02 – MOTOR VOLTAGE
FLT M25 – COMMON BUS
FLT M26 – RUNTIME ERROR
FLT M28 – SAFETY COMM
(2198-H
xxx
-ERS2 drives only)
Motor Voltage Mismatch Fault X
DC Common Bus Fault
Runtime Error
Safety Module Communication
Error
X
X
X
Table 67 - Drive Behavior, NODE FLT Fault Codes
Exception Fault Code Exception Text
X
X
X
X
X
–
–
–
Permanent
Magnet Motor
Induction Motor
Fault Action
X
–
–
–
NODE FLT 01 – LATE CTRL UPDATE
NODE FLT 02 – PROC WATCHDOG
NODE FLT 03 – HARDWARE
NODE FLT 05 – CLOCK SKEW FLT
NODE FLT 06 – LOST CTRL CONN
Control Connection Update
Fault
Processor Watchdog Fault
Hardware Fault
NODE FLT 07 – CLOCK SYNC Clock Sync Fault
NODE FLT 09 – DUPLICATE IP ADDRESS Duplicate IP Address Fault
X
Clock Skew Fault X
Lost Controller Connection Fault X
X
X
X
X
X
X
X
X
X
X
X
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
X
X
X
X
X
X
–
–
–
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Best Available
Stopping Action
(applies to major faults)
Decel/Hold
Disable/Coast
Disable/Coast
Decel/Hold
Decel/Hold
Best Available
Stopping Action
(applies to major faults)
Disable/Coast
Decel/Disable
Disable/Coast
Disable/Coast
Best Available
Stopping Action
(applies to major faults)
Decel/Disable
Disable/Coast
Disable/Coast
Disable/Coast
Decel/Disable
Disable/Coast
Disable/Coast
164
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Before You Begin
Chapter
8
Remove and Replace Servo Drives
This chapter provides remove and replace procedures for Kinetix® 5500 drives.
Topic
Remove and Replace Kinetix 5500 Servo Drives
Page
ATTENTION:
This drive contains electrostatic discharge (ESD) 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, refer to Guarding Against Electrostatic Damage, publication 8000-4.5.2
, or any other applicable ESD awareness handbook.
When each drive is installed, network settings are configured from the setup screens. Before removing the drive, revisit the Network menu and make note of
the static IP or DHCP settings. Refer to Configure the Drive on page 113 to
access those settings.
IMPORTANT
If you intend to use the same Logix Designer application after replacing your drive, the new drive must be the same catalog number as the old drive.
You also need these tools available before you begin removal and replacement procedures:
• Screwdrivers (to loosen/remove screws)
• Voltmeter (to make sure no voltage exists on drive connectors)
• Non-conductive probe for removing DC bus T-connectors
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
165
Chapter 8
Remove and Replace Servo Drives
Remove and Replace
Kinetix 5500 Servo Drives
166
Follow these steps to remove and replace servo drives from the panel.
Remove Power and All Connections
1.
Verify that all control and input power has been removed from the system.
ATTENTION:
To avoid shock hazard or personal injury, make sure that all power has been removed before proceeding. This system can have multiple sources of power. More than one disconnect switch can be required to de-energize the system.
2.
Wait five minutes for the DC bus to discharge completely before proceeding.
SHOCK HAZARD:
This product contains stored energy devices. To avoid the hazard of electrical shock, verify that voltage on capacitors has been discharged before attempting to service, repair, or remove this unit. Do not attempt the procedures in this document unless you are qualified to do so and are familiar with solid-state control equipment and the safety procedures in publication NFPA 70E.
3.
Label and remove all wiring connectors from the drive you are removing.
To identify each connector, refer to
on
TIP
You do not need to remove the shunt (RC) connector, unless there is an external shunt wired to it.
4.
Remove the shared-bus input wiring connectors, T-connectors, and busbars from the drive you are removing.
IMPORTANT
DC bus T-connectors latch on both sides when inserted into the drive. To remove the DC bus T-connector, at least one latch must be pried away with a non-conductive probe.
Refer to
Shared-bus Connection System on page 51 .
5.
Use a screwdriver to loosen the two cable clamp screws, removing the screw on the right.
Retention Screw
(loosen, do not remove)
Motor Cable
6.
Remove the single motor cable from the cable shield clamp.
7.
Remove the ground screw and braided ground strap.
Refer to
Ground the System Subpanel on page 80 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Remove and Replace Servo Drives
Chapter 8
Remove the Servo Drive
You can remove single-axis drives from the panel or any single drive from a multi-axis configuration by using the same procedure.
IMPORTANT
This procedure applies to any 2198-H
xxx
-ERS
x
drive in any configuration.
Top Screws
(bottom screws not shown)
Follow these steps to remove Kinetix 5500 servo drives from the panel.
1.
Loosen the top and bottom screws of the drive to remove.
Frame 1 and 2 drives have one top and bottom screw. Frame 3 drives have two top and bottom screws.
2.
Grasp the top and bottom of the drive with both hands and pull the drive straight out and away from the panel, clearing the zero-stack mounting tabs and cutouts.
2
1
Kinetix 5500 Servo Drives
(removing middle drive)
Replace the Servo Drive
To replace the servo drive, reverse the steps shown above or refer to Mount
Your Kinetix 5500 Drive on page 60 :
• Torque mounting, shield clamp, and ground screws to 2.0 N•m
(17.7 lb•in), max
• Reconnect the feedback connector kit and torque the mounting screws to 0.4 N•m (3.5 lb•in), max
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
167
Chapter 8
Remove and Replace Servo Drives
Start and Configure the Drive
Follow these steps to configure the replacement drive.
IMPORTANT
If you intend to use the same Logix Designer application after replacing your drive, the new drive must be the same catalog number as the old drive.
IMPORTANT
If a 2198-H
xxx
-ERS2 drive was previously configured by a safety controller,
reset the drive to the Out of Box state. Refer to Out-of-Box State
on
1.
Reapply power to the drive/system.
Refer to
Apply Power to the Kinetix 5500 Drive on page 143
for the procedure.
2.
Configure the network settings for the drive.
a. If your old drive was configured as Static IP, you need to set the IP address, gateway, and subnet mask in the new drive identical to the old drive.
Refer to Configure the Drive on page 113 to access those settings.
b. If you replaced a 2198-H
xxx
-ERS2 servo drive in an integrated safety
application, review Understand Integrated Safety Drive Replacement
on
page 183 and follow the appropriate procedure in
Integrated Safety Drive in a GuardLogix System on page 184 to
properly set the safety network number for the new drive.
3.
Download the Logix Designer application to the controller.
4.
Verify the drive/system is working properly.
168
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Certification
Chapter
9
Kinetix 5500 Safe Torque-off - Hardwired
Safety
The 2198-H
xxx
-ERS servo drives are equipped for hardwired safe torque-off
(STO). The hardwired STO function meets the requirements of Performance
Level d (PLd) and safety category 3 (CAT 3) per ISO 13849-1 and SIL 2 per
IEC 61508, IEC 61800-5-2 and IEC 62061.
Topic
Probability of Dangerous Failure Per Hour
Safe Torque-off Connector Data
Wire the Safe Torque-off Circuit
Safe Torque-off Specifications
Page
A ControlLogix® 5570, ControlLogix 5580, CompactLogix™ 5370, or
CompactLogix 5380 controller is required for hardwired safety control of the
Kinetix® 5500 safe torque-off function. The 2198-H
xxx
-ERS servo drives use the STO connector for wiring external safety devices and cascading hardwired safety connections from one drive to another.
The TÜV Rheinland group has approved 2198-H
xxx
-ERS servo drives with hardwired safe torque-off for use in safety-related applications up to
ISO 13849-1, Performance Level d (PL d) and Category 3, SIL CL 2 per
IEC 61508, IEC 61800-5-2, and IEC 62061, in which removing the motion producing power is considered to be the safe state.
For product certifications currently available from Rockwell Automation, go to website rok.auto/certifications .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
169
Chapter 9
Kinetix 5500 Safe Torque-off - Hardwired Safety
Important Safety Considerations
The system user is responsible for the following:
• Validation of any sensors or actuators connected to the system
• Completing a machine-level risk assessment
• Certification of the machine to the desired ISO 13849-1 performance level or IEC 62061 SIL level
• Project management and proof testing in accordance with
ISO 13849
Category 3 Requirements According to ISO 13849-1
Safety-related parts are designed with these attributes:
• A single fault in any of these parts does not lead to the loss of the safety function.
• A single fault is detected whenever reasonably practicable.
• Accumulation of undetected faults can lead to the loss of the safety function and a failure to remove motion producing power from the motor.
Stop Category Definition
Stop Category 0 as defined in IEC 60204 or safe torque-off as defined by
IEC 61800-5-2 is achieved with immediate removal of motion producing power to the actuator.
IMPORTANT
In the event of a malfunction, the most likely stop category is Stop Category
0. When designing the machine application, timing and distance must be considered for a coast to stop. For more information regarding stop categories, refer to IEC 60204-1.
Performance Level (PL) and Safety Integrity Level (SIL)
For safety-related control systems, Performance Level (PL), according to ISO
13849-1, and SIL levels, according to IEC 61508 and IEC 62061, include a rating of the systems ability to perform its safety functions. All of the safetyrelated components of the control system must be included in both a risk assessment and the determination of the achieved levels.
Refer to the ISO 13849-1, IEC 61508, and IEC 62061 standards for complete information on requirements for PL and SIL determination.
170
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Kinetix 5500 Safe Torque-off - Hardwired Safety
Chapter 9
Description of Operation
The safe torque-off feature provides a method, with sufficiently low probability of failure, to force the power-transistor control signals to a disabled state.
When disabled, or any time power is removed from the safety enable inputs, all of the drive output-power transistors are released from the ON-state. This results in a condition where the drive performs a Category 0 Stop. Disabling the power transistor output does not provide mechanical isolation of the electrical output that is required for some applications.
Under normal operation, the safe torque-off inputs are energized. If either of the safety enable inputs are de-energized, then all of the output power transistors turn off. The safe torque-off response time is less then 12 ms.
ATTENTION:
Permanent magnet motors can, in the event of two simultaneous faults in the IGBT circuit, result in a rotation of up to 180 electrical degrees.
ATTENTION:
If any of the safety enable inputs de-energize, the Start Inhibit field indicates SafeTorqueOffInhibit and GuardStopRequestStatus bit of
AxisGuardStatus tag set to 1. Both inputs must be de-energized within 1 second and re-energized within 1 second to avoid GuardStopInputFault conditions.
Figure 72 - System Operation when Inputs are Meeting Timing Requirements
SS_IN_CH0
24V DC
0V DC
24V DC
SS_IN_CH1
0V DC
1
GuardStopInputFault
0
1
GuardStopRequestStatus
0
1 Second
100 ms
1 2 3 4 5 6
3
4
Event Description
1 At least one input is switched-off. GuardStopRequestStatus bit is set to 1.
2
Second input is switched-off within 1 second. This event must always occur prior to Event 3 to prevent
GuardStopInputFault.
5
6
First input is switched-on.
Second input is switched-on within 1 second of event 3.
Both inputs are in OFF state simultaneously within 1 second. As a result, GuardStopInputFault is not posted.
The GuardStopRequestStatus bit sets back to 0 if event 4 occurs within a 100 ms interval after event 3. If event 4 is outside of the 100 ms interval, but within the a 1 second interval after event 3, then the
GuardStop RequestStatus bit sets back to 0 after the 1 second interval following event 3 (not immediately following event 4).
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
171
Chapter 9
Kinetix 5500 Safe Torque-off - Hardwired Safety
Fault Codes
For fault code descriptions and possible solutions, see the Kinetix 5500 Fault
Codes.xlsx file attached to this publication. For more information about the
file, see Access the Attachments on page 12 .
Figure 73 demonstrates when the safe torque-off mismatch is detected and a
GuardStopInputFault is posted.
Figure 73 - System Operation in the Event that the Safety Enable Inputs Mismatch
SS_IN_CH0
24V DC
0V DC
24V DC
SS_IN_CH1
GuardStopInputFault
SafeTorqueOffInhibit
0V DC
1
0
1
0
1 Second
When one safety input is turned off, the second input must also be turned off, otherwise a fault is asserted (see Figure 74 ). The fault is asserted even if the first safety input is turned on again, without the second input transitioning to the
ON state.
Figure 74 - System Operation in the Event that the Safety Enable Inputs Mismatch
Momentarily
SS_IN_CH0
24V DC
SS_IN_CH1
GuardStopInputFault
SafeTorqueOffInhibit
0V DC
24V DC
0V DC
1
0
1
0
1 Second
ATTENTION:
The safe torque-off fault is detected upon demand of the safe torque-off function. After troubleshooting the STO function or performing maintenance that might affect the STO function, the STO function must be executed to verify correct operation.
IMPORTANT
The GuardStopInputFault can be reset only if both inputs are in the OFFstate for more than 1 second. After the fault reset requirement is satisfied, an MAFR command in the Logix Designer application must be issued to reset the GuardStopInputFault.
172
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Probability of Dangerous
Failure Per Hour
Kinetix 5500 Safe Torque-off - Hardwired Safety
Chapter 9
Safety-related systems are classified as operating in a High-demand/continuous mode. The SIL value for a High-demand/continuous mode safety-related system is directly related to the probability of a dangerous failure occurring per hour (PFH).
PFH calculation is based on the equations from IEC 61508 and show worstcase values. Table 68 provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the data.
IMPORTANT
Determination of safety parameters is based on the assumptions that the system operates in High-demand mode and that the safety function is requested at least once every three months.
Table 68 - PFH for 20-year Proof Test Interval
Attribute
PFH (1e-9)
Proof test (years)
Value
0.35
20
Safe Torque-off Connector
Data
The 10-pin connector consists of two parallel 5-pin rows for cascading safety connections from drive-to-drive in multi-axis configurations.
Figure 75 - Pin Orientation for 10-pin Safe Torque-off (STO) Connector
Pin 1
SB+
SB-
S1
SC
S2
Table 69 - Safe Torque-off (STO) Connector Pinouts
3
4
5
STO Pin Description
1
2
Safety bypass plus signal. Connect to both safety inputs to disable the STO function.
Safety bypass minus signal. Connect to safety common to disable the STO function.
STO input 1 (SS_IN_CH0).
STO input common (SCOM).
STO input 2 (SS_IN_CH1).
Signal
SB+
SB-
S1
SC
S2
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
173
Chapter 9
Kinetix 5500 Safe Torque-off - Hardwired Safety
Wire the Safe Torque-off
Circuit
This section provides guidelines for wiring your Kinetix 5500 safe torque-off drive connections.
IMPORTANT
The National Electrical Code and local electrical codes take precedence over the values and methods provided.
IMPORTANT
To improve system performance, run wires and cables in the wireways as
established in Establishing Noise Zones beginning on page 44 .
IMPORTANT
Pins ST0-1 and ST0-5 (SB+ and SB-) are used to disable the safe torque-off function. When wiring to the STO connector, use an external 24V supply for the external safety device that triggers the safe torque-off request. To avoid jeopardizing system performance, do not use pin ST0-1 as a power supply for the external safety device.
174
Safe Torque-off Wiring Requirements
The safe torque-off (STO) connector uses spring tension to secure the wire.
Depress the tab, along side each pin, to insert or release the wire. Two rows of pins are provided for drive-to-drive connections. Wire must be copper with
75 °C (167 °F) minimum rating.
IMPORTANT
Stranded wires must terminate with ferrules to prevent short circuits, per table D7 of ISO 13849-1.
Figure 76 - Safe Torque-off (STO) Terminal Plug
Kinetix 5500 Drive
Top View
1
2
3
4
5
SB+
SB-
S1
SC
S2 r DC
Remo
Bus Only
Table 70 - Safe Torque-off (STO) Terminal Plug Wiring
Safe Torque-off (STO) Connector
Pin Signal
Recommended Wire
Size
mm
2
(AWG)
STO-1
STO-2
STO-3
STO-4
STO-5
SB+
SB-
S1
SC
S2
0.2…1.5
(24…16)
(1) This connector uses spring tension to hold the wires in place.
Strip Length
mm (in.)
10 (0.39)
Torque Value
N•m (lb•in)
N/A
(1)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Safe Torque-off Feature
Kinetix 5500 Safe Torque-off - Hardwired Safety
Chapter 9
The safe torque-off circuit, when used with suitable safety components, provides protection according to ISO 13849-1 (PLd), Category 3 or according to IEC 61508, IEC 61800-5-2, and IEC 62061 (SIL CL2). All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding.
The safe torque-off circuit is designed to safely turn off all of the output-power transistors. You can use the safe torque-off circuit in combination with other safety devices to achieve Stop Category 0 and protection-against-restart as specified in IEC 60204-1.
ATTENTION:
This option is suitable only for performing mechanical work on the drive system or affected area of a machine. It does not provide electrical safety.
SHOCK HAZARD:
In Safe Torque-off mode, hazardous voltages can still be present at the drive. To avoid an electric shock hazard, disconnect power to the system and verify that the voltage is zero before performing any work on the drive.
ATTENTION:
Personnel responsible for the application of safety-related programmable electronic systems (PES) shall be aware of the safety requirements in the application of the system and shall be trained in using the system.
Safe Torque-off Feature Bypass
The 2198-H
xxx
-ERS drives do not operate without a safety circuit or safety bypass wiring. For applications that do not require the safe torque-off feature you must install jumper wires to bypass the safe torque-off circuitry.
Each 2198-H
xxx
-ERS drive includes one 10-pin wiring plug for wiring to safety devices. To bypass the safety function, wire these signals as shown in
Figure 77 . With the jumper wires installed, the safe-off feature is not used.
Figure 77 - Safe Torque-off Bypass Wiring
Pin 1 SB+
SB-
S1
SC
S2
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
175
Chapter 9
Kinetix 5500 Safe Torque-off - Hardwired Safety
Dual-channel
Equivalent
Safety Device
Cascade the Safe Torque-off Signal
The total number of drives in a single cascaded safety circuit is limited by the current carrying capacity of the cascaded safety wiring. Refer to Table 71 for current rating per channel, per drive.
Figure 78 - Cascaded Safe Torque-off Wiring
Middle Drive
Last Drive
SB+
SB-
S1
SC
S2
First Drive
Pin 1
Pin 1
24V DC
Safe Torque-off
Specifications
To maintain safety rating, Kinetix 5500 drives must be installed inside protected control panels or cabinets appropriate for the environmental conditions of the industrial location. The protection class of the panel or cabinet must be IP54 or higher.
Table 71 - Safe Torque-off Signal Specifications
Attribute
Safety inputs
(per channel)
Input current
Input ON voltage range
Input OFF current, max
(@ V in < 5V DC)
Value
< 10 mA
18…26.4V DC
Input OFF voltage, max 5V DC
Input ON current, per input, max 10 mA, each drive
(1)
2 mA
Pulse rejection width
External power supply
700
μ s
SELV/PELV
Input type Optically isolated and reverse voltage protected
(1) The maximum number of drives cascaded with safe torque-off wiring is 50.
For additional information regarding Allen-Bradley® safety products, including safety relays, light curtain, and gate interlock applications, refer to https://ab.rockwellautomation.com/Safety .
176
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Certification
Chapter
10
Kinetix 5500 Safe Torque-off - Integrated
Safety
The 2198-H
xxx
-ERS2 servo drives are equipped for integrated safe torque-off
(STO). The integrated STO function meets the requirements of Performance
Level e (PLe) and safety category 3 (CAT 3) per ISO 13849-1 and SIL 3 per
IEC 61508, IEC 61800-5-2 and IEC 62061.
With integrated safety, the GuardLogix® 5570 or Compact GuardLogix 5570 safety controller issues the safe torque-off (STO) command over the
EtherNet/IP™ network and the 2198-H
xxx
-ERS2 servo drive executes the
STO command.
Topic
Probability of Dangerous Failure Per Hour
Understand Integrated Safety Drive Replacement
Replace an Integrated Safety Drive in a GuardLogix System
Motion Direct Commands in Motion Control Systems
Safe Torque-off Specifications
Safe Torque-off Specifications
Page
The TÜV Rheinland group has approved 2198-H
xxx
-ERS2 servo drives with integrated safe torque-off for use in safety-related applications up to
ISO 13849-1, Performance Level e (PL e) and Category 3, SIL CL 3 per
IEC 61508, IEC 61800-5-2, and IEC 62061, in which removing the motion producing power is considered to be the safe state.
For product certifications currently available from Rockwell Automation, go to website rok.auto/certifications .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
177
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
Important Safety Considerations
The system user is responsible for the following:
• Validation of any sensors or actuators connected to the system
• Completing a machine-level risk assessment
• Certification of the machine to the desired ISO 13849-1 performance level or IEC 62061 SIL level
• Project management and proof testing performed in accordance with
ISO 13849
Safety Application Requirements
Safety application requirements include evaluating probability of failure rates
(PFH), system reaction time settings, and functional verification tests that fulfill SIL 3 criteria. Refer to
Probability of Dangerous Failure Per Hour
on
for more PFH information.
Creating, recording, and verifying the safety signature is also a required part of the safety application development process. Safety signatures are created by the safety controller. The safety signature consists of an identification number, date, and time that uniquely identifies the safety portion of a project. This includes all safety logic, data, and safety I/O configuration.
For safety system requirements, including information on the safety network number (SNN), verifying the safety signature, and functional verification tests refer to the GuardLogix 5570 Controller Systems Safety Reference Manual, publication 1756-RM099 .
IMPORTANT
You must read, understand, and fulfill the requirements detailed in publication 1756-RM099 prior to operating a safety system that uses a
GuardLogix controller and 2198-H
xxx
-ERS2 servo drive.
Category 3 Requirements According to ISO 13849
Safety-related parts are designed with these attributes:
• A single fault in any of these parts does not lead to the loss of the safety function.
• A single fault is detected whenever reasonably practicable.
• Accumulation of undetected faults can lead to the loss of the safety function and a failure to remove motion producing power from the motor.
178
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
Stop Category Definition
Stop Category 0 as defined in IEC 60204 or safe torque-off as defined by
IEC 61800-5-2 is achieved with immediate removal of motion producing power to the actuator.
IMPORTANT
In the event of a malfunction, the most likely stop category is Stop Category
0. When designing the machine application, timing and distance must be considered for a coast to stop. For more information regarding stop categories, refer to IEC 60204-1.
Performance Level (PL) and Safety Integrity Level (SIL)
For safety-related control systems, Performance Level (PL), according to ISO
13849-1, and SIL levels, according to IEC 61508 and IEC 62061, include a rating of the systems ability to perform its safety functions. All of the safetyrelated components of the control system must be included in both a risk assessment and the determination of the achieved levels.
Refer to the ISO 13849-1, IEC 61508, and IEC 62061 standards for complete information on requirements for PL and SIL determination.
Description of Operation
The safe torque-off (STO) feature provides a method, with sufficiently low probability of failure, to force the power-transistor control signals to a disabled state. When the command to execute the STO function is received from the
GuardLogix controller, all of the drive output-power transistors are released from the ON-state. This results in a condition where the drive is coasting.
Disabling the power transistor output does not provide mechanical isolation of the electrical output that is required for some applications.
The 2198-H
xxx
-ERS2 drive STO function response time is less than 10 ms.
Response time is the delay between the time the drive STO function receives the integrated safety packet with an STO request and the time when motion producing power is removed from the motor.
STO State Reset
The 2198-H
xxx
-ERS2 servo drives support both manual and automatic restart types for exiting the STO state.
• Manual restart indicates a transition from 0 to 1 on the SO.Reset tag is required to allow torque after the SO.SafeTorqueOff tag has transitioned from 0 to 1.
• Automatic restart indicates torque will be allowed only by transitioning the SO.SafeTorqueOff tag from 0 to 1. The SO.Reset tag is used only for resetting safety faults.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
179
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
IMPORTANT
2198-H
xxx
-ERS2 servo drives enter the STO state if any STO function fault is detected.
Refer to Figure 79 for an understanding of the 2198-H
xxx
-ERS2 STO-state manual restart functionality.
Figure 79 - Kinetix 5500 STO Timing Diagram - Manual Restart
Drv:SO.SafeTorqueOff
Drv:SO.Reset
Drv:SI.ResetRequired
Drv:SI.TorqueDisabled
Axis.SafeTorqueOffActiveInhibit
Axis.SafeTorqueOffActiveStatus
Axis.SafeTorqueDisabledStatus
Axis.SafetyResetRequestStatus
Axis.SafetyResetRequiredStatus
Safe Torque-off Request
Reset Request
Fault Codes
For fault code descriptions and possible solutions, see the Kinetix® 5500 Fault
Codes.xlsx file attached to this publication. For more information about the
file, see Access the Attachments on page 12 .
180
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Probability of Dangerous
Failure Per Hour
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
Safety-related systems are classified as operating in a High-demand/continuous mode. The SIL value for a High-demand/continuous mode safety-related system is directly related to the probability of a dangerous failure occurring per hour (PFH).
PFH calculation is based on the equations from IEC 61508 and show worstcase values. Table 72 provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the data.
IMPORTANT
Determination of safety parameters is based on the assumptions that the system operates in High-demand mode and that the safety function is requested at least once every three months.
Table 72 - PFH for 20-year Proof Test Interval
Attribute
PFH (1e-9)
Proof test (years)
Value
1.54
20
Safe Torque-off Feature
The safe torque-off feature, when used with suitable safety components, provides protection according to ISO 13849-1 (PLe), Category 3 or according to IEC 61508, IEC 61800-5-2, and IEC 62061 (SIL CL3). All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding.
The safe torque-off feature is designed to safely turn off all of the output power transistors. You can use the safe torque-off feature in combination with other safety devices to achieve Stop Category 0 and protection-against-restart as specified in IEC 60204-1.
ATTENTION:
This option is designed to restrict motion producing power on the drive system or affected area of a machine. It does not provide electrical safety.
SHOCK HAZARD:
In Safe Torque-off mode, hazardous voltages can still be present at the drive. To avoid an electric shock hazard, disconnect power to the system and verify that the voltage is zero before performing any work on the drive.
ATTENTION:
Personnel responsible for the application of safety-related programmable electronic systems (PES) shall be aware of the safety requirements in the application of the system and shall be trained in using the system.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
181
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
Out-of-Box State
The 2198-H
xxx
-ERS2 servo drives ship in the out-of-box state.
ATTENTION:
In the out-of-box state, motion producing power is allowed by the safe torque-off (STO) function unless an integrated safety connection configuration has been applied to the drive at least once.
In the out-of-box state, you can configure 2198-H
xxx
-ERS2 servo drives:
• Without a GuardLogix 5570 safety controller for a non-safety application.
• With a GuardLogix 5570 safety controller when the safe torque-off
(STO) function is not required.
Out-of-Box State Support
After the integrated safety connection configuration is applied to the
2198-H
xxx
-ERS2 servo drive at least once, you can restore the drive to the outof-box state.
Follow these steps to restore your 2198-H
xxx
-ERS2 servo drive to the out-ofbox state.
1.
Right-click the 2198-H
xxx
-ERS2 servo drive you created and choose
Properties.
2.
Click the Connection tab.
The Connection tab appears.
182
3.
Check Inhibit Module.
4.
Click Apply and click the Safety tab.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
The Safety tab appears.
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
5.
In the Configuration Ownership field, click Reset Ownership.
IMPORTANT
Only authorized personnel should attempt Reset Ownership.
If any active connection is detected, the reset is rejected.
6.
Cycle drive power.
The drive is in the out-of-box state.
IMPORTANT
If power to the drive is not cycled after step 5 , the drive does not transition to the out-of-box state and maintains STO function.
IMPORTANT
When the drive returns to the out-of-box state, STO safety integrity is lost.
Understand Integrated
Safety Drive Replacement
GuardLogix controllers retain I/O device configuration on-board and are able to download the configuration to the replacement device.
IMPORTANT
If a 2198-H
xxx
-ERS2 servo drive was used previously, clear the existing configuration before installing it on a safety network by resetting the
drive to its out-of-box condition. To see how this is done, refer to Out-of-
Box State Support on page 182 .
Replacing a 2198-H
xxx
-ERS2 servo drive that sits on an integrated safety network is more complicated than replacing standard devices because of the safety network number (SNN).
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
183
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
The device number and SNN make up the safety device’s DeviceID. Safety devices require this more complex identifier to make sure that duplicate device numbers do not compromise communication between the correct safety devices. The SNN is also used to provide integrity on the initial download to the 2198-H
xxx
-ERS2 servo drive.
When the Logix Designer application is online, the Safety tab of the Module
Properties dialog box displays the current configuration ownership. When the opened project owns the configuration, Local is displayed.
Communication error is displayed if the module read fails. Refer to
Integrated Safety Drive in a GuardLogix System on page 184
for integrated safety drive replacement information.
Replace an Integrated Safety
Drive in a GuardLogix System
When you replace an integrated safety drive, the replacement device must be configured properly and the replacement drives operation be user-verified.
ATTENTION:
During drive replacement or functional test, the safety of the system must not rely on any portion of the affected drive.
Two options for safety drive replacement are available on the Safety tab of the
Controller Properties dialog box in the Logix Designer application:
• Configure Only When No Safety Signature Exists
• Configure Always
Figure 80 - Safety Drive Replacement Options
184
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
Configure Only When No Safety Signature Exists
This setting instructs the GuardLogix controller to automatically configure a safety drive only when the safety task does not have a safety task signature, and the replacement drive is in an out-of-box condition, meaning that a safety network number does not exist in the safety drive.
If the safety task has a safety task signature, the GuardLogix controller automatically configures the replacement CIP Safety™ I/O device only if the following is true:
• The device already has the correct safety network number.
• The device electronic keying is correct.
• The node or IP address is correct.
For detailed information, see the GuardLogix 5570 Controllers User Manual, publication 1756-UM022 or Compact GuardLogix 5370 Controllers User
Manual, publication 1769-UM022 .
Configure Always
When the Configure Always feature is enabled, the controller automatically checks for and connects to a replacement drive that meets all of the following requirements:
• The controller has configuration data for a compatible drive at that network address
• The drive is in Hardwired STO mode or has an SNN that matches the configuration
ATTENTION:
Enable the Configure Always feature only if the entire integrated safety control system is not being relied on to maintain SIL 3 behavior during the replacement and functional testing of a Kinetix 5500 drive. Do not place drives that are in Hardwired STO mode on an integrated safety network when the Configure Always feature is enabled.
If other parts of the integrated safety control system are being relied upon to maintain SIL 3, make sure that the controller’s Configure Always feature is disabled.
It is your responsibility to implement a process to make sure proper safety functionality is maintained during device replacement.
ATTENTION:
Do not place any devices in the out-of-box condition on any integrated safety network when the Configure Always feature is enabled, except while following the device replacement procedure in the GuardLogix user manual appropriate for your Logix 5000™ controller:
• GuardLogix 5570 Controllers User Manual, publication 1756-UM022
• Compact GuardLogix 5370 Controllers User Manual, publication
1769-UM022 .
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
185
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
Motion Direct Commands in
Motion Control Systems
You can use the Motion Direct Command (MDC) feature to initiate motion while the controller is in Program mode, independent of application code that is executed in Run mode. These commands let you do a variety of functions, for example, move an axis, jog an axis, or home an axis.
A typical use might involve a machine integrator testing different parts of the motion system while the machine is being commissioned or a maintenance engineer, under certain restricted scenarios in accordance with safe machine operating procedures, wanting to move an axis (like a conveyor) to clear a jam before resuming normal operation.
ATTENTION:
To avoid personal injury or damage to equipment, follow these rules regarding Run mode and Program mode.
• Only authorized, trained personnel with knowledge of safe machine operation should be allowed to use Motion Direct Commands
• Additional supervisory methods, like removing the controller key switch, should be used to maintain the safety integrity of the system after returning the safety controller to RUN mode
186
Understand STO Bypass When Using Motion Direct Commands
If a Safety-only connection between the GuardLogix safety controller and the
2198-H
xxx
-ERS2 servo drive was established at least once after the drive was received from the factory, the drive does not allow motion while the safety controller is in Program mode by default.
This is because the safety task is not executed while the GuardLogix safety controller is in Program mode. This applies to applications running in a singlesafety controller (with Motion and Safety connections). When an integrated safety drive has a Motion connection to a standard controller and a separate
Safety connection to a dual-safety controller, the standard controller can transition to Program mode while the safety controller stays in Run mode and continues to execute the safety task.
However, 2198-H
xxx
-ERS2 drive systems are designed with a bypass feature for the STO function in single-safety controller configurations. You can use the
MDC feature to allow motion while following all the necessary and prescribed steps per machine safety operating procedures.
ATTENTION:
Consider the consequences of allowing motion through the use of
MDC when the controller is in Program mode. You must acknowledge warning messages in the Logix Designer application that warn of the drive bypassing the
STO function and unintended motion can occur. The integrated safety drive does not respond to the request of STO function if MDC mode is entered.
ATTENTION:
It is your responsibility to maintain machine safety integrity while executing motion direct commands. One alternative is to provide ladder logic for
Machine Maintenance mode that leaves the controller in Run mode with safety functions executing.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
Logix Designer Application Warning Messages
When the controller is in Run mode, executing safety functions, the
2198-H
xxx
-ERS2 drive follows the commands that it receives from the safety controller. Safety state = Running, Axis state = Stopped/Running, as shown in
Figure 81 .
Figure 81 - Safety State Indications When Controller is in Run Mode (safety task executing)
When the controller transitions to Program mode, the integrated safety drive is in the safe state (torque not permitted). Safety state = Not Running, Axis state
= Start Inhibited, as shown in Figure 82 ).
Figure 82 - Safety State Indications After Controller Transitions to Program Mode
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
187
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
When you issue a motion direct command to an axis to produce torque in
Program mode, for example MSO or MDS, with the safety connection present to the drive, a warning message is presented before the motion direct command is executed, as shown in Figure 83 .
Figure 83 - STO Bypass Prompt When the Safety Controller is in Program Mode
The warning in Figure 83 is displayed the first time a motion direct command is issued.
After you acknowledge the warning message by clicking Yes, torque is permitted by the drive and a warning message is indicated in the software as shown in Figure 84 . Safety state = Not Running (torque permitted), Axis state
= Stopped/Running, Persistent Warning = Safe Torque Off Bypassed.
IMPORTANT
Switch the controller to Run mode to exit Motion Direct Command mode with STO function bypassed.
Figure 84 - Safety State Indications After Controller Transitions to Program Mode
(MDC executing)
188
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
IMPORTANT
The persistent warning message text Safe Torque Off bypassed appears when a motion direct command is executed.
Warning message persists even after the dialog is closed and reopened as long as the integrated safety drive is in STO Bypass mode.
The persistent warning message is removed only after the integrated safety drive is restored to the Safe state.
Torque Permitted in a Multi-workstation Environment
The warning in Figure 85 is displayed to notify a second user working in a multi-workstation environment that the first user has placed the integrated safety drive in the STO state and that the current action is about to bypass the
STO state and permit torque.
Figure 85 - STO Bypass Prompt When MDC is Issued in Multi-workstation Environment
Warning Icon and Text in Axis Properties
In addition to the other warnings that require your acknowledgment, the
Logix Designer application also provides warning icons and persistent warning messages in other Axis Properties dialog boxes when the integrated safety drive is in STO Bypass mode.
Figure 86 - Axis and Safe State Indications on the Hookup Services Dialog Box
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
189
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
Figure 87 - Axis and Safe State Indications on Motion Direct Commands Dialog Box
Figure 88 - Axis and Safe State Indications on the Motion Console Dialog Box
190
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Kinetix 5500 Safe Torque-off - Integrated Safety
Chapter 10
Functional Safety Considerations
ATTENTION:
Before maintenance work can be performed in Program mode, the developer of the application must consider the implications of allowing motion through motion direct commands and should consider developing logic for run-time maintenance operations to meet the requirements of machine safety operating procedures.
ATTENTION:
Motion is allowed when motion direct commands are used in
Program mode and STO function is not available.
Motion direct commands issued when the controller is in Program mode causes the drive to bypass the STO Active condition.
It is your responsibility to implement additional preventive measures to maintain safety integrity of the machinery during execution of motion direct commands in Program mode.
ATTENTION:
To avoid personal injury and damage to equipment in the event of unauthorized access or unexpected motion during authorized access, return the controller to RUN mode and remove the key before leaving the machine unattended.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
191
Chapter 10
Kinetix 5500 Safe Torque-off - Integrated Safety
Safe Torque-off
Specifications
To maintain safety rating, Kinetix 5500 drives must be installed inside protected control panels or cabinets appropriate for the environmental conditions of the industrial location. The protection class of the panel or cabinet must be IP54 or higher.
Table 73 - Safe Torque-off Network Specifications
Attribute
Safety connection RPI, min
Input assembly connections
Output assembly connections
Integrated safety open request support
Axis safety status
Axis safety faults
3
1
Value
6 ms
Logix Designer Tag Name
N/A
N/A
N/A
Type 1 and Type 2 requests N/A
Bit 0: Safety fault Axis.SafetyFaultStatus
Bit 1: Safety reset request Axis.SafetyResetRequestStatus
Bit 2: Safety Reset Required Axis.SafetyResetRequiredStatus
Bit 3: Safe torque-off active Axis.SafeTorqueOffActiveStatus
Bit 4: Safe torque disabled Axis.SafeTorqueDisabledStatus
Bit 5…31: Undefined (0)
Bit 1: Safety core fault
N/A
Axis.SafetyCoreFault
Bit 3: Safe torque-off fault Axis.SafeTorqueOffFault
All others: Undefined (0) N/A
Table 74 - Safe Torque-off Assembly Specifications
Attribute
Safety input assembly
Safety output assembly
Instance Attribute Value
Bit 0: Torque disabled
0X1A0 Bit 6: Safety fault
Bit 7: Reset required
0X180
Logix Designer Tag Name
Drv:SI.TorqueDisabled
Drv:SI.SafetyFault
Drv:SI.ResetRequired
Bit 0: Safe torque-off output Drv:SO.SafeTorqueOff
Bit 7: Reset request Drv:SO.Reset
192
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Appendix
A
Interconnect Diagrams
This appendix provides wiring examples and system block diagrams for your
Kinetix® 5500 system components.
Topic
Kinetix 5500 Servo Drive and Rotary Motor Wiring Examples
Kinetix 5500 Drive and Linear Actuator Wiring Examples
Page
Interconnect Diagram Notes
This appendix provides wiring examples to assist you in wiring the
Kinetix 5500 drive system. These notes apply to the wiring examples on the pages that follow.
Table 75 - Interconnect Diagram Notes
11
12
8
9
6
7
4
5
2
3
Note Information
1
For power wiring specifications, refer to Wiring Requirements on page 82 .
For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Selection on page 34 .
AC (EMC) line filter is required for EMC compliance. Place line filter 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 AC line filter specifications, refer to Kinetix Servo Drives Specifications
Technical Data, publication KNX-TD003 .
Terminal block is required to make connections.
Cable shield clamp must be used to meet CE requirements.
PE ground connection bonded to the panel must be used to meet CE requirements.
DC connector covered with protective knockout is default configuration. Remove knockout to insert DC bus T-connector and bus-bars. Do not attach discrete wiring to the
DC bus terminals is.
Internal shunt wired to the RC connector is default configuration. Remove internal shunt wires to attach external shunt wires.
Power Configuration on page 75
for more information.
10
ATTENTION:
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards ISO 14121-1 and ISO 13849-1 estimation and safety performance categories. For more information refer to Understanding the Machinery Directive, publication SHB-900 .
For motor cable specifications, refer to Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004 .
MPL-A15
xx
…MPL-A45
xx
, MPM-A115
xx…
MPM-A130
xx
, MPF-A3
xx…
MPF-A45
xx,
MPS-A
xxx
, MPAR-A
xxx
, MPAS-A
xxx
, and LDAT-S
xx-x
B
x
encoders use the +5V DC supply.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
193
Appendix A
Interconnect Diagrams
Table 75 - Interconnect Diagram Notes (continued)
Note Information
13 MPL-B supply.
xx
, MPL-A5
xx
, MPM-B
xx,
MPM-A165
xx…
MPM-A215
xx
, MPF-B
xx,
MPF-A5
xx,
MPS-B
xxx
, MPAR-B
xxx
, MPAS-B
xxx,
and LDAT-S
xx-x
D
x
encoders use the +9V DC
14
15
Brake connector pins are labeled plus (+) and minus (-) or F and G respectively. Power connector pins are labeled U, V, W, and (GND) or A, B, C, and (D) respectively.
LDAT-Series linear thrusters do not have a brake option, so only the 2090-CPWM7DF-
xx
AA
xx
or 2090-CPWM7DF-
xx
AF
xx
motor power cables apply.
Power Wiring Examples
You must supply input power components. The single-phase and three-phase line filters are wired downstream of the circuit protection.
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
195…264V AC rms or
324…528V AC rms
Three-phase Input
Single-axis Drive Wiring Examples
Figure 89 - Kinetix 5500 Drives Power Wiring (three-phase operation)
Refer to table on
for note information.
2198-H
xxx
-ERS
x
Kinetix 5500 Drives
PE Ground
2
1
24V_COM
+24V
Control Power
(CP) Connector
2198-DB
xx
-F
Three-phase
AC Line Filter
2
1
4
3
L3
L2
L1
Mains AC Input
(IPD) Connector
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
2
1
4
3
Circuit Protection *
DC+
DC-
DC+
SH
DC Bus
(DC) Connector
Shunt
(RC) Connector
Three-phase
Motor Power
Connections
Motor Brake
(BC) Connector
MBRK -
MBRK +
2
1
Motor Feedback
(MF) Connector
D+
D-
1
2
MBRK -
MBRK +
Motor Brake
Connections
DATA +/EPWR+
DATA -/EPWR-
Motor Feedback
Connections
(refer to
* Indicates User Supplied Component
Internal Shunt
Ground Screws
Digital Input
(IOD) Connector
IN1
COM
IN2
SHLD
3
4
1
2
Registration and
Home Input
Connections
194
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Interconnect Diagrams
Appendix A
Figure 90 - Kinetix 5500 Drives Power Wiring (single-phase operation)
195…264V AC rms
Single-phase Input
Refer to table on
for note information.
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
2
1
24V_COM
+24V
2198-H003-ERS
x
, 2198-H008-ERS
x
, or
2198-H015-ERS
x
Kinetix 5500 Drives
PE Ground
Control Power
(CP) Connector
2198-DB
xx
-F
Three-phase
AC Line Filter
2
1
4
3
L3
L2
L1
Mains AC Input
(IPD) Connector
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
4
3
2
1
Circuit Protection *
DC+
DC-
DC Bus
(DC) Connector
(does not apply in single-phase operation)
Motor Brake
(BC) Connector
MBRK -
MBRK +
2
1
DC+
SH
Shunt
(RC) Connector
Motor Feedback
(MF) Connector
D+
D-
1
2
* Indicates User Supplied Component
Internal Shunt
Ground Screws
Digital Input
(IOD) Connector
IN1
COM
IN2
SHLD
3
4
1
2
Three-phase
Motor Power
Connections
MBRK -
MBRK +
Motor Brake
Connections
DATA +/EPWR+
DATA -/EPWR-
Motor Feedback
Connections
Registration and
Home Input
Connections
for note information.
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
Figure 91 - Kinetix 5500 Capacitor Module
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
2198-CAPMOD-1300
Capacitor Module
PE Ground
2
1
24V_COM
+24V
PE Ground
24V_COM
+24V
Control Power
(CP) Connectors
195…264V AC rms or
324…528V AC rms
Three-phase Input
Circuit Protection *
2198-DB
xx
-F
Three-phase
AC Line Filter
4
3
2
1
L3
L2
L1
Motor, digital input, and shunt connections not shown for clarity.
DC+
DC-
* Indicates User Supplied Component
2198-H0
x
0-ADP-IN
Bus Bar Connectors
Module Status
(MS) Connector
RELAY-
RELAY+
2
1
Relay output to Logix 5000™ controller to monitor capacitor module status.
DC+
DC-
DC Bus
(DC) Connectors
2198-H0
x
0-DP-T
Bus Bar Connectors
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
195
Appendix A
Interconnect Diagrams
Bus-sharing Wiring Examples
For bus-sharing configurations, use the 2198-H0
x
0-
xx-x
shared-bus connection system to extend power from drive to drive.
Figure 92 - Kinetix 5500 Drives with Shared AC Bus
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
Refer to table on
for note information.
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
PE Ground
2
1
24V_COM
+24V
195…264V AC rms or
324…528V AC rms
Three-phase Input
Circuit Protection *
2198-DB
xx
-F
Three-phase
AC Line Filter
2
1
4
3
L3
L2
L1
DC+
DC-
* Indicates User Supplied Component
2198-H0
x
0-ADP-IN
Bus Bar Connectors
24V_COM
+24V
L3
L2
L1
PE Ground
DC+
DC-
2198-H0
x
0-AP-T
Bus Bar Connectors
24V_COM
+24V
Control Power
(CP) Connectors
L3
L2
L1
Three-phase Input
(IPD) Connectors
DC+
DC-
DC Bus
(DC) Connectors
2198-H0
x
0-AP-T
Bus Bar Connectors
Figure 93 - Kinetix 5500 Drives with Shared AC/DC Bus
Refer to table on
for note information.
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
PE Ground
2
1
24V_COM
+24V
195…264V AC rms or
324…528V AC rms
Three-phase Input
Circuit Protection *
2198-DB
xx
-F
Three-phase
AC Line Filter
2
1
4
3
L3
L2
L1
DC+
DC-
* Indicates User Supplied Component
2198-H0
x
0-ADP-IN
Bus Bar Connectors
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
24V_COM
+24V
L3
L2
L1
DC+
DC-
2198-H0
x
0-ADP-T
Bus Bar Connectors
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
24V_COM
+24V
Control Power
(CP) Connectors
L3
L2
L1
Three-phase Input
(IPD) Connectors
DC+
DC-
DC Bus
(DC) Connectors
2198-H0
x
0-ADP-T
Bus Bar Connectors
196
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Interconnect Diagrams
Appendix A
Figure 94 - Kinetix 5500 Drives with Shared DC (common bus)
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
Refer to table on
for note information.
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
PE Ground
2
1
24V_COM
+24V
195…264V AC rms or
324…528V AC rms
Three-phase Input
Circuit Protection *
2198-DB
xx
-F
Three-phase
AC Line Filter
2
1
4
3
L3
L2
L1
Three-phase Input
(IPD) Connector
DC+
DC-
* Indicates User Supplied Component
2198-H0
x
0-ADP-IN
Bus Bar Connectors
24V_COM
+24V
L3
L2
L1
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
DC+
DC-
2198-H0
x
0-DP-T
Bus Bar Connectors
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
24V_COM
+24V
Control Power
(CP) Connectors
L3
L2
L1
DC+
DC-
DC Bus
(DC) Connectors
2198-H0
x
0-DP-T
Bus Bar Connectors
Figure 95 - Kinetix 5500 Drives with Shared AC/DC Hybrid Bus
Refer to table on
for note information.
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
Bonded Cabinet Ground Bus *
Chassis
Customer Supplied
+24V DC
Power Supply *
PE Ground
2
1
24V_COM
+24V
195…264V AC rms or
324…528V AC rms
Three-phase Input
Circuit Protection *
2198-DB
xx
-F
Three-phase
AC Line Filter
2
1
4
3
L3
L2
L1
DC+
DC-
* Indicates User Supplied Component
2198-H0
x
0-ADP-IN
Bus Bar Connectors
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
24V_COM
+24V
L3
L2
L1
Three-phase Input
(IPD) Connector
DC+
DC-
2198-H0
x
0-ADP-T
Bus Bar Connectors
L3
L2
L1
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
PE Ground
24V_COM
+24V
Control Power
(CP) Connectors
DC+
DC-
DC Bus
(DC) Connectors
2198-H0
x
0-DP-T
Bus Bar Connectors
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
197
Appendix A
Interconnect Diagrams
Shunt Resistor Wiring
Example
Refer to the
External Passive-shunt Resistor Connections on page 105 for the
Bulletin 2097 external shunt resistor catalog numbers available for
Kinetix 5500 servo drives.
IMPORTANT
Before wiring the Bulletin 2097 external shunt to the RC connector, remove the wires from the servo drive internal shunt. Do not connect internal and external shunt resistors to the drive.
Figure 96 - Shunt Resistor Wiring Example
2198-H
xxx
-ERS
x
Kinetix 5500 Drive
Shunt (RC)
Connector
DC+
SH
2097-R
x
Shunt
Resistor
Internal Shunt
Refer to the Kinetix 300 Shunt Resistor Installation Instructions, publication
2097-IN002 , for shunt resistor installation instructions.
198
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Interconnect Diagrams
Appendix A
Kinetix 5500 Servo Drive and
Rotary Motor Wiring
Examples
These compatible Kinetix VP rotary motors use single cable technology. The motor power, brake, and feedback wires are all packaged in a single cable.
Figure 97 - Kinetix 5500 Drives with Kinetix VP Motors (Bulletin VPL, VPF, VPH, and VPS)
2198-H
xxx
-ERS
x
Kinetix 5500 Servo Drives
for note information.
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
2
1
4
3
Brown
Black
Blue
Green/Yellow
A/U
B/V
C/W
VPL-A/B
xxxx
-C/P/Q/W,
VPF-A/B
xxxx
-C/P/Q/W,
VPH-A/B
xxxx
-C/Q/W, or VPS-B
xxx
D-P Motors with High Resolution
Feedback
Three-phase
Motor Power
Motor Brake
(BC) Connector
MBRK +
MBRK -
1
2
Black
White
F/+
G/–
Motor
Brake
Motor Feedback
(MF) Connector
2198-KITCON-DSL
Connector Kit
D+
D-
1
2
Blue
White/Blue
Data+/EPWR+
Data-/EPWR-
Shield
2090-CSBM1DF-
xx
AA
xx
or 2090-CSBM1DF-
xx
AF
xx
or
2090-CSBM1DG-
xx
AA
xx
or 2090-CSBM1DG-
xx
AF
xx
Single Motor Cable
E/1
H/2
Motor
Feedback
SpeedTec DIN
Single Motor Connector
Power, Brake, and
Feedback Connector
Refer to Kinetix 5500 Feedback Connector
Kit Installation Instructions, publication
2198-IN002 , for connector kit specifications.
Connector
Plug
2090-CS
x
M1DF single cables have flying-lead conductors designed specifically for Kinetix 5500 servo drives. 2090-CS
x
M1DG cables have flyingleads that are longer than 2090-CS
x
M1DF cables to accommodate
Kinetix 5500 or Kinetix 5700 servo drives.
Figure 98 - Grounding Technique for Feedback Cable Shield
Mounting Screws (2)
Cover
2198-KITCON-DSL
Feedback Connector Kit
Clamp Screws (2)
Exposed Shield
Feedback Cable
(EPWR+, EPWR-)
Grounding Plate
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
199
Appendix A
Interconnect Diagrams
2198-H
xxx
-ERS
x
Kinetix 5500 Servo Drives
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
4
3
2
1
Motor Brake
(BC) Connector
MBRK +
MBRK -
1
2
Motor Feedback
(MF) Connector
D+
D-
1
2
Shield
Brown
Black
Blue
Green/Yellow
2090-CP
x
M7DF-
xx
AA
xx
(standard) or
2090-CP
x
M7DF-
xx
AF
xx
(continuous-flex)
Motor Power Cable
White
Black
These compatible MP-Series™ rotary motors have separate connectors and cables for power/brake and feedback connections.
Figure 99 - Kinetix 5500 with MP-Series Rotary Motors
MPL-A15
xx…
MPL-A5
xx,
MPL-B15
xx…
MPL-B6
xx,
MPM-A/B
xxx,
MPF-A/B
xxx,
and
MPS-A/B
xxx
Servo Motors with
High Resolution Feedback
Refer to table on page 193 for note information.
A
B
C
D
G
F
U
V
W
Three-phase
Motor Power
GND
Motor
Feedback
Thermostat
9
10
5
6
3
4
11
13
1
2
14
MBRK+
MBRK-
Motor Brake
12
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
2198-H2DCK Feedback
Converter Kit
3
4
5
10
14
6
7
11
1
2
COM
Refer to DSL feedback converter kit illustration (lower left) for proper grounding technique.
2090-CFBM7DF-CEAA
xx
(standard) or
2090-CFBM7DF-CEAF
xx
(continuous-flex)
(flying-lead) Feedback Cable
Grounding Technique for
Feedback Cable Shield
Feedback Connector
SpeedTec DIN
Motor Connectors
2198-H2DCK
Hiperface-to-DSL
Feedback Converter Kit
Clamp Screws (2)
Exposed shield secured under clamp.
Cable Clamp
Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006 , for converter kit specifications.
Power Connector
200
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Interconnect Diagrams
Appendix A
Kinetix 5500 Drive and Linear
Actuator Wiring Examples
These Kinetix VP linear actuators use single cable technology. The motor power, brake, and feedback wires are all packaged in a single cable.
Figure 100 - Kinetix 5700 Drives with Kinetix VP Electric Cylinders
2198-H
xxx
-ERS
x
Kinetix 5500 Servo Drives
Refer to table on page 193 for note information.
VPAR-B
xxxxx
-P/Q/W
Electric Cylinders with High-resolution
Feedback
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
2
1
4
3
Brown
Black
Blue
Green/Yellow
A/U
B/V
C/W
Three-phase
Motor Power
Motor Brake
(BC) Connector
MBRK +
MBRK -
1
2
Black
White
F/+
G/–
Motor
Brake
Motor Feedback
(MF) Connector
2198-KITCON-DSL
Connector Kit
D+
D-
1
2
Blue
White/Blue
Data+/EPWR+
Data-/EPWR-
Shield
2090-CSBM1DF-
xx
AA
xx
or 2090-CSBM1DF-
xx
AF
xx
or
2090-CSBM1DG-
xx
AA
xx
or 2090-CSBM1DG-
xx
AF
xx
Single Motor Cable
E/1
H/2
Motor
Feedback
SpeedTec DIN
Single Motor Connector
Power, Brake, and
Feedback Connector
2090-CS
x
M1DF single cables have flying-lead conductors designed specifically for Kinetix 5500 servo drives. 2090-CS
x
M1DG cables have flyingleads that are longer than 2090-CS
x
M1DF cables to accommodate
Kinetix 5500 or Kinetix 5700 servo drives.
See the cable-shield grounding technique for single cables on page 199
.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
201
Appendix A
Interconnect Diagrams
2198-H
xxx
-ERS
x
Kinetix 5500 Servo Drives
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
4
3
2
1
Motor Brake
(BC) Connector
MBRK +
MBRK -
Motor Feedback
(MF) Connector
D+
D-
1
2
Shield
Brown
Black
Blue
Green/Yellow
2090-CPWM7DF-
xx
AA
xx
(standard) or
2090-CPWM7DF-
xx
AF
xx
(continuous-flex)
Motor Power Cable
These compatible linear actuators have separate connectors and cables for power/brake and feedback connections.
Figure 101 - Kinetix 5500 with LDAT-Series Linear Thrusters
LDAT-S
xxxxxx-x
D
x
Linear Thrusters with
High Resolution Feedback
Refer to table on
page 193 for note information.
A
C
B
D
U
V
W
Three-phase
Motor Power
GND
Motor
Feedback
Thermostat
1
2
3
4
9
10
5
6
11
13
14
12
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
2198-H2DCK Feedback
Converter Kit
3
4
1
2
5
10
14
6
7
11
COM
Refer to DSL feedback converter kit illustration (lower left) for proper grounding technique.
2090-CFBM7DF-CEAA
xx
(standard) or
2090-CFBM7DF-CEAF
xx
(continuous-flex)
(flying-lead) Feedback Cable
Grounding Technique for
Feedback Cable Shield
Feedback Connector
SpeedTec DIN
Motor Connectors
2198-H2DCK
Hiperface-to-DSL
Feedback Converter Kit
Clamp Screws (2)
Exposed shield secured under clamp.
Cable Clamp
Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006 , for converter kit specifications.
Power Connector
202
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Interconnect Diagrams
Appendix A
2198-H
xxx
-ERS
x
Kinetix 5500 Servo Drives
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
4
3
2
1
Motor Brake
(BC) Connector
MBRK +
MBRK -
1
2
Motor Feedback
(MF) Connector
D+
D-
1
2
Figure 102 - Kinetix 5500 with MP-Series Linear Stages
MPAS-A/B
xxxxx
-V
xx
S
x
A
Ballscrew Linear Stages with
High Resolution Feedback
Refer to table on
page 193 for note information.
Shield
Brown
Black
Blue
Green/Yellow
2090-CP
x
M7DF-
xx
AA
xx
(standard) or
2090-CP
x
M7DF-
xx
AF
xx
(continuous-flex)
Motor Power Cable
White
Black G
F
A
C
B
D
U
V
W
Three-phase
Motor Power
GND
Motor
Feedback
Thermostat
MBRK+
MBRK-
Motor Brake
1
2
3
4
9
10
5
6
11
13
14
12
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
2198-H2DCK Feedback
Converter Kit
3
4
1
2
5
10
14
6
7
11
COM
Refer to DSL feedback converter kit illustration (lower left) for proper grounding technique.
2090-CFBM7DF-CEAA
xx
(standard) or
2090-CFBM7DF-CEAF
xx
(continuous-flex)
(flying-lead) Feedback Cable
Grounding Technique for
Feedback Cable Shield
Feedback Connector
SpeedTec DIN
Motor Connectors
2198-H2DCK
Hiperface-to-DSL
Feedback Converter Kit
Clamp Screws (2)
Exposed shield secured under clamp.
Cable Clamp
Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006 , for converter kit specifications.
Power Connector
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
203
Appendix A
Interconnect Diagrams
2198-H
xxx
-ERS
x
Kinetix 5500 Servo Drives
Cable Shield
Clamp
Motor Power
(MP) Connector
U
V
W
2
1
4
3
Motor Brake
(BC) Connector
MBRK +
MBRK -
1
2
Motor Feedback
(MF) Connector
D+
D-
1
2
Shield
Brown
Black
Blue
Green/Yellow
Refer to
for motor power cable.
White
Black
Figure 103 - Kinetix 5500 with MP-Series Electric Cylinders
G
F
A
C
B
D
MPAR-A/B
xxxxx
and
MPAI-A/B
xxxxx
Electric Cylinders with
High Resolution Feedback
U
V
W
Three-phase
Motor Power
GND
Motor
Feedback
Thermostat
3
4
1
2
9
10
5
6
11
13
14
MBRK+
MBRK-
Motor Brake
12
Refer to table on
page 193 for note information.
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
2198-H2DCK Feedback
Converter Kit
3
4
1
2
5
10
14
6
7
11
COM
Refer to DSL feedback converter kit illustration (lower left) for proper grounding technique.
(flying-lead) motor feedback cable.
204
Grounding Technique for
Feedback Cable Shield
2198-H2DCK
Hiperface-to-DSL
Feedback Converter Kit
Clamp Screws (2)
Feedback Connector
SpeedTec DIN
Motor Connectors
Power Connector
Exposed shield secured under clamp.
Cable Clamp
Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006 , for converter kit specifications.
MP-Series Electric Cylinder
Cat. No.
MPAR-A/B1
xxx
(series A)
MPAR-A/B2
xxx
(series A)
MPAR-A/B1
xxx
(series B)
MPAR-A/B2
xxx
(series B)
MPAR-A/B3
xxx
MPAI-A/B2
xxxx
MPAI-A/B3
xxxx
MPAI-A/B4
xxxx
MPAI-B5
xxxx
MPAI-A5
xxxx
Table 76 - MP-Series Electric Cylinder Power and Feedback Cables
Power Cable
Cat. No.
63
64
83
110
144
32
40
32
40
2090-XXNPMF-16S
2090-CP
2090-CP
2090-CP
x x x xx
M4DF-16AF
M7DF-16AA
M7DF-16AF
(standard) or
xx xx xx
(continuous-flex)
(standard) or
(continuous-flex)
144
2090-CP
x
M7DF-14AA
xx
(standard) or
2090-CP
x
M7DF-14AF
xx
(continuous-flex)
Feedback Cable
Cat. No.
2090-XXNFMF-S
xx
(standard) or
2090-CFBM4DF-CDAF
xx
(continuous-flex)
2090-CFBM7DF-CEAA
xx
(standard) or
2090-CFBM7DF-CEAF
xx
(continuous-flex)
2090-CFBM7DF-CEAA
xx
(standard) or
2090-CFBM7DF-CEAF
xx
(continuous-flex)
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
System Block Diagrams
Interconnect Diagrams
Appendix A
This section provides block diagrams of the Kinetix 5500 drive modules.
Figure 104 - Kinetix 5500 Drive Block Diagram
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
205
Appendix A
Interconnect Diagrams
DC+
DC Bus
Connector
DC-
24V Control Power
24V+
24V-
Module Status
Connector
(NO relay output)
RELAY+
RELAY-
Status Indicator
Figure 105 - Kinetix 5500 Capacitor Module Block Diagram
Protection
Relay K2
Precharge
Fuse F2
Relay K1
Capacitor Bank
1360 μF
SMPS
Chassis
206
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Appendix
B
Upgrade the Drive Firmware
This appendix provides procedures for upgrading firmware by using
ControlFLASH™ software.
Topic
Page
Upgrading drive firmware by using ControlFLASH software involves configuring your Logix 5000™ controller communication, selecting the drive to upgrade, and upgrading the firmware.
IMPORTANT
If the drive firmware contains updated safety firmware, you must deenergize the safety inputs first or the upgrade fails.
To update the drive firmware in Feedback Only mode, you must inhibit the
axis first. Refer to Inhibit Feedback Only Axis on page 210
for more information.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
207
Appendix B
Upgrade the Drive Firmware
Before You Begin
These are the minimum firmware revisions and software versions required for upgrading drive firmware.
Table 77 - Kinetix 5500 System Requirements
Description
Studio 5000 Logix Designer® application
RSLinx® software
ControlFLASH software kit
(1)
Catalog numbers of the targeted Kinetix® 5500 drive module you want to upgrade.
Network path to the targeted Kinetix 5500 drive module you want to upgrade.
Firmware Revision
21.00 or later
2.58 or later
11.00 or later
(1) Download the ControlFLASH kit from http://support.rockwellautomation.com/controlflash . Contact Rockwell Automation
Technical Support at (440) 646-5800 for assistance.
For more ControlFLASH information (not drive specific), refer to the ControlFLASH Firmware Upgrade Kit Quick Start, publication
1756-QS105 .
IMPORTANT
Control power must be present at CP-1 (24V+) and CP-2 (24V-) prior to upgrading your target drive.
IMPORTANT
The axis state on the LCD display must be STANDBY, CONFIGURING, or
PRECHARGE before beginning this procedure.
IMPORTANT
The axis state on the LCD display must be STANDBY, when Protected mode is enabled. See
Table 52 on page 111 for more information.
ATTENTION:
To avoid personal injury or damage to equipment during the firmware upgrade due to unpredictable motor activity, do not apply threephase AC or common-bus DC input power to the drive.
208
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Upgrade the Drive Firmware
Appendix B
Configure Logix 5000 Controller Communication
This procedure assumes that your communication method to the Logix 5000 controller is the Ethernet network. It also assumes that your Logix 5000
Ethernet module or controller has already been configured.
For more controller information, refer to Additional Resources on page 12
.
Follow these steps to configure Logix 5000 controller communication.
1.
Open your RSLinx Classic software.
2.
From the Communications menu, choose Configure Drivers.
The Configure Drivers dialog box appears.
3.
From the Available Driver Types pull-down menu, choose Ethernet devices.
4.
Click Add New.
The Add New RSLinx Classic Driver dialog box appears.
5.
Type the new driver name.
6.
Click OK.
The Configure driver dialog box appears.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
209
Appendix B
Upgrade the Drive Firmware
7.
Type the IP address of your Kinetix 5500 servo drive.
8.
Click OK.
The new Ethernet driver appears under Configured Drivers.
9.
Click Close.
10.
Minimize the RSLinx application dialog box.
Inhibit Feedback Only Axis
If an axis is configured as Feedback Only, you must inhibit the axis prior to performing the firmware upgrade. Follow these steps to inhibit an axis.
1.
Open your Logix Designer application.
2.
Right-click the 2198-H
xxx
-ERS
x
servo drive you configured as
Feedback Only and choose Properties.
The Module Properties dialog box appears.
3.
Click the Connection tab.
210
4.
Check Inhibit Module.
5.
Click OK.
6.
Save your file and download the program to the controller.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Upgrade Firmware
Upgrade the Drive Firmware
Appendix B
Follow these steps to select the drive module to upgrade.
1.
In the Logix Designer application, from the Tools menu, choose
ControlFLASH.
TIP
You can also open ControlFLASH software by choosing
Start>Programs>FLASH Programming Tools>ControlFLASH.
The Welcome to ControlFLASH dialog box appears.
2.
Click Next.
The Catalog Number dialog box appears.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
211
Appendix B
Upgrade the Drive Firmware
3.
Select your drive module.
In this example, the 2198-H003-ERS servo drive is selected.
4.
Click Next.
The Select Device to Update dialog box appears.
5.
Expand your Ethernet node, Logix backplane, and EtherNet/IP™ network module.
6.
Select the servo drive to upgrade.
7.
Click OK.
The Firmware Revision dialog box appears.
8.
Select the firmware revision to upgrade.
9.
Click Next.
212
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
The Summary dialog box appears.
Upgrade the Drive Firmware
Appendix B
10.
Confirm the drive catalog number and firmware revision.
11.
Click Finish.
This ControlFLASH warning dialog box appears.
12.
Click Yes (only if you are ready).
This ControlFLASH warning dialog box appears.
13.
Acknowledge the warning and click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
213
Appendix B
Upgrade the Drive Firmware
The Progress dialog box appears and updating begins.
The axis state on the LCD display changes from CONFIGURING,
STOPPED, or PRECHARGE to FIRMWARE UPDATE, which indicates that the upgrade is in progress.
After the upgrade information is sent to the drive, the drive resets and performs diagnostic checking.
14.
Wait for the Progress dialog box to time out.
It is normal for this process to take several minutes.
IMPORTANT
Do not cycle power to the drive during this process or the firmware upgrade does not complete successfully.
15.
Verify that the Update Status dialog box appears and indicates success or failure as described below.
Upgrading Status
Success
Failure
If
Update complete appears in a green Status dialog box, then go to step 16 .
Update failure appears in a red Status dialog box, then refer to
ControlFLASH Firmware Upgrade Kit User Manual, publication
1756-UM105 , for troubleshooting information.
214
16.
Click OK.
IMPORTANT
If you are upgrading a feedback-only axis and you checked Inhibit
Module on the Connection tab in Module Properties, you must clear the
Inhibit Module checkbox before resuming normal operation.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Upgrade the Drive Firmware
Appendix B
Verify the Firmware Upgrade
Follow these steps to verify your firmware upgrade was successful.
TIP
Verifying the firmware upgrade is optional.
1.
Open your RSLinx software.
2.
From the Communications menu, choose RSWho.
3.
Expand your Ethernet node, Logix backplane, and EtherNet/IP network module.
4.
Right-click the drive module and choose Device Properties.
The Device Properties dialog box appears.
5.
Verify the new firmware revision level.
6.
Click Close.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
215
Appendix B
Upgrade the Drive Firmware
Notes:
216
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Appendix
C
Size Multi-axis Shared-bus Configurations
This appendix provides information and examples for sizing your
Kinetix® 5500 drive shared-bus configurations.
Topic
Control Power Current Calculations
Page
Shared-bus configurations include the following types:
• Shared AC
• Shared DC (common bus)
• Shared AC/DC
• Shared AC/DC Hybrid
These restrictions apply to all shared-bus configurations:
• Shared-bus configurations must use the shared-bus connection system.
IMPORTANT
Do not make drive-to-drive connections with discrete wires.
• Single-phase drive operation is not supported.
• Shared AC/DC and shared AC/DC hybrid configurations result in a derating of 30% of the total converter power available.
• The zero-stack tabs and cutouts must be engaged from drive-to-drive.
Systems cannot start in one cabinet and end in another.
• Program drives for the same converter AC input voltage.
Shared-bus Configurations
Shared AC configurations are configured as Standalone in the project file and do not share these restrictions that apply to multi-axis shared-bus configurations:
• All drives in a bus-sharing group must be configured with the same bus power-sharing group number in the Logix Designer application.
• The maximum number of drives in any bus power-sharing group cannot exceed eight.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
217
Appendix C
Size Multi-axis Shared-bus Configurations
Shared AC Configurations
In shared AC configurations, the first (leftmost) drive receives AC input voltage. The shared-bus connection system extends the AC bus to all downstream drives:
• All drives are configured in the project file as Standalone drives.
• Drives must be of the same power rating (catalog number).
• Shared AC configurations do not support Bulletin 2198 capacitor modules.
• The maximum number of drives in Shared AC configurations is restricted as described in Table 78 .
Table 78 - Shared AC Panel Layout
Frame Size Drive Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
1
2
3
Number of Drives Configured as Shared AC, max
5
3
2
Figure 106 - Typical Shared AC Configuration
Bonded Cabinet
Ground
Kinetix 5500 Servo Drives
(top view)
Do not remove the protective knock-out DC connector cover.
Three-phase
Input Power
24V Input
Control Power
For an example shared AC installation with additional details, refer to
Shared AC Installations on page 18 .
218
Shared DC Configurations
In a Shared DC (DC common bus) configuration, the first (leftmost) drive is the leader drive and is the only drive that receives the AC input voltage. All drives to the right of the leader drives are follower drives. They receive the DC bus voltage extended from the leader drive through the shared-bus connection system:
• For DC common-bus installations, the power rating of the leader drive must be greater than or equal to the power rating of the follower drives.
• The leader drive is configured in the project file as Shared AC/DC.
• The follower drives are configured in the project file as Shared DC.
• Shared DC configurations support Bulletin 2198 capacitor modules.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Size Multi-axis Shared-bus Configurations
Appendix C
Table 79 - Shared DC Panel Layout
Frame Size
Combination
1
2 and 1
2
2 and 1
2
2 and 1
2
3 and 1
3 and 2
3
Leader Drive Cat. No.
2198-H003-ERS
2198-H008-ERS
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x x x
Follower Drives, max
4
4
6
6
6
7
(1)
Follower Cat. No.
2198-H003-ERS
x
2198-H003-ERS
x
2198-H008-ERS
x
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
Number of Capacitor
Modules, max
0
1
1
1
3
3
4
(1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004 .
Figure 107 - Typical DC Common Bus Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
DC Bus Connections
2198-H040-ERS
x
Common-bus Leader Drive
2198-CAPMOD-1300 Capacitor Module
(optional component)
2198-H008-ERS
x
Common-bus
Follower Drives
IMPORTANT
Total number of drives in Kinetix 5500 drive system must not exceed 8.
For an example shared DC installation with additional details, refer to Typical
Shared DC Common-bus Installations on page 20
.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
219
Appendix C
Size Multi-axis Shared-bus Configurations
Shared AC/DC Configurations
In a shared AC/DC configuration, the first (leftmost) drive receives AC input voltage. The shared-bus connection system extends the AC and DC bus to all downstream drives:
• All drives are configured in the project file as Shared AC/DC drives.
• Drives must be of the same power rating (catalog number).
• Shared AC/DC configurations support Bulletin 2198 capacitor modules
• Total available converter power is derated by 30%.
• The maximum number of drives configured as Shared AC/DC is described in Table 80 .
Table 80 - Shared AC/DC Panel Layout
Drive Cat. No.
Frame Size
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
1
2
2198-H040-ERS
x
2198-H070-ERS
x
3
Drives Configured as Shared AC/DC, max
8
4
(1)
Number of Capacitor
Modules, max
0
1
4
2 4
(1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004 .
Figure 108 - Typical Shared AC/DC Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
DC Bus Connections
2198-CAPMOD-1300 Capacitor Module
(optional component)
Kinetix 5500 Servo Drives
(top view)
For an example shared AC/DC installation with additional details, refer to
Typical Shared AC/DC Installations on page 19 .
220
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Size Multi-axis Shared-bus Configurations
Appendix C
Shared AC/DC Hybrid Configurations
In shared AC/DC hybrid configurations, three-phase AC input power is supplied to two or more (leader) drives that act as converters. This parallel converter configuration increases the DC power supplied to the inverter
(follower) drives:
• The leftmost drives in a hybrid configuration act as parallel converter drives and must be of the same power rating (catalog number).
• Shared DC (inverter) drives mounted to the right of the shared AC/DC
(converter) drives must have the same or lower power rating (catalog number) than the shared AC/DC drives.
• The total motoring load must not exceed the rated load for the drives sourcing the DC power. Each follower drive must be sized for the motor load connected to it.
• Total available converter power is derated by 30%.
• The maximum number of drives configured in the project file as
Shared AC/DC is restricted according to Table 80 on page 220 .
• The maximum number of drives configured in the project file as
Shared DC is restricted according to Table 79 on page 219 .
• Shared AC/DC hybrid configurations support Bulletin 2198 capacitor modules.
Figure 109 - Typical Shared AC/DC Hybrid Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
DC Bus Connections
2198-H040-ERS
x
Common-bus (converter)
Leader Drives
2198-CAPMOD-1300 Capacitor Module
(1)
(optional component)
2198-H008-ERS
x
Common-bus (inverter)
Follower Drives
(1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004 .
For an example shared AC/DC hybrid installation with additional details, refer to
Typical Shared AC/DC Bus Hybrid Installations on page 21
.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
221
Appendix C
Size Multi-axis Shared-bus Configurations
Power-sharing Sizing
Examples
For best results, size motors based on load torque requirements by using
Motion Analyzer software. Select drives based on continuous or peak torque requirements. Based on the load profile, use Motion Analyzer software to estimate the net converter and inverter power and bus regulator capacity.
Table 81 - Converter and Bus Regulator Capacity
Configuration
Shared AC
Available Converter Capacity
Converter power rating of each drive
Common bus
Shared AC/DC
Converter power rating of leader drive
Shared AC/DC hybrid
Sum of converter power ratings times 0.7
(70%)
Available Regenerative Capacity
Internal shunt of each drive
Sum of all internal shunts from each drive in bus-sharing group
Shared DC Example
In this example four 2198-H040-ERS drives are used in a common-bus configuration.
Figure 110 - DC Common Bus Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
DC Bus Connections
2198-H040-ERS
Common-bus Leader Drive
2198-H040-ERS
Common-bus
Follower Drives
Each 2198-H040-ERS drive is rated at 8.4 kW continuous output power to bus. However, only the leader drive acts as the converter, so the available converter power to the system is 8.4 kW. In this example, total motoring load must not exceed 8.4 kW.
222
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Size Multi-axis Shared-bus Configurations
Appendix C
Shared AC/DC Hybrid Example
If the required motoring power exceeds the available converter power sourced by the shared DC configuration, then connect a second converter drive to make a shared AC/DC hybrid configuration. This increases the available converter power.
In this example, the same four 2198-H040-ERS drives are used, however, two are connected as parallel converter (leader) drives and the other two as common-bus (follower) drives. The total converter power is derated by 30%.
Figure 111 - Shared AC/DC Hybrid Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
DC Bus Connections
2198-H040-ERS
Common-bus (converter)
Leader Drives
2198-H040-ERS
Common-bus (inverter)
Follower Drives
The available converter power to the system is (8.4 • 2) • 0.7 = 11.76 kW. In this example, total motoring load must not exceed 11.76 kW. The available converter power was increased by 40% over the same drives in shared DC configuration.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
223
Appendix C
Size Multi-axis Shared-bus Configurations
Shared AC/DC Example
If the required motoring power exceeds the available converter power sourced by two leader drives, then connect all four drives as parallel converter drives.
This further increases the available converter power.
In this example, the same four 2198-H040-ERS drives are used, however, all four are connected as parallel converter (leader) drives. The total converter power is derated by 30%.
Figure 112 - Shared AC/DC Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
DC Bus Connections
2198-H040-ERS
Converter Drives
The available converter power to the system is (8.4 • 4) • 0.7 = 23.52 kW. In this example, total motoring load must not exceed 23.52 kW. The available converter power was increased by 180% over the same drives in shared DC configuration.
Control Power Current
Calculations
Kinetix 5500 servo drives and the Bulletin 2198 capacitor module have different 24V DC power consumption. Factors to consider when calculating the combined current demand from your 24V DC power supply includes the following:
• Catalog number for each drive in the system
• Whether the motor or actuator includes the holding brake option
• Whether the system includes Bulletin 2198 capacitor modules (1 to 4 modules are possible)
224
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Size Multi-axis Shared-bus Configurations
Appendix C
Table 82 - Control Power Current Demand
Cat. No.
24V Current
(non-brake motor)
A
DC
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
2198-CAPMOD-1300
0.4
0.8
1.3
0.3
(1) Inrush current duration is less than 30 ms.
2.8
3.3
N/A
24V Current
(2 A brake motor)
A
DC
2.4
24V Inrush Current
(1)
A
2.0
3.0
2.0
Kinetix 5500 System Current Demand Example
In this example, the Kinetix 5500 drive system includes two 2198-H040-ERS drives, four 2198-H008-ERS drives, and one capacitor module.
Figure 113 - Shared AC/DC Hybrid Configuration
Bonded Cabinet
Ground
Three-phase
Input Power
24V Input
Control Power
3.5 A min, non-brake motors
15.2 A min, brake motors
DC Bus Connections
2198-H040-ERS
Servo Drives
2198-H008-ERS
Servo Drives
Table 83 - Kinetix 5500 System Current Demand Calculations
Kinetix 5500 Module
Cat. No.
Qty
4
2
24V Current
(non-brake motors)
A
DC
0.4 x 4 = 1.6
2198-H008-ERS
x
2198-H040-ERS
x
2198-CAPMOD-1300 1
0.8 x 2 = 1.6
0.3 x 1 = 0.3
Total current demand 3.5
(1) Inrush current duration is less than 30 ms.
24V Current
(2 A brake motors)
A
DC
2.4 x 4 = 9.6
2.8 x 2 = 5.6
N/A
15.2
2198-CAPMOD-1300
Capacitor Module
24V Inrush Current
(1)
A
2 x 4 = 8
3 x 2 = 6
2 x 1 = 2
16
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
225
Appendix C
Size Multi-axis Shared-bus Configurations
Energy Calculations
The Kinetix 5500 servo drives have internal shunt resistors for dissipating excessive energy. In addition, Bulletin 2097 external shunt resistors and
Bulletin 2198 capacitor modules are available to increase the shared DC bus capacitance.
Use this table to calculate the total energy absorbing potential (joules) and determine if a capacitor module or external shunt resistor is needed.
Table 84 - Energy Absorbing Potential
Kinetix 5500 Drive
Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
2198-H025-ERS
2198-H040-ERS
2198-H070-ERS
x x x x
J
Internal Shunt
427.09
549.01
575.223
601.434
1827.01
(1)
External Shunt
kJ
12.51
12.521
12.549
22.647
27.218
J
Capacitor Module
(1)
N/A
554.4
676.32
702.53
728.74
1954.3
(1) Value assumes the use of one servo drive and one capacitor module.
(2) Value assumes the use of one servo drive and the maximum number of capacitor modules allowed.
J
Capacitor Module, max
(2)
N/A
554.4
676.32
957.162
983.373
2208.95
Refer to Motion Analyzer software, version 7.0 or later, for custom shunt sizing.
226
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Appendix
D
Motor Control Feature Support
This appendix provides feature descriptions for the induction motors and permanent-magnet motors that are supported by Kinetix® 5500 servo drives.
Topic
Current Limiting for Frequency Control
Stability Control for Frequency Control
Current Regulator Loop Settings
Selection of Motor Thermal Models
Speed Limited Adjustable Torque (SLAT)
Page
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
227
Appendix D
Motor Control Feature Support
Frequency Control Methods
The Kinetix 5500 servo drives support three open-loop frequency control methods. These are the choices:
•
Basic Volts/Hertz
- This method is used in single asynchronous-motor applications
• Basic Volts/Hertz - Fan Pump
- This method is similar to Basic Volts/
Hertz, but is specifically tailored for fan/pump applications
•
Sensorless Vector with Slip Compensation
- This method is used for most constant torque applications. Provides excellent starting, acceleration, and running torque
To configure your induction motor in the Logix Designer application, refer to
Configure Induction-motor Frequency-control Axis Properties on page 130
.
Open-loop frequency control is suitable in applications such as conveyors, pumps, and fans. Features include the following:
• Start Boost and Run Boost
• Electronic motor thermal-overload protection per Class 10 requirements
• Two skip frequencies, in which the drive does not operate
• All three-phase induction motors, suitable for variable speed drive
(VFD) operation, are supported
Table 85 - Motor Specifications
Attribute
Output frequency, max
Pole pairs, max
Motor cable length, max
Value
590 Hz
50
50 m (164 ft)
(1)
(1) Applies to all Kinetix 5500 (frame 2 and 3) drives. For Kinetix 5500 (frame 1) drives in continuous-flex applications, 30 m (98 ft) is the maximum cable length.
228
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Basic Volts/Hertz
Volts/hertz operation creates a fixed relationship between output voltage and output frequency. Voltage is applied to the motor, which is based on the operating frequency command at a fixed volts/hertz ratio. The ratio is calculated from the motor nameplate data and entered into the Logix Designer application>Axis Properties>Frequency Control category.
The Basic Volts/Hertz method provides various patterns. The default configuration is a straight line from zero to rated voltage and frequency. As seen in
Figure 114 , you can change the volts/hertz ratio to provide increased
torque performance when required by programming five distinct points on the curve.
Table 86 - Basic Volts/Hertz Definitions
Curve Feature
Start boost
Run boost
Break voltage/frequency
Definition
Used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds.
Used to create additional running torque at low speeds. The value is typically less than the required acceleration torque. The drive lowers the boost voltage to this level when running at low speeds (not accelerating). This reduces excess motor heating that could result if the higher start/accel boost level were used.
Used to increase the slope of the lower portion of the Volts/Hertz curve, providing additional torque.
Motor nameplate voltage/ frequency
Sets the upper portion of the curve to match the motor design. Marks the beginning of the constant power region.
Maximum voltage/frequency Slopes the portion of the curve that is used above base speed.
Figure 114 - Basic Volts/Hertz Method
Voltage, max
Base Voltage
(nameplate)
Break Voltage
Start/Accel Boost
Run Boost
Break
Frequency
Base Frequency,
(nameplate)
Frequency, max
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
229
Appendix D
Motor Control Feature Support
Basic Volts/Hertz for Fan/Pump Applications
The Basic Volts/Hertz Fan/Pump (fan/pump) method is based on the Basic
Volts/Hertz (V/Hz) method, but is specifically tailored for fan/pump applications.
Figure 115 - Output Voltage Equation
V x
= f x f n
2
V n
– V boost
+ V boost
Where:
V
x
= Output voltage f
x
= Output frequency
V
n
= Rated voltage
F
n
= Rated frequency
V
boost
= Run boost voltage
For maximum system efficiency, fan/pump loads use variable frequency drives that are equipped with a specific V/Hz curve where voltage is proportional to square of the frequency.
Figure 116 - Basic Volts/Hertz Fan/Pump Method
Voltage, max
Base Voltage
(nameplate)
Run Boost
Frequency (Hz)
Base Frequency,
(nameplate)
Frequency, max
TIP
The Fan/Pump control method supports the run-boost attribute, but does not support break-voltage, break-frequency, or start-boost.
230
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Velocity Trim
Velocity Command
+
Sensorless Vector
The Sensorless Vector method uses a volts/hertz core enhanced by a current resolver, slip estimator, and a voltage-boost compensator based on the operating conditions of the motor.
Figure 117 - Sensorless Vector Method
Motor Pole
Pairs x
V/Hz
+
Voltage
Control
Inverter
Motor
Vboost
Estimator
Slip Speed
Slip
Estimation
Torque
Estimate
Load
Torque
Estimator
Current
Resolver
Current
Feedback
The algorithms operate on the knowledge of the relationship between the rated slip and torque of the motor. The drive uses applied voltages and measured currents to estimate operating slip-frequency. You can enter values to identify the motor resistance value or you can run a motor test to identify the motor resistance value (see
Motor Tests and Autotune Procedure on page 244
).
Motor nameplate data and test results are ways to accurately estimate the required boost voltage.
The sensorless vector method offers better torque production and speed regulation over a wider speed range than basic volts/hertz.
Dynamic boost is applied internally to compensate voltage drop and improve starting torque.
Figure 118 - Approximate Load Curve
Voltage, max
Base Voltage
(nameplate)
Dynamic Boost Applied
Ideal, volts/hertz
Base Frequency,
(nameplate)
Frequency, max
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
231
Appendix D
Motor Control Feature Support
Current Limiting for
Frequency Control
The current limiting module prevents the OutputCurrent value from exceeding the OperativeCurrentLimit value when the drive is configured in
Frequency Control mode.
Figure 119 - Current Limiting Module
Velocity from Planner
(MAJ)
Fine
Command
Velocity
+
–
Velocity
Reference
Operative
Current Limit
+
–
Output
Current
PI
In Frequency Control mode, OperativeCurrentLimit is the minimum value of the motor-thermal current limit, inverter-thermal current limit, motor-peak current limit, drive-peak current limit, and the CurrentVectorLimit value.
The Effects of Current Limiting
Indirect current limiting is available for induction motors configured for frequency control. You can use this feature to help prevent overcurrent faults due to aggressive acceleration/deceleration profiles or impact loads. The
Current Limiting attribute uses a PI regulator to control the OutputCurrent by adjusting the velocity reference.
IMPORTANT
When configured for Frequency Control (induction motors only), select the
Decel and disable stopping action only when the Current Limiting feature is enabled.
6
4
10
8
16
14
12
2
0
0
Figure 120 - Effects of Current Limiting on an Aggressive Acceleration
Aggressive Acceleration, No Current Limiting
70 16
Aggressive Acceleration, Current Limiting Active
200 400
Output Current
0
600 800 1000
Time (ms)
1200
Operative Current Limit
1400
1600
1800
Output Frequency
-10
2000
40
30
60
50
20
10
6
4
2
0
0
10
8
14
12
0
200 400
Output Current
600 800 1000
Time (ms)
1200
Operative Current Limit
1400 1600 1800 2000
-10
Output Frequency
20
10
40
30
70
60
50
232
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Attribute
Offset
Type
3022
3023
3024
3025
12
10
8
6
4
2
0
4000 4200 4400
Output Current
Impact Load, No Current Limiting
Figure 121 - Effects of Current Limiting on an Impact Load
Impact Load, Current Limiting Active
70 12
60
10
50
40
8
6
30
20
4
10
0
2
4600 4800 5000
Time (ms)
Operative Current Limit
5200 5400 5600
Output Frequency
-10
5800
0
4000 4200 4400
Output Current
4600 4800 5000
Time (ms)
Operative Current Limit
5200 5400 5600
Output Frequency
-10
5800
70
60
50
40
30
20
10
0
SINT
REAL
REAL
REAL
Current limiting for frequency control is not enabled by default. You can enable via messaging by using the following device-specific attributes.
TIP
We recommend you leave the Kp, Ki, Kd gains at the default values.
Table 87 - Enable Current Limiting via Messaging
Attribute Name
Conditional
Implementation
Description
Current Limiting
Enable
Current Limiting Kd
Frequency Control
Induction Motor only
Current Limiting Ki
Current Limiting Kp
When enabled, limits the rate of change to the velocity reference during high-current situations for improved current limiting. This feature is only active when executing an MDS command and when configured for Frequency Control.
0 = Current Limiting is disabled
1 = Current Limiting is enabled
Derivative gain for the current limiting function. Only functional when configured for Frequency
Control and when executing an MDS command. Units of seconds.
Integral gain for the current limiting function. Only functional when configured for Frequency Control and when executing an MDS command. Units of feedback counts / (Amp, inst* Seconds).
Proportional gain for the current limiting function. Only functional when configured for Frequency
Control and when executing an MDS command. Units of feedback counts / Amp, inst.
IMPORTANT
For induction motors greater than 5 Hp, it is recommended that the Stability
Control feature also be enabled when Current Limiting is enabled.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
233
Appendix D
Motor Control Feature Support
Enable the Current Limiting Feature
In this example, a Message Configuration (MSG) instruction is configured to enable the CurrentLimitingEnable attribute for axis 1. The Instance field is used to direct the message to the proper axis.
234
Set the CurrentVectorLimit Attribute Value
For current limiting, the CurrentVectorLimit attribute is used to help determine the OperativeCurrentLimit of the drive. Set the
CurrentVectorLimit value to artificially lower OperativeCurrentLimit below the drive or motor peak current limits.
1.
Select the Parameter List category and scroll to CurrentVectorLimit.
2.
Set the CurrentVectorLimit value appropriate for your application.
IMPORTANT
The CurrentVectorLimit attribute appears in the Parameter List of the Logix
Designer application, version 29.00 and later. If you are using a previous version, the CurrentVectorLimit attribute must be set via a Message
Configuration (MSG) instruction.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Stability Control for
Frequency Control
Stability control is available for induction motors configured for frequency control. This feature can be used to help remove resonances that are sometimes seen on larger motors. The stability control feature adjusts the
OutputFrequency and OutputVoltage commands to stabilize the
OutputCurrent.
10
0
-10
Figure 122 - Effects of Stability Control
60
Id Feedback, Iq Feedback versus Commanded Speed with Stability Control Disabled
25
Id Feedback, Iq Feedback versus Commanded Speed with Stability Control Enabled
50
20
40
15
30
10
20
5
0
-5
-20
Commanded Frequency, Hz
Iq Feedback Id Feedback
Commanded Frequency, Hz
Iq Feedback Id Feedback
Attribute
Offset
Type
3026
3027
3028
3029
SINT
REAL
REAL
REAL
Stability control for frequency control is not enabled by default. You can enable via messaging by using the following device-specific attributes.
TIP
We recommend you leave the angle, voltage gains, and filter bandwidth at the default values.
Table 88 - Enable Current Limiting via Messaging
Attribute Name
Stability Control
Enable
Stability Filter
Bandwidth
Stability Voltage
Gain
Stability Angle Gain
Conditional
Implementation
Description
Frequency Control
Induction Motor only
Enables stability control when configured for frequency control.
0 = Stability Control is disabled
1 = Stability Control is enabled
Sets the bandwidth of the low-pass filter applied to the current feedback signal. This bandwidth is common to both the angle and voltage stability control algorithms. Units of radians/second.
The gain of the voltage stability control function. Only active when configured for frequency control.
Units of Volt (inst,p-n)/Amp (inst).
The gain of the electrical angle stability control function. Only active when configured for frequency control. Units of radians/Amp (inst).
IMPORTANT
Because the stability control feature works by manipulating the
OutputVoltage and OutputFrequency signals, these signals may appear
'noisy' when the feature is enabled.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
235
Appendix D
Motor Control Feature Support
Enable the Stability Control Feature
In this example, a Message Configuration (MSG) instruction is configured to enable the StabilityControl attribute for axis 1. The Instance field is used to direct the message to the proper axis.
236
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Skip Speeds
Motor Control Feature Support
Appendix D
Some machines have a resonant operating frequency (vibration speed) that is undesirable or could cause equipment damage. To guard against continuous operation at one or more resonant points, you can configure the skip-speed attributes in the Logix Designer application>Axis Properties>Parameter List category.
The value that is programmed into the SkipSpeed1 or SkipSpeed2 attribute sets the central speed of a skip-speed band within which the drive does not operate. The width of the band is determined by the SkipSpeedBand attribute.
The range is split, half above and half below the SkipSpeed
x
attribute. Any command set-point within this band is adjusted by the skip-speed feature to fall at either the upper or lower skip-speed band boundary value. The skipspeed feature contains hysteresis (25% of the SkipSpeedBand value) to prevent frequent switching of VelocityReference.
Figure 123 - Single Skip Speed Example
Speed
Velocity
Setpoint
Velocity
Reference
SkipSpeedBand Upper Boundary
SkipSpeed
SkipSpeedBand Lower Boundary
Time
A SkipSpeedBand value of 0 disables the skip-speed feature.
IMPORTANT
When a single SkipSpeed value is desired, the SkipSpeed1 and
SkipSpeed2 settings must be the same.
IMPORTANT
Acceleration and deceleration are affected by the skip-speed feature. Too large of a SkipSpeedBand value can result in an overcurrent drive fault.
IMPORTANT
The MaximumFrequency attribute is always enforced. Skip-speed band boundary values beyond the MaximumFrequency value do not apply.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
237
Appendix D
Motor Control Feature Support
Multiple Skip Speeds
The Kinetix 5500 drives feature two independent skip-speed attributes
(SkipSpeed1 and SkipSpeed2) that use the same SkipSpeedBand.
Figure 124 - Multiple Skip Speed Example
238
SkipSpeed2
SkipSpeedBand
SkipSpeed1
SkipSpeedBand
0
0 Time
When skip-speed band boundaries of SkipSpeed1 and SkipSpeed2 overlap, the skip-speed hysteresis is calculated using the effective skip band.
, SkipSpeed1 is set to 0 and SkipSpeed2 is set to 15 hz. The skip band is 10 Hz wide.
0
-5
10
5
-10
0
At point A the axis is enabled, and the motor begins to rotate at -5 Hz even though the command is 0 Hz. As the command reaches hysteresis point the output frequency begins to follow the command. During deceleration, when the command decreases to 0 Hz, the output frequency continues at 5 Hz until the axis is disabled (point B), or the command is changed outside of the skip band.
25
20
15
Figure 125 - Zero-speed Skip Frequency
30
SkipSpeed1 = 0 Hz
SkipSpeed2 = 15 Hz
Skip Band = 10 Hz
A
B
5000 10,000 15,000 20,000 25,000 30,000 35,000 40,000
Output Frequency Command Frequency
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Flux Up
Motor Control Feature Support
Appendix D
AC induction motors require that flux builds in the motor stator before controlled torque can develop. To build flux, voltage is applied. There are two methods to flux the motor and three configurable FluxUpControl settings.
With the No Delay setting (normal start), flux is established when the output voltage and frequency are applied to the motor. While flux is building, the unpredictable nature of the developed torque can cause the rotor to oscillate even though acceleration of the load can occur. In the motor, the acceleration profile does not follow the commanded acceleration profile due to the lack of developed torque.
Figure 126 - Acceleration Profile during Normal Start - No Flux Up
Frequency
Reference
Rated Flux
Stator
Rotor
0
Oscillation due to flux being established.
Time
With the Automatic setting (default) DC current is applied to the motor so that flux builds before rotation. The flux-up time period is based on the level of flux-up current and the rotor time constant of the motor. The flux-up current is not adjustable.
In the Manual setting, DC current is applied to the motor so that flux builds before rotation. The flux-up time period is determined by the FluxUpTime attribute. The flux-up current is not adjustable.
Figure 127 - Flux Up Current versus Flux Up Time
Flux Up Current = Maximum DC Current
Rated Flux
Current
Rated Motor Flux
Motor Flux
0
T1
T2
T3
T4
Flux Up Time
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
239
Appendix D
Motor Control Feature Support
240
Once rated flux is reached in the motor, normal operation can begin and the desired acceleration profile achieved.
Figure 128 - Rated Flux Reached
Flux Up
Voltage
Flux Up
IR Voltage - SVC
Greater of IR Voltage or
Voltage Boost - V/Hz
Normal Operation
Time
Stator Voltage
Rotor Speed
Motor Flux
Stator Frequency
Flux Up Attributes
ID
558
559
Access
Set
Set
Attribute
Flux Up Control
Flux Up Time
(1)
Conditional Implementation
Ind Motor only
0 = No Delay
1 = Manual Delay
2 = Automatic Delay
Ind Motor only
Units: Seconds
Default: 0.0000
Min/Max: 0.0000 / 1000.00
(1) This is the time designated for the Manual Delay setting. This attribute is not supported by the Automatic delay method. The flux-up feature is disabled if FluxUpControl is set to Manual Delay and FluxUpTime is set to 0.
FluxUpControl Attribute
When the motion axis is enabled, DC current is applied to an induction motor to build stator flux before transitioning to the Running state. This attribute controls how an induction motor is to be fluxed in the Starting state prior to transitioning to the Running state.
Table 89 - FluxUp Control Delay Methods
Delay Method
No delay
Manual delay
Automatic delay
Description
The axis transitions immediately to the Running state while the motor flux is building.
The axis remains in the Starting state while the motor stator flux is building according to the
Flux Up Time attribute.
The drive determines the amount of delay time to fully flux the motor based on the motor configuration attribute data or measurements.
FluxUpTime Attribute
When FluxUpControl is configured for Manual Delay, this attribute sets the length of delay time to fully flux the motor before transitioning to the Running state.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Configure the Flux Up Attributes
Follow these steps to configure the flux-up attributes.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the Parameter List category and scroll to FluxUpControl.
3.
From the FluxUpControl pull-down menu, choose the proper delay value appropriate for your application.
4.
If you chose Manual Delay in
, enter a value in the FluxUpTime attribute appropriate for your application.
If you chose No Delay or Automatic Delay in
, the FluxUpTime attribute does not apply.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
241
Appendix D
Motor Control Feature Support
Current Regulator Loop
Settings
Current loop bandwidth is set differently based on the selected motor type.
Table 90 - Current Regulator Loop Settings
Motor Type
Default Torque/Current Loop Bandwidth
Hz
Rotary permanent magnet
Rotary interior permanent magnet
Linear permanent magnet
1000
IMPORTANT
The Logix Designer application does not perform calculations when the
Torque/Current Loop Bandwidth attribute is updated. This bandwidth affects many other gains and limits. Changing, (lowering) the torque loop bandwidth without updating all the dependent attributes can result in drive/motor instability.
Motor Category
From the Motor category you can enter motor nameplate or datasheet values
(phase-to-phase parameters) for rotary induction motors.
In this example, the Motor category>Nameplate / Datasheet parameters, were taken from a typical motor performance datasheet. Max Speed and Peak
Current values are typically application dependent.
Figure 129 - Motor Nameplate / Datasheet Example
242
See
for motor manufacturer performance data sheet example.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Figure 130 - Motor Manufacturer Performance Data Sheet
C E R T I FI C A T I ON DA T A SHE E T
T Y PI C A L M OT OR PE R FOR M A NC E DA T A
H P
1
PH H z
3 60 kW
.75
SY NC . R PM
V O L T S
F UL L L O AD E F F : 84
F UL L L O AD PF : 75
1800
F L A MPS
3/ 1.5
F .L . R PM
1725
ST A R T T Y PE
INV ER TER ONL Y
3/4 L O AD E F F : 82.5
3/4 L O AD PF : 65.5
F R A ME
56C
1/2 L O AD E F F : 78.5
1/2 L O AD PF : 51
DUT Y
E NC L O SUR E
C ONTINUOUS
TENV
G T D. E F F
81.5
I NSL
F 3
S.F .
1.0
K V A C O DE
P
A MB°C
40
E L E C . T Y PE
SQ C AGE INV DUTY
DE SI G N
E L E V A T I O N
3300
A
NO L O A D A MPS
2 / 1
F .L . T O R Q UE
3 L B -F T
SO UND PR E SSUR E
@ 3 F T .
62 dB A
R 1
8.378
R M
11132.8
L O C K E D R O T O R A MPS
30 / 15
L .R . T O R Q UE
10.8 L B -F T 360%
B.D. T O R Q UE
15 L B -F T 500%
F .L . R I SE °C
65
SO UND PO W E R
72 dB A
R O T O R W K ^2 MA X . W K ^2
0.11 L B -F T ^2 0 L B -F T ^2
SA F E ST A L L T I ME
0 SE C .
E QUI V A L E NT W Y E C K T .PA R A M E T E R S (OHM S PE R PHA SE )
R 2
5.6232
X 1
10.7068
X 2
9.9116
ST A R T S /
H O UR
0
A PPR O X .
MO T O R W G T
42 L B S.
X M
278.036
ZR E F
284
X R
1.7
T D
0.0071
T D0
0.136
Motor>Model Category
From the Motor>Model category you can enter additional motor nameplate or datasheet values (phase-to-neutral parameters) for induction motors.
The Motor>Model parameters are used in closed-loop induction-motor control mode, sensorless vector control mode, and when FluxUp is enabled, and are estimated automatically by the Logix Designer application based on the motor nameplate data. You can also enter these parameter values directly from the motor nameplate/datasheet or indirectly by running a Motor>Analyzer test.
Figure 131 - Phase-to-Neutral Parameters
IMPORTANT
If you do not know the Stator Leakage, Rotor Leakage, Stator Resistance,
Rated Flux Current, and system inertia, you can run the static motor test and
Autotune procedure to determine the parameter values.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
243
Appendix D
Motor Control Feature Support
Motor>Analyzer Category
From the Motor>Analyzer category you can perform three types of tests to identify motor parameters.
In this example, the Calculate Model test was run. If the Motor>Analyzer test executes successfully, and you accept the test values, they populate the Model
Parameter attributes.
Figure 132 - Motor Analyzer Category
244
Motor Tests and Autotune Procedure
You can perform three types of tests to identify motor parameters and one test for motor/system inertia. These parameters are used by sensorless-vector
frequency-control and induction motor closed-loop modes. Table 91
recommends which test to use based on the control mode and application.
Table 91 - Motor Tests and Autotune Matrix
Control Mode
Induction motor - Frequency control
Description Calculate Static
Basic volts/hertz Not required Not required
Basic volts/hertz for Fan/Pump
Not required
Sensorless vector Required
(1)
Not required
Preferred
(1) Not required for the Logix Designer application, version 29.00 and later.
Dynamic
Not required
Not required
Not required
Autotune (inertia test)
Not required
Not required
Not required
For motor/system autotune procedure, see Tune Induction Motors
on
for more information.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
The Motor>Analyzer category offers three choices for calculating or measuring electrical motor data.
Follow these steps to run motor tests and identify motor parameters.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the Motor>Analyzer category.
Nameplate data was entered on
page 242 . The nameplate data must be
entered before running the Calculate test.
3.
Click Start to run the test.
4.
Click Accept Test Results to save the values.
5.
Click OK.
Motor Analyzer Category Troubleshooting
Calculate Model
When a Calculate test is run, the drive uses motor nameplate data to estimate the motor’s Rated Flux Current, Stator Resistance (Rs), Stator Leakage
Reactance (X1) and Rotor Leakage Reactance (X2). The drive also calculates the rated slip speed based on rated speed and rated frequency. No measurements are taken when using the Calculate test.
Static Motor Test
Use the Static test if the motor shaft cannot rotate or if it is already coupled to the load. Only tests that do not create motor movement are run. During this test, the Stator Resistance (Rs), Stator Leakage Reactance (X1), and Rotor
Leakage Reactance (X2) values are measured during a series of static tests. The
Rated Flux Current is estimated, since measurement of this value requires
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
245
Appendix D
Motor Control Feature Support
246
motor movement. The drive also calculates the rated slip speed based on rated speed and rated frequency.
The Static test requires that you enter initial estimates for Rated Flux Current,
Rated Slip Speed, Stator Resistance (Rs), Stator Leakage Reactance (X1), and
Rotor Leakage Reactance (X2) into the Motor Model fields.
• For the Logix Designer application, version 29.00 or later, initial estimates are populated by the controller.
• For the Logix Designer application, version 28.00 or earlier, this can be done by running and accepting the results of a Calculate test, or by entering the values directly into the Logix Designer application.
Dynamic Motor Test
Dynamic tests are run with the motor disconnected from the load because the motor shaft turns and there are no travel limits. This is often the most accurate test method. During this test, the Stator Resistance (Rs), Stator Leakage
Reactance (X1) and Rotor Leakage Reactance (X2) values are measured in a series of static tests. The Rated Flux Current is measured during a rotational test, in which the drive commands 75% of the motor rated speed.
The rated slip speed is measured during a second rotational test, in which the drive commands a speed (default of 100% of the motor rated speed) and set a torque limit (default of 50% of the motor rated torque). This quickly accelerates the motor to rated speed and then decelerates back to zero speed.
IMPORTANT
The Dynamic test does not support travel limits.
The Dynamic test also requires that you enter initial estimates for Rated Flux
Current, Rated Slip Speed, Stator Resistance (Rs), Stator Leakage Reactance
(X1), and Rotor Leakage Reactance (X2) into the Motor Model fields.
• For the Logix Designer application, version 29.00 or later, initial estimates are automatically populated by the controller.
• For the Logix Designer application, version 28.00 or earlier, this can be done by running and accepting the results of a Calculate test, or by entering the values directly into the Logix Designer application.
The Dynamic test uses the Ramp Acceleration and Ramp Deceleration attributes to set the rotational test ramp-up and ramp-down times. If the resulting acceleration/deceleration times are less than 10 seconds, 10 seconds is used. If these attributes are not supported, 10 seconds is also used.
The Dynamic test also uses the IM Slip Test Velocity Command (percent of rated speed) and IM Slip Test Torque Limit (percent of rated torque) attributes to define the motion profile for the slip measurement. The default values are 100.0 and 50.0 respectively. The speed command dictates the speed that the motor spins up to and the torque dictates how quickly the motor reaches that speed. In general, A higher speed and lower torque results in a longer acceleration and a more accurate rated slip speed. However, be aware
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Attribute
Offset
Type
3095 REAL
3096 REAL that the dynamic test will not return expected results if the torque limit is set below 30.0.
Table 92 - Slip Test via Messaging
Attribute Name
IM Slip Test Torque Limit
IM Slip Test Velocity Command
Conditional
Implementation
Description
Closed loop induction motor only
Sets positive and negative torque limits for the slip test within the Dynamic motor test
(similar to the torque limits in the inertia test). Units are in percent of rated torque.
Sets the velocity command for the slip test within the Dynamic motor test, (similar to the velocity command in the inertia test). Units are in percent of motor rated speed.
The Dynamic test requires the Positive and Negative Torque Limits for said axis are not over-written while the test is in progress. This can be satisfied by making sure that (1) these cyclic attributes are not checked as writable within the Drive Parameters tab of the axis properties and (2) these parameters are not being messaged via an MSG instruction.
When configured for closed-loop control, the Dynamic test requires that an accurate system inertia is set in the Logix Designer application.
• For the Logix Designer application, version 29.00 or later, a default value is automatically populated by the controller.
• For the Logix Designer application, version 28.00 or earlier, this can be done by running and accepting the results of an Autotune test, or by entering the motor inertia value directly into the Logix Designer application.
When configured for closed-loop control, the Dynamic test uses the velocity regulator tuning as entered into the Logix Designer application. If the motor is coupled to a load, the velocity regulator tuning may need to be adjusted to make sure the velocity response is well controlled. The Dynamic test fails if the steady-state velocity feedback is not within a ±30% tolerance of the commanded velocity.
IMPORTANT
The Dynamic test is not supported in closed-loop Torque Control.
If using the Dynamic test in Frequency Control mode, uncouple the motor from any load or results may not be valid. In closed-loop control, either a coupled or uncoupled load produces valid results.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
247
Appendix D
Motor Control Feature Support
Selection of Motor Thermal
Models
The Kinetix 5500 drives contain two motor thermal-overload protection algorithms that you can use to prevent the motor from overheating.
Generic Motors
The default thermal model is a generic I
2
T Class 10 overload protection algorithm. This model is active if the MotorWindingToAmbientResistance or the MotorWindingToAmbientCapacitance values are 0.0. The purpose of this algorithm is to limit the time a motor is operating with excessive levels of current. The relationship between Motor Overload Factory Limit trip-time and motor output current is shown in
Figure 133 - Motor Overload Curve
248
100,000
10,000
1000
100
10
0 100 125 150 175 200 225
250
You can use the MotorOverloadLimit attribute (default of 100%, max of
200%) to increase the motor overload trip-time by artificially increasing the motor rated current (for thermal protection only). MotorOverloadLimit should only be increased above 100% if cooling options are applied. Increasing
MotorOverloadLimit causes MotorCapacity to increase more slowly.
The generic motor thermal model also derates the motor rated current (for thermal protection only) when operating at low speeds. The derating factor is
30% at 0 Hz and 0% at 20 Hz, with linear interpolation between. Operating at output frequencies less than 20 Hz causes MotorCapacity to increase more quickly.
When the generic motor thermal-model is active, the MotorCapacity attribute increases only if the motor output current is greater than the effective motor rated current (taking into account the MotorOverloadLimit and low speed derating factor). The default MotorThermalOverloadFactoryLimit and
MotorThermalOverloadUserLimit values for this thermal model are both
100%.
IMPORTANT
The generic motor-thermal model does not support Current Foldback as a Motor Overload Action.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Thermally Characterized Motors
If the MotorWindingToAmbientResistance and
MotorWindingToAmbientCapacitance attribute values are both non-zero, the motor is considered thermally characterized and an alternate motor thermal model is run. The purpose of this algorithm is to limit the time a motor is operating with excessive levels of current. This thermal model uses the firstorder time constant determined from the
MotorWindingToAmbientResistance and
MotorWindingToAmbientCapacitance values to estimate the motor thermal capacity based on the motor output current.
The MotorOverloadLimit attribute (default of 100%, max of 200%) can be used to increase the motor overload trip-time by increasing the
MotorThermalOverloadFactoryLimit value. The MotorOverloadLimit should be increased above 100% only if cooling options are applied. Increasing
MotorOverloadLimit does not change the behavior of MotorCapacity.
This thermal model supports setting the MotorOverloadAction attribute as
Current Foldback. Selecting the Current Foldback action results in a reduction in the current reference via the MotorThermalCurrentLimit attribute value that is reduced in proportion the percentage difference between the
MotorCapacity and the MotorOverloadLimit values.
When this thermal model is active, the MotorCapacity attribute is non-zero if the motor output current is non-zero. The default
MotorThermalOverloadFactoryLimit and MotorThermalOverloadUserLimit values for this thermal model are both 110%.
IMPORTANT
This thermal model does not derate the motor-rated current when operating at low speeds. Operating at low output frequencies does not cause the MotorCapacity behavior to change.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
249
Appendix D
Motor Control Feature Support
Speed Limited Adjustable
Torque (SLAT)
Speed limited adjustable torque (SLAT) is a special mode of operation used primarily in web handling applications. While configured for SLAT, the drive typically operates as a torque regulator. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output, relative to the applied
TorqueTrim attribute.
A torque regulated application can be described as any process requiring tension control. For example, a winder or unwinder with material being drawn or pulled with a specific tension required. The process also requires that another element set the speed.
When operating as a torque regulator, the motor current is adjusted to achieve the desired torque. If the material being wound or unwound breaks, the load decreases dramatically and the motor can potentially go into a runaway condition.
The SLAT feature is used to support applications that require a robust transition from torque regulation to velocity regulation (and vice versa). The
SLAT feature can be configured via the SLATConfiguration attribute as:
Table 93 - SLAT Configuration Descriptions
Name
SLAT Disable
Description
SLAT function is disabled. Normal Velocity Loop operation.
SLAT Min Speed/Torque
SLAT Max Speed/Torque
Drive automatically switches from Torque regulation to Velocity regulation if
VelocityError < 0 and switches back to Torque regulation if VelocityError > SLATSetPoint for SLATTimeDelay.
Drive automatically switches from Torque regulation to Velocity regulation if
VelocityError > 0 and switches back to Torque regulation if VelocityError < SLATSetPoint for SLATTimeDelay.
Direction of the applied torque and direction of the material movement determine whether SLAT minimum or SLAT maximum mode should be used.
Motion Polarity Setting
The Motion Polarity setting in the Logix Designer application>Axis
Properties>Polarity does not affect SLAT behavior, however, you may require clarification on whether to use the SLAT Min Speed/Torque or SLAT Max
Speed/Torque configuration when Motion Polarity is set to Inverted. In this case, the velocity error displayed in the Logix Designer application is inverted compared to what is actually used by the axis to control the SLAT function. So, if the SLAT configuration is set to Min and then Motion Polarity is switched to Inverted, change the SLAT configuration to Max.
250
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Table 94 - SLAT Operation When Motion Polarity Is Inverted
Velocity Command
Positive (clockwise)
Negative (CCW)
Motion Polarity
Normal
Inverted
Normal
Inverted
SLAT Configuration
Min
Max
Min
Max
SLAT Min Speed/Torque
SLAT Min Speed/Torque is a special mode of operation primarily used in web handling applications. The drive typically operates as a torque regulator, provided that the TorqueTrim attribute is less than the torque output due to the velocity regulator's control effort. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output relative to the torque reference.
When used for SLAT control, an application dependent VelocityCommand value is applied to the drive via an MAJ instruction. An application dependent
TorqueTrim value is also applied via cyclic write. Under normal operation,
VelocityCommand is set to a level that results in the velocity regulator's control effort becoming saturated when the motor's speed is mechanically limited. The
TorqueReference value equals the TorqueTrim value, resulting in a positive
VelocityError value.
Should the mechanical speed limitation be removed (example: web break), the motor accelerates and VelocityError becomes negative. At this time, a forced transition to velocity regulation occurs, and the motor's speed is regulated to the VelocityCommand attribute.
Select Minimum of Velocity Loop Output or Torque Command
(speed control is OFF)
The axis remains in velocity regulation until VelocityError exceeds
SLATSetPoint for a time specified by SLATTimeDelay. At this point, the axis returns to operating as a torque regulator.
Figure 134 - SLAT Min Speed/Torque
Velocity Error < 0
Select Velocity Loop Output
(speed control is ON)
Velocity Error > SLAT Setpoint for SLAT Time
See the Integrated Motion on the EtherNet/IP™ Network Reference Manual, publication MOTION-RM003 , for more information on SLAT attributes.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
251
Appendix D
Motor Control Feature Support
SLAT Max Speed/Torque
SLAT Max Speed/Torque is a special mode of operation primarily used in web handling applications. The drive typically operates as a torque regulator, provided that the TorqueTrim attribute is greater than the torque output due to the velocity regulator's control effort. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output relative to the torque reference.
When used for SLAT control, an application dependent VelocityCommand value is applied to the drive via an MAJ instruction. An application dependent
TorqueTrim value is also applied via cyclic write. Under normal operation,
VelocityCommand is set to a level that results in the velocity regulator's control effort becoming saturated when the motor's speed is mechanically limited. The
TorqueReference value equals the TorqueTrim value, resulting in a negative
VelocityError value.
Should the mechanical speed limitation be removed (example: web break), the motor accelerates and VelocityError becomes positive. At this time, a forced transition to velocity regulation occurs, and the motor's speed is regulated to the VelocityCommand attribute.
Select Maximum of Velocity Loop Output or Torque Command
(speed control is OFF)
The axis remains in velocity regulation until VelocityError is less than
SLATSetPoint for a time specified by SLATTimeDelay. At this point, the axis returns to operating as a torque regulator.
Figure 135 - SLAT Max Speed/Torque
Velocity Error > 0
Select Velocity Loop Output
(speed control is ON)
Velocity Error < SLAT Setpoint for SLAT Time
See the Integrated Motion on the EtherNet/IP Network Reference Manual, publication MOTION-RM003 , for more information on SLAT attributes.
SLAT Attributes
ID
833
834
835
Access
Set
Set
Set
Attribute
SLAT Configuration
SLAT Set Point
SLAT Time Delay
Conditional Implementation
0 = SLAT Disable
(1)
1 = SLAT Min Speed/Torque
2 = SLAT Max Speed/Torque
Velocity Units
Seconds
(1) SLAT Disable, when viewed in version 28.00 (and earlier) of the Logix Designer application, reads Torque Only.
252
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Configure the Axis for SLAT
Follow these steps to configure the SLAT attributes.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the General category.
The General dialog box appears.
3.
From the Axis Configuration pull-down menu, choose Velocity Loop.
The Velocity Loop dialog box appears.
4.
Enter values for the Velocity Loop attributes appropriate for your application.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
253
Appendix D
Motor Control Feature Support
5.
Click Apply.
6.
Select the Parameters List category.
The Motion Axis Parameters dialog box appears.
7.
From the SLATConfiguration pull-down menu, choose the SLAT configuration appropriate for your application.
IMPORTANT
SLAT parameters are configurable only when Velocity Loop is chosen from the General category, Axis Configuration pull-down menu.
8.
Click Apply.
9.
Enter values for SLATSetPoint and SLATTimeDelay attributes appropriate for your application.
10.
Click OK.
11.
Select the Drive Parameters category.
254
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
The Drive Parameters to Controller Mapping dialog box appears.
When using SLAT with Kinetix 5500 drives, the velocity command is sent to the drive via an MAJ instruction. The torque command is sent via the cyclic write TorqueTrim attribute. See the Integrated Motion on the EtherNet/IP
Network Reference Manual, publication MOTION-RM003 , for more information on cyclic read and cyclic write.
For MAJ instructions:
• When using SLAT, start the axis with the MSO instruction.
• The VelocityCommand is sent via the MAJ instruction.
• The TorqueCommand is sent to AxisTag.TorqueTrim.
• To make changes to the VelocityCommand, you must re-trigger the
MAJ with the Speed value or use a MCD (motion change dynamics) instruction.
• To stop the axis use a MAS instruction.
• The axis accelerates and decelerates at the MAJ instruction programmed
Acceleration and Deceleration rates.
• You can also change the rates using the MCD instruction.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
255
Appendix D
Motor Control Feature Support
Motor Overload Retention
The motor overload retention feature protects the motor in the event of a drive power-cycle, in which the motor thermal state is lost.
With motor overload retention, upon drive power-up the MotorCapacity attribute initially reads:
• 20% if the motor is configured to use an integral thermal switch or an integral motor winding temperature is available
• 50% if the motor is not configured to use an integral thermal switch or an integral motor winding temperature is not available
If you have a separate monitoring algorithm within your Logix 5000™ controller, you can use the InitialMotorCapacity attribute (3075)
10
or (C03)
16 to change the initial MotorCapacity value that the motor overload retention feature populates.
• You can write to the InitialMotorCapacity attribute only in the Stopped state after power-up
• You cannot write to the InitialMotorCapacity attribute after the first time the axis is enabled following a power cycle.
Use a message instruction to write to the InitialMotorCapacity value.
In this example, the source element tag motorcapacity is a REAL Data type.
256
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Phase Loss Detection
Motor Control Feature Support
Appendix D
The phase-loss detection feature is designed to determine if motor power wiring is electrically connected to a motor and that reasonable current control exists. This attribute enables the operation of the drive's torque proving functions that work in conjunction with mechanical brake control.
When the ProvingConfiguration attribute is enabled, the drive performs a torque prove test of the motor current while in the Starting state to prove that current is properly flowing through each of the motor phases before releasing the brake. If the torque prove test fails, the motor brake stays engaged and a
FLT-S09 Motor Phase Loss exception (fault) is generated.
IMPORTANT
The mechanical brake must be set as soon as the drive is disabled. When the brake is under the control of the axis state machine, this is automatic.
But, when controlled externally, failure to set the brake when the drive is disabled can cause a free-fall condition on a vertical application.
Table 95 - Phase-loss Detection Startup Sequence
Startup Phase Description
Phase 1
When the drive receives an enable request, the Starting state begins execution and torque proving starts.
Phase 2
Phase 3
The torque proving feature ramps current to the motor-phase output connector and verifies that the current feedback circuitry detects current on each of the phases.
Once motor-current feedback has been verified in each motor phase, the drive attempts to enable the current control loop at a user-specified current level, and verifies that the currentloop error tolerance is within range.
Torque proving is available for all motoring configurations including closedloop servo control and induction motors.
For permanent magnet (PM) motors, the drive attempts to apply current to the motor phases such that all current through the motor is flux current. However, due to the electrical angle of the motor at the time of the MSO instruction, it may not be possible to verify the motor phase wiring with only flux current.
Therefore, with a PM motor it is possible that the motor shaft can move slightly during torque proving if no motor brake exists to hold the load.
Phase-loss Detection Attributes
ID Access Attribute
590 SSV ProvingConfiguration
591 SSV TorqueProveCurrent
Conditional Implementation
0 = Disabled
1 = Enabled
% Motor Rated
Units: Amps
Default: 0.000
Min/Max: 0/10,000
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
257
Appendix D
Motor Control Feature Support
Phase-loss Detection Configuration
Follow these steps to configure the phase-loss detection attributes.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the Parameter List category and scroll to ProvingConfiguration.
258
3.
From the ProvingConfiguration pull-down menu, choose Enabled to enable the torque proving feature.
4.
Enter a value in the TorqueProveCurrent attribute appropriate for your application.
5.
Click OK.
The TorqueProveCurrent attribute is active only if ProvingConfiguration is set to Enabled. TorqueProveCurrent lets you specify the amount of current that is used during the torque proving test and calculated as a percentage of motor rating. The higher the TorqueProveCurrent value the more current the drive delivers to the motor to verify that the motor phase wiring is available and capable of that current level. High current levels conversely cause more thermal stress and (potentially) can cause more torque to be driven against the motor brake during the test. If the TorqueProveCurrent level selected is too small, the drive cannot distinguish the proving current from noise, and in this case the drive posts an INHIBIT M04 torque-proving configuration fault code. The minimum amount of torque proving current depends on catalog number of the drive.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Phase Loss Detection Current Example
In this example, a 2198-H025-ERS
x
servo drive is paired with a
VPL-B1003T-C motor with 6.77 A rms rated current. Use the phase-loss detection equation and table to calculate the initial minimum torque-proving current as a percentage of motor rated current. Depending on the unique characteristics of your application, the required torque-proving current value can be larger than the initial recommended value.
Figure 136 - Phase-loss Detection Equation
Rating From Table
Motor Rated Current
x 100% =
0.5746 A
6.77 A x 100% = 8.49%
Table 96 - Recommended Phase-loss Detection Current
Drive Cat. No.
2198-H003-ERS
x
2198-H008-ERS
x
2198-H015-ERS
x
2198-H025-ERS
x
2198-H040-ERS
x
2198-H070-ERS
x
1.257
2.011
3.268
5.782
Phase-loss Detection Current, min
A, rms
0.2514
0.6285
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
259
Appendix D
Motor Control Feature Support
Velocity Droop
The velocity droop function can be useful when some level of compliance is required due to rigid mechanical coupling between two motors. The feature is supported when the axis is configured for Frequency Control, Velocity
Control, or Position Control.
Closed Loop Control
The closed-loop velocity droop function is supported when configured for either Velocity or Position control. The velocity error input to the integral term is reduced by a fraction of the velocity regulator's output, as controlled by the
VelocityDroop attribute. Therefore, as torque loading on the motor increases, actual motor speed is reduced in proportion to the droop gain. This is helpful when some level of compliance is required due to rigid mechanical coupling between two motors.
IMPORTANT
The closed-loop velocity droop function acts to reduce the velocity error input to the integral term, but never changes the polarity of the velocity error.
IMPORTANT
When configured for closed-loop control, the units of the VelocityDroop attribute are Velocity Control Units / Sec / % Rated Torque.
Frequency Control
The velocity droop function is also supported when configured for Frequency
Control. As the estimated Iq current within the motor increases, the velocity reference is reduced in proportion to the VelocityDroop attribute. Therefore, as torque loading on the motor increases, actual motor speed is reduced in proportion to the droop gain. This is helpful when some level of compliance is required due to rigid mechanical coupling between two motors.
IMPORTANT
The frequency-control velocity droop function acts to reduce the velocity reference, but never changes the direction of the velocity reference.
IMPORTANT
When configured for frequency control, the units of the VelocityDroop attribute are Velocity Control Units / Sec / % Rated Iq Current.
Velocity Droop Attribute
ID
464/321
Access Attribute
SSV Velocity Droop
Conditional Implementation
Velocity Units / Sec / % Rated
260
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Motor Control Feature Support
Appendix D
Velocity Droop Configuration
Follow these steps to configure the velocity droop attribute.
1.
In the Controller Organizer, right-click an axis and choose Properties.
2.
Select the Parameter List category and scroll to VelocityDroop.
3.
Enter a value in the Velocity Droop attribute appropriate for your application.
4.
Click OK.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
261
Appendix D
Motor Control Feature Support
Commutation Test
The commutation test determines an unknown commutation offset and can also be used to determine the unknown polarity of the start-up commutation wiring. You can also use the commutation test to verify a known commutation offset and the polarity start-up commutation wiring.
IMPORTANT
For Kinetix 5500 drives, this test applies to only third-party motors.
IMPORTANT
When motors have an unknown commutation offset and are not listed in the Motion Database by catalog number, you cannot enable the axis.
Figure 137 - Hookup Tests - Commutation Tab
Adaptive Tuning
262
To run the commutation test, see Test the Axes on page 148
.
The adaptive tuning feature is an algorithm inside the Kinetix 5500 servo drives. The algorithm continuously monitors and, if necessary, adjusts or adapts various filter parameters and, in some cases, control-loop gains to compensate for unknown and changing load conditions while the drive is running. Its primary function is to:
• Automatically adjust torque-loop notch and low-pass filter parameters to suppress resonances
• Automatically adjust control-loop gains to avoid instability when detected
See Motion System Tuning Application Techniques, publication MOTION-
AT005 , for more information on the AdaptiveTuningConfiguration attribute.
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Numerics
2090-CSBM1DF
2090-CSBM1DG
2198-CAPMOD-1300
2198-DBR
xx
-F
2198-DB
xx
-F
2198-H2DCK
,
,
2198-KITCON-DSL
,
24V input power connector
evaluation
pinouts
wiring
A
about this publication
absolute position feature
AC line filters
2198-DBR
xx
-F
2198-DB
xx
-F
noise reduction
actions category
adaptive tuning
additional resources
Add-on Profile
alarm
application requirements
applying power
associated axes tab
audience for this manual
axis properties
,
axis unstable
B
basic volts/hertz
BC connector
pinouts
wiring
Beldon
block diagrams
capacitor module
power
bonding
EMI (electromagnetic interference)
examples
high frequency energy
subpanels
brake relay
Bulletin
MPAI electric cylinders
MPAR electric cylinders
MPAS linear stages
bus
configuration
regulator
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
bus-sharing
group
group example
groups
C
cables
catalog numbers
categories
Ethernet cable length
induction motors
shield clamp
calculate model
capacitor module
catalog number
description
interconnect diagram
status indicator
support
wiring
catalog numbers
capacitor module
motor cables
,
,
servo drives hardwired
integrated
shared-bus connection system
category 3
requirements
stop category definitions
,
CE
compliance
certification
application requirements
PL and SIL
TÜV Rheinland
user responsibilities
website
,
circuit breaker selection
clamp
,
commutation offset
CompactLogix
Ethernet connections
compatibility
motor feedback
Index
263
Index
264 configuring
basic volts/hertz
controller
fan/pump volts/hertz
feedback-only axis
,
flux up
frequency control category
general category
hardwired
home screen
hookup test
induction motor tuning
induction-motor frequency-control axis
integrated safety
IP address
Logix 5000 communication
master feedback
menu screens
module properties
,
inhibit module
motion group
motor category
test
motor category
motor feedback
motor>analyzer category
network parameters
parameter list category
,
power tab bus-sharing group example
bus-sharing groups
sensorless vector
servo motor axis actions category
delay times
general category
load category
motor category
parameter list category
scaling category
setup screens
SLAT
SPM motor closed-loop axis properties
startup sequence
torque proving
velocity droop
connecting
CompactLogix
ControlLogix
converter kit shield clamp
Ethernet cables
motor shield clamp
,
connector kit
2198-H2DCK
2198-KITCON-DSL
connector locations
servo drives
control power
input specifications
pinouts
system calculations
wiring
ControlFLASH
firmware upgrade
troubleshooting
controller
and drive behavior
CompactLogix
configure
ControlLogix
properties date/time tab
enable time synchronization
ControlLogix
Ethernet connections
conventions used in this manual
converter kit
2198-H2DCK
cable lengths, max
,
cable preparation motor feedback
motor power/brake
description
Kinetix 5500 AOP
CP connector
pinouts
wiring
current limiting
current regulator loop
D
date/time tab
DC bus connector
pinouts
delay times
digital inputs
pinouts
wiring
disable
display
download program
drilling hole patterns
drive replacement
integrated safety
dynamic motor test
E
earth ground
EMC
motor ground termination
EMI (electromagnetic interference)
bonding
enable time synchronization
enclosure
power dissipation
requirements
sizing
encoder support
DSL
energy calculations
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
Index erratic operation
Ethernet connector
pinouts
EtherNet/IP
connecting cables
connections
PORT1 and PORT2 connectors
external shunt resistor
pinouts
wiring
F
fan/pump
fan/pump volts/hertz
fault
code summary
codes
codes (see attached spreadsheet)
status only
feedback
configurations
feedback-only axis
grounding technique
feedback-only axis
firmware upgrade
system requirements
verify upgrade
flux up
attributes
frequency control category
,
fuse selection
G
general
category
,
tab
grounded power configuration
grounding
multiple subpanels
screws
H
hardwired connections
hardwired STO
HF bonding
high frequency energy
Hiperface-to-DSL feedback converter kit
hole patterns
home screen
soft menu
hookup test
I
I/O
digital inputs specifications
IEC 61508
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
IEC 62061
ignore
induction motor control
configure flux up
control methods basic volts/hertz
fan/pump
sensorless vector
flux up
attributes
frequency-control axis
motor analyzer category
and inertia tests
data sheet
model category
multiple skip speed
open-loop frequency control
,
skip speed
SLAT
inhibit module
input power wiring
24V control
3-phase delta
determine input power
grounded power configuration
grounding screws
mains
remove grounding screws
ungrounded power configuration
installing drive accessories
AC line filters
external shunt resistor
installing your drive
bonding examples
bonding subpanels
cable categories
circuit breakers
clearance requirements
fuse selection
HF bonding
passive shunts
system mounting requirements
transformer
integrated safety
connections
drive replacement
out-of-box state
protocol
STO state reset
integrated STO
interconnect diagrams
2198 drive with LDAT
2198 drive with MPAR/MPAI
2198 drive with MPAS
2198 drive with MPL/MPM/MPF/MPS
2198 drive with VPAR
2198 drive with VPL/VPF/VPH/VPS
bus-sharing drives shared AC
shared AC/DC
shared AC/DC hybrid
265
Index
266
shared DC
capacitor module
feedback grounding technique
notes
shunt resistor
single-axis drive single-phase
three-phase
IOD connector
pinouts
wiring
IP address
IPD connector
pinouts
wiring
ISO 13849-1 CAT 3
requirements
stop category definitions
,
K
Kinetix 5500
Kinetix VP electric cylinders
L
Lapp
LCD display
messages
LDAT-Series linear thrusters
linear actuators
interconnect diagram
LDAT
MPAR/MPAI
MPAS
link
link/activity status indicator
speed status indicator
load category
load observer
Logix 5000 communication
Logix Designer
Logix Designer application
M
mains input power connector
pinouts
wiring
major fault
master feedback
menu screens
MF connector
pinouts
wiring
minor fault
module definition
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
module properties
associated axes tab
general tab
,
module definition
,
new tag
power tab
safety tab
module status connector
pinouts
module status indicator
Motion Analyzer website
motion direct commands
STO bypas
warning messages
motion group
motor
analyzer category
category
data sheet
feedback compatibility
model category
motor and inertia tests
overload retention
thermal models
motors
accel/decel problems
brake connector pinouts
wiring
cable catalog numbers
cable length
category
feedback connector pinouts
wiring
ground termination
induction
interconnect diagram
MPL/MPM/MPF/MPS
VPL/VPF/VPH/VPS
overheating
power connector pinouts
wiring
shield clamp wiring
,
testing
tuning
velocity
mounting your capacitor module
mounting order
mounting your drive
attaching to the panel
drilling hole patterns
mounting order
shared-bus connection system
single-axis
zero-stack tab and cutout
MP connector
pinouts
wiring
MPAI electric cylinders
MPAR electric cylinders
MPAS linear stages
Index
MS connector
pinouts
multiple skip speed
N
navigation buttons
network
parameters
status indicator
new tag
data type
noise
abnormal
feedback
reduction
O
open-loop frequency control
out-of-box state
P
panel requirements
parameter list category
,
passive shunt
use cases
PFH definition
pinouts
24V input power connector
DC bus connector
digital inputs connector
Ethernet connector
mains input power connector
module status connector
motor brake connector
motor feedback connector
motor power connector
safe torque-off
shunt connector
planning your installation
power dissipation
power tab
bus configuration
bus regulator
bus-sharing group
group example
groups
power structure
power up
product selection website
publications, related
R
rated slip speed
regenerative energy
related publications
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
remove grounding screws
remove/replace drive
remove drive
remove power
replace drive
startup and configure
routing power and signal wiring
S
SAB
safe torque-off
bypass wiring
cascaded wiring
configurations hardwired
integrated
operation
PFH
pinouts
specifications
safety
tab
scaling category
sensorless vector
setup screens
shared AC
configurations
interconnect diagram
shared AC/DC
configurations
interconnect diagram
power sharing example
shared AC/DC hybrid
configurations
interconnect diagram
power sharing example
shared DC
configurations
interconnect diagram
power sharing example
shared-bus
configurations
connection system
catalog numbers
guidelines
shield clamp
,
,
shunt connector
pinouts
wiring
shunt resistor
interconnect diagram
shunts
passive
shutdown
sizing
control power
energy calculations
power sharing examples shared AC/DC
shared AC/DC hybrid
267
Index
268
shared DC
shared-bus configurations
shared AC
shared AC/DC
shared AC/DC hybrid
shared DC
shared-bus guidelines
skip speed
SLAT
attributes
configuring
slip test messaging
soft menu
home screen
software
Logix Designer application
specifications
brake relay
control power input
digital inputs
EtherNet/IP connections
motor feedback absolute position
Stegmann DSL
safe torque-off
,
speed limited adjustable torque
SPM motor closed-loop axis properties
stability control
startup sequence
static motor test
status indicators
capacitor module
link speed status
link/activity status
module status
network status
STO
bypass
connector pinouts
connector wiring
state reset
stop
drive
planner
Studio 5000 Logix Designer
system
block diagrams capacitor module
power
components
ground
mounting requirements
overview
EtherNet/IP
shared AC
shared AC/DC
shared AC/DC hybrid
shared DC
standalone
T
testing axes
hookup test
time synchronization
torque proving
attributes
configuring
training
transformer sizing
troubleshooting
alarm
capacitor module status
ControlFLASH
controller/drive fault behavior
disable
fault code summary
codes
codes (see attached spreadsheet)
status only
general system problems
abnormal noise
axis unstable
erratic operation
feedback noise
motor accel/decel
motor overheating
motor velocity
no rotation
ignore
LCD display messages
link speed status indicator
link/activity status indicator
major fault
minor fault
module status indicator
network status indicator
safety precautions
shutdown
status indicators
stop drive
planner
tuning
induction motor
PM motor
tuning axes
load observer
typical installation
EtherNet/IP
shared AC
shared AC/DC
shared AC/DC hybrid
shared DC
standalone
U
ungrounded power configuration
use cases
passive shunt
user responsibilities
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
V
velocity droop
attribute
configure
verify upgrade
voltage drop
24V input power
W
website
certifications
Motion Analyzer
product selection
wiring
BC connector
capacitor module
converter kit shield clamp
CP connector
earth ground
Ethernet cables
external shunt resistor
grounded power configuration
grounding screws
guidelines
input power type
IOD connector
IPD connector
MF connector
motor cable shield clamp
MP connector
RC connector
remove grounding screws
requirements
routing power and signal wiring
safe torque-off bypass
safe torque-off cascaded
STO connector
ungrounded power configuration
Z
zero-stack tab and cutout
Index
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
269
Index
Notes:
270
Rockwell Automation Publication 2198-UM001I-EN-P - May 2019
.
Rockwell Automation Support
Use the following resources to access support information.
Technical Support Center
Local Technical Support Phone
Numbers
Direct Dial Codes
Literature Library
Product Compatibility and
Download Center (PCDC)
Knowledgebase Articles, How-to Videos, FAQs, Chat,
User Forums, and Product Notification Updates.
Locate the phone number for your country.
https://rockwellautomation.custhelp.com/ http://www.rockwellautomation.com/global/support/get-support-now.page
Find the Direct Dial Code for your product. Use the code to route your call directly to a technical support engineer.
http://www.rockwellautomation.com/global/support/direct-dial.page
Installation Instructions, Manuals, Brochures, and
Technical Data.
http://www.rockwellautomation.com/global/literature-library/overview.page
Get help determining how products interact, check features and capabilities, and find associated firmware.
http://www.rockwellautomation.com/global/support/pcdc.page
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete the How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf
.
Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page
.
Allen-Bradley, CompactLogix, ControlFLASH, ControlLogix, GuardLogix, HPK-Series, Kinetix, Logix 5000, MP-Series, PanelView Plus, POINT Guard I/O, POINT I/O, Rockwell Automation, Rockwell Software, RSLinx, Stratix, Studio 5000,
Studio 5000 Logix Designer, and TL-Series, are trademarks of Rockwell Automation, Inc.
EtherNet/IP, CIP Safety, and CIP Sync are trademarks of ODVA, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Otomasyon Ticaret A.Ĺž., Kar Plaza Ä°Ĺź Merkezi E Blok Kat:6 34752 Ä°çerenköy, Ä°stanbul, Tel: +90 (216) 5698400
Publication 2198-UM001I-EN-P - May 2019
Supersedes Publication 2198-UM001H-EN-P - November 2016 Copyright © 2019 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Standalone and multi-axis operation
- Shared AC/DC power configurations
- EtherNet/IP communication
- Safe Torque-Off (STO) functionality
- Logix 5000 controller integration
- Modular design for scalability