Allen-Bradley Kinetix 7000 BM06-S, BM07-S, BM08-S, BM09-S, BM10-S, BM11-S, BM12-S servo drive User Manual
Kinetix 7000 BM06-S, Kinetix 7000 BM07-S, Kinetix 7000 BM08-S, Kinetix 7000 BM09-S, Kinetix 7000 BM10-S, Kinetix 7000 BM11-S, Kinetix 7000 BM12-S are high-power servo drives designed to provide a Kinetix Integrated Motion solution for applications with output power requirements in the range of 22…149 kW (40…248 A). These drives feature a safe-off feature and are available with 460V AC input power, or capable of operating with a shared DC bus.
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User Manual
Kinetix 7000 High Power Servo Drive
Catalog Numbers 2099-BM06-S, 2099-BM07-S, 2099-BM08-S, 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, 2099-BM12-S
Important User Information
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).
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
New and Updated
Information
Summary of Changes
This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.
This table contains the changes made to this revision.
Topic Page
In Figure 1, updated the image of the LIM to reflect the current design of the LIM. 13
Revised Figure 49 to reflect current design and location of ground wires.
In the Feedback and I/O Cable Connections section, updated the information about the cables that can be used with HPK-Series motors.
81
94
In Figure 83, updated the information about the cables that can be used with
Bulletin MPL and MPM motors.
In Figure 84, updated the information about the cables that can be used with HPK-
Series motors.
176
177
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
3
Summary of Changes
Notes:
4
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Table of Contents
Summary of Changes
New and Updated Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preface
Start
Chapter 1
CE Requirements - System without LIM . . . . . . . . . . . . . . . . . . . . . . . 19
CE Requirements - System with LIM . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 2
Install the Kinetix 7000 Drive System
System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cable Categories for Kinetix 7000 Systems . . . . . . . . . . . . . . . . . . . . . 35
Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 36
Kinetix 7000 Connector Data
Chapter 3
Locate and Identify Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . 42
Digital and Analog Input/Output (IOD) Connector Pinout. . . . . 45
General Purpose I/O (GPIO) Terminal Block Connections . . . . . 46
General Purpose Relay (GPR) Terminal Block Connections . . . . . 46
Motor Feedback (MF) Connector Pinouts . . . . . . . . . . . . . . . . . . . . . 47
Auxiliary Feedback (AF) Connector Pinouts . . . . . . . . . . . . . . . . . . . 49
Safe-off (SO) Terminal Block Connections . . . . . . . . . . . . . . . . . . . . . 50
Control Power (CP) Terminal Block Connections . . . . . . . . . . . . . . 51
Power Terminal Block (PTB) Connections. . . . . . . . . . . . . . . . . . . . . 51
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
5
6
Table of Contents
Connect the Kinetix 7000 Drive
System
Digital Inputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Analog Inputs (IOD Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog Outputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General Purpose I/O (GPIO Connector) . . . . . . . . . . . . . . . . . . . . . . . 63
General Purpose Relay (GPR Connector). . . . . . . . . . . . . . . . . . . . . . . 64
Motor (MF) and Auxiliary Feedback (AF) Connections . . . . . . . . . . . . . 66
Motor and Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . . . . 66
Chapter 4
Building Your Own Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 75
Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Power Distribution Systems Without a Ground Reference . . . . . . . 77
Setting the Ground Jumper in Ungrounded Power Configurations . . . 78
Removing the Ground Wires on 2099-BM09-S and
Removing the Ground Wires on 2099-BM11-S and
Grounding the Kinetix 7000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 81
Grounding Your System to the Subpanel . . . . . . . . . . . . . . . . . . . . . . . 81
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Motor Power Cable Shield Termination . . . . . . . . . . . . . . . . . . . . . . . . 82
MP-Series (Bulletin MPL) Motor Connectors . . . . . . . . . . . . . . . . . . 83
Input Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Wire the Kinetix 7000 Drive Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Wire the Control Power (CP) Connector . . . . . . . . . . . . . . . . . . . . . . 88
Wire DC Input Power (Common Bus Configurations Only). . . . . 89
Wire the Safe-off (SO) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Table of Contents
Wire the General Purpose Relay (GPR) and General Purpose I/O
Wire Motor Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Flying-lead Feedback Cable Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Wire Feedback and I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connect Premolded Motor Feedback Cables . . . . . . . . . . . . . . . . . . . 96
Wire Panel-mounted Breakout Board Kits. . . . . . . . . . . . . . . . . . . . . . 97
Wire Low-profile Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
SERCOS Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . 102
Configure and Start the Kinetix 7000
Drive System
Chapter 5
Node Addressing Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Configure the Logix SERCOS interface Module . . . . . . . . . . . . . . . . . . . 112
Configure the Logix Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Configure the SERCOS Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Configure the Kinetix 7000 Drive Modules. . . . . . . . . . . . . . . . . . . . 119
Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Configure Drive Parameters and System Variables . . . . . . . . . . . . . . . . . 136
Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Troubleshoot the Kinetix 7000 Drive
System
Chapter 6
Interpret Error Codes and Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 140
Specifications and Dimensions
Appendix A
Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
7
Table of Contents
Interconnect Diagrams
Upgrade Firmware
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Precharge Capacities of the Regenerative Power Supply . . . . . . . . . . . . . 159
Appendix B
Kinetix 7000 Drive/Rotary Motor Wiring Examples . . . . . . . . . . . 174
Kinetix Safe-off Feature Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Appendix C
8
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Preface
About This Publication
This manual provides detailed installation instructions for mounting, wiring, and troubleshooting your Kinetix® 7000 drive, and system integration for your drive/ motor combination with a Logix controller.
Who Should Use This Manual
This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 7000 drive, and programmers directly involved in the operation, field maintenance, and integration of the Kinetix 7000 drive with a SERCOS interface module.
If you do not have a basic understanding of the Kinetix 7000 drive, contact your local Rockwell Automation sales representative before using this product for the availability of training courses.
Conventions Used in This
Manual
These conventions are used throughout this manual.
•
Bulleted lists such as this one provide information, not procedural steps.
•
Numbered lists provide sequential steps or hierarchical information.
Additional Resources
Resource
Kinetix 7000 DC-DC Converter and Control Board Kits, publication 2099-IN002
Kinetix 7000 Drive Installation Instructions, publication 2099-IN003
Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010
ControlLogix® SERCOS interface Module Installation Instructions, publication
1756-IN572
Logix5000™ Controllers General Instructions Reference Manual, publication
1756-RM003
ControlLogix System User Manual, publication 1756-UM001
CompactLogix™ SERCOS interface Module Installation Instructions, publication 1768-IN005
CompactLogix Controllers User Manual, publication 1768-UM001
SoftLogix™ Motion Card Setup and Configuration Manual, publication 1784-UM003
SoftLogix 5800 User Manual, publication 1789-UM002
8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001
System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001
The following documents contain additional information concerning related products from Rockwell Automation.
Description
Provides information on removing and replacing the DC-DC converter, DC-DC converter fuse, and the control board assembly in a Kinetix 7000 drive.
Provides information on installing a Kinetix 7000 drive.
Provides information on proper handling, installing, testing, and troubleshooting fiber-optic cables.
Provides details about installing a 3, 8, or 16-Axis ControlLogix SERCOS interface module.
Provides programmers with details about each available instruction for a
Logix5000 controller. You should be familiar with how the Logix5000 controller stores and processes data before consulting this publication.
Provides information about configuring and troubleshooting a ControlLogix system.
Provides information on installing and troubleshooting a CompactLogix SERCOS interface motion module.
Provides information on installing, configuring, programming, and operating a
CompactLogix system.
Provides information on configuring and troubleshooting a SoftLogix PCI card.
Provides information on configuring, programming, and operating a SoftLogix system.
Provides a hardware description and start-up and programming procedures for the 8720MC-RPS Regenerative Power Supply.
Provides information, examples, and techniques designed to minimize system failures caused by electrical noise.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
9
Preface
Resource
Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002
Kinetix Motion Control Selection Guide, publication GMC-SG001
Kinetix 7000 Drive Systems Design Guide, publication GMC-RM007
Kinetix Servo Drives Specifications Technical Data, publication GMC-TD003
Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004
Motion Analyzer Sizing and Selection Tool, https://motionanalyzer.rockwellautomation.com
Rockwell Automation Configuration and Selection Tools, http://www.rockwellautomation.com/global/support/configuration.page
Rockwell Automation Product Certification Website: http://www.rockwellautomation.com/products/certification/
SERCOS and Analog Motion Configuration and Startup, publication
MOTION-UM001
Motion Coordinate System User Manual, publication MOTION-UM002
Logix5000 Controllers Motion Instructions Reference Manual, publication MOTION-RM002
National Electrical Code, published by the National Fire Protection Association of Boston, MA
Safety Products, publication S117-CA001
Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls, publication SGI-IN001
Understanding the Machinery Directive, publication SHB-900
Allen-Bradley Industrial Automation Glossary, publication AG-7.1
Description
Provides detailed installation instructions for wiring and troubleshooting a
Kinetix 7000 safe-off drive.
Provides descriptions and specifications for the 2099 product family including motors and accessories.
The purpose of this publication is to assist you in identifying the drive system components and accessory items you’ll need for your Kinetix 7000 drive/motor combination.
Provides catalog numbers and product specifications, including performance, environmental, certifications, load force, and dimension drawings for Allen-
Bradley® servo drives.
Provides catalog numbers, product specifications, and dimensions for Allen-
Bradley servo drive accessories.
Online tool for sizing and selecting servo drive systems with the compatible motor, actuator, and accessories required for each axis.
Provides online product selection and system configuration tools, including
AutoCAD (DXF) drawings.
Provides online access to declarations of conformity (DoC) currently available from Rockwell Automation.
Provides information to create a motion coordinate system with SERCOS or analog motion modules.
Provides information on configuring and troubleshooting your ControlLogix,
CompactLogix, and SoftLogix SERCOS interface modules.
Provides programmers with details about the motion instructions that are available for a Logix5000 controller.
Provides access to articles on wire sizes and types for grounding electrical equipment.
Provides information on principle standards and implementation of safety products and catalogs available safety products.
Provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solidstate components.
Provides information on the CE marking process, with references to key European requirements and resources, and examples of safety component applications.
A glossary of industrial automation terms and abbreviations.
You can view or download publications at http://literature.rockwellautomation.com
. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell
Automation sales representative.
10
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Chapter
1
Start
Use this chapter to become familiar with the design and installation requirements for Kinetix 7000 drive systems.
Topic
Page
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
11
Chapter 1
Start
About the Drive System
The Kinetix 7000 high-power servo drive is designed to provide a Kinetix
Integrated Motion solution for applications with output power requirements in the range of 22…149 kW (40…248 A).
Table 1 - Kinetix 7000 Drive System Overview
Kinetix 7000
Component
Servo Drive
Catalog Numbers
2099-BM
xx
-S
(1)
Regenerative Power
Supply
Logix Controller
Platform
8720MC-RPS
1756-L60M03SE module
1756-M
xx
SE module
1768-M04SE module
1784-PM16SE PCI card
RSLogix™ 5000
Software
9324-RLD300ENE
Rotary Servo Motors MP-Series, HPK-Series, and
RDD-Series
Cables Motor Power, Feedback, and
Brake cables
Description
The Kinetix 7000 servo drive with safe-off feature is available with 460V AC input power, or capable of operating with a shared DC bus.
The 8720MC-RPS is a sinusoidal PWM converter that may serve as a regenerative power supply for one or more drives.
The SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix platform and
Kinetix 7000 drive system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (SERCOS) protocol over a fiber-optic cable.
RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of controllers.
Compatible rotary servo motors include MP-Series (Bulletin MPL and MPM) 400V class motors, HPK-Series motors, and
RDD-Series direct-drive motors.
Bulletin 2090 motor power/brake and feedback cables are available with bayonet, threaded, and SpeedTec connectors.
Power/brake cables have flying leads on the drive end and straight connectors that connect to servo motors. Feedback cables have flying leads that wire to low-profile connector kits on the drive end and straight connectors on the motor end.
AC Line Filters
Communication
2090-XXLF-TC
xxxx
Line Interface Module 2094-BL50/75S, or 2094-
XL75S-C
x
External Shunt
Modules
NA
Large power motors may require user power wiring to handle larger current requirements.
Bulletin 2090 SERCOS fiber-optic cables are available as enclosure only, PVC, nylon, and glass with connectors at both ends.
Bulletin 2090-XXLF-TC
xxxx
three-phase AC line filters are required to meet CE and available for use in all Kinetix 7000 drive systems.
The line interface module (LIM) contains the circuit breakers, power supplies, and safety contactor required for Kinetix 7000 operation. Individual components can be purchased separately in place of the LIM.
See External Shunt Modules on page 158
intended for use with Kinetix 7000 drives.
for active shunt solutions from Rockwell Automation® Encompass Partners and
(1) See the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 , for more information.
12
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Typical Drive System
Diagrams
460V AC
Three-Phase
Input Power
Start
Chapter 1
Typical Kinetix 7000 system installations include three-phase AC configurations, with and without the line interface module (LIM), and DC common bus configurations.
Figure 1 - Kinetix 7000 System Configuration with LIM and External Resistive Shunt
RSLogix 5000 Software
Input
Logix 5000 Controller
Output
1756-M
xx
SE SERCOS
Interface Module
ControlLogix Chassis
Safe-off,
General Purpose I/O,
General Purpose Relay
Connections
Commissioning
2090-SC
xxx
-
x
SERCOS Fiber-Optic Ring
2099-BM
xx
-S Kinetix 7000 Drive
2094-BL75S
Line Interface Module
(optional component)
2090-K6CK-D
xxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Auxiliary Feedback
24V DC
Control Power
2090-XXLF-TC
xxxx
AC Line Filter
External Shunt Module (optional component). See
External Shunt Modules on page 158 for more
information.
Motor Power Cable
HPK-Series Motors, RDD-Series Direct Drive Motors, MPM-
B165
xx
and MPM-B215
xx
, and MPL-B5
xxx
, MPL-B6
xxx
,
MPL-B8
xxx
, and MPL-B9
xxx
(shown) Servo Motors
Encoder
Feedback
Cable
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
13
Chapter 1
Start
Input Fusing
Input
Contactor
Three-Phase
Input Power
Figure 2 - Kinetix 7000 System Configuration without Line Interface Module (LIM)
RSLogix 5000 Software
Input
Logix 5000
Controller
Output
1756-M
xx
SE
SERCOS Interface Module
ControlLogix
Chassis
Safe-off,
General Purpose I/O,
General Purpose Relay connections
Commissioning
2090-SC
xxx
-
x
SERCOS Fiber-Optic Ring
2099-BM
xx
-S Kinetix 7000 Drive
2090-K6CK-D
xxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Auxiliary Feedback.
1606-XL
xxx
24V DC
Control Power
Control Power Supply
Input
Input
Allen-Bradley
1606-XL
P o w e r S u p p l y
2090-XXLF-TC
xxxx
AC Line Filter
External Shunt Module (optional component).
See External Shunt Modules on page 158 for more
information.
Motor Power Cable
HPK-Series Motors, RDD-Series Direct Drive Motors, MPM-
B165
xx
and MPM-B215
xx
, and MPL-B5
xxx
, MPL-B6
xxx
,
MPL-B8
xxx
, and MPL-B9
xxx
(shown) Servo Motors
Encoder
Feedback
Cable
14
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Three-phase
Input Power
Input
Fusing
Start
Chapter 1
The Kinetix 7000 drive system shown in Figure 3 illustrates a regenerative power
only configuration with a 8720MC regenerative power supply (RPS). The harmonic filter and varistor are available separately, but are included with the
RPS unit when ordering the 8720MC-RPS065BM-HV2. In this configuration the Kinetix 7000 drive provides motoring power and the 8720MC-RPS065 provides regenerative power.
8720MC-RFI80
AC Line Filter
(required for CE)
Figure 3 - Kinetix 7000 System Configuration with AC Input and Regenerative Power Supply
RSLogix 5000 Software
Logix Controller
Programming Network
Logix SERCOS interface Module
ControlLogix Chassis
RST PRG ENT
8720
MC
A
V
8720MC-LR
xx
Line Reactor
8720MC-RPS065BM-HV2
Regenerative Power Supply
Magnetic
Contactor
DC Bus
2099-BM
xx
-S
Kinetix 7000 Drive
2090-K6CK-D
xxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
1606-XL
xxx
24V DC
Control Power
Control Power
Supply Input
Input
Allen-Bradley
1606-XL
P o w e r S u p p l y
Regenerative
Power Only
8720MC-HF-B2 Harmonic Filter
Included with
8720MC-RPS065BM-HV2.
8720MC-VA-B Varistor
Included with
8720MC-RPS065BM-HV2.
2090-SC
xxx-x
SERCOS Fiber-optic Ring
Kinetix 7000 High Power
Servo Drive System
Motor
Power
Cable
Encoder
Feedback
Cable
Three-phase
Input Power
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165
xx
and MPM-
B215
xx
, and MPL-B5
xxx
, MPL-B6
xxx
,
MPL-B8
xxx
, and MPL-B9
xxx
(shown)
Servo Motors
Input
Fusing
Magnetic
Contactor
2090-XXLF-TC
xxxx
AC Line Filter
(required for CE)
1321-3R Type Line Reactor,
3% compatible with
Kinetix 7000 Drive
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
15
Chapter 1
Start
Input
Fusing
Three-phase
Input Power
The Kinetix 7000 drive system shown in
Figure 4 illustrates a DC common bus
configuration with two follower Kinetix 7000 (2099-BM11-S) drives and an
8720MC regenerative power supply (RPS). In full-line regenerative mode the
8720MC-RPS190 unit provides motoring and regenerative power.
Figure 4 - Kinetix 7000 System Configuration with AC Input and 8720MC-RPS190 with Full-line
Regeneration
RSLogix 5000 Software
Logix SERCOS interface Module
Logix Controller
Programming Network
RST PRG ENT
8720
MC
REGENERATIVE POWER SUPPLY
8720MC-EF190-VB
EMC Line Filter
This unit includes an AC line filter (required for CE), magnetic contactor, harmonic filter, and varistor.
IMPORTANT
The 8720MC-EF190-VB line filter unit and two
8720MC-LR10-100B line reactors are required when using the
8720MC-RPS190 regenerative power supply.
Ground
Fault
Protection
Fusing
RST PRG ENT
8720
MC
A
V
8720MC-LR10-100B
Line Reactor
(two units in parallel)
8720MC-RPS190BM
Regenerative Power Supply
Kinetix 7000 Drive
2099-BM11-S
2090-K6CK-D
xxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
1606-XL
xxx
24V DC
Control Power
Control Power
Supply Input
Input
Allen-Bradley
1606-XL
P o w e r S u p p l y
DC Bus
Fusing
Full Regenerative
Motor
Power Cable
HPK-Series Motors
2090-SC
xxx-x
SERCOS Fiber-optic Ring
2099-BM11-S
Kinetix 7000 Drive
2090-K6CK-D
xxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
1606-XL
xxx
24V DC
Control Power
Control Power
Supply Input
Input
Allen-Bradley
1606-XL
P o w e r S u p p l y
DC Bus
Fusing
DC Bus
Encoder
Feedback Cable
Motor
Power Cable
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165
xx
and MPM-
B215
xx
, and MPL-B5
xxx
, MPL-B6
xxx
,
MPL-B8
xxx
, and MPL-B9
xxx
(shown)
Servo Motors
Encoder
Feedback
Cable
16
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Start
Chapter 1
Three-Phase
Input Power
Input
Fusing
8720MC-LR
xx
Line Reactor
The Kinetix 7000 drive system shown in Figure 5
illustrates a DC common bus configuration with two follower Kinetix 7000 drives and an 8720MC regenerative power supply (RPS). The harmonic filter and varistor are available separately, but are included when ordering the 8720MC-RPS065BM-HV2 RPS unit. In full-line regenerative mode the 8720MC-RPS065BM-HV2 unit provides motoring power and regenerative power. In common bus mode, you must calculate the total bus capacitance of your DC common bus system. This lets you plan your panel layout and sufficiently size the 8720MC-RPS to precharge the entire system.
8720MC-RF180
AC Line Filter
Figure 5 - Kinetix 7000 System Configuration with DC Input from 8720MC-RPS065 Providing Fullline Regeneration
Input
Output
Logix 5000
Controller
1756-M
xx
SE SERCOS
Interface Module
ControlLogix
Chassis
RSLogix 5000 Software
Commissioning
Magnetic
Contactor
Harmonic Filter
(included with
8720MC-RPS065BM-HV2
Regenerative Power Supply)
Varistor
(included with
8720MC-RPS065BM-HV2
Regenerative Power Supply)
2090-SC
xxx
-
x
SERCOS Fiber-Optic Ring
8720MC-RPS065BM-HV2
Regenerative Power Supply
2099-BM
xx
-S
Kinetix 7000 Drive
2099-BM
xx
-S
Kinetix 7000 Drive
Ground
Fault
Protection
Fusing
A
V k W
R S T PRG ENT
8720
MC
R E G E N E R A T I W ER UPPLY S U P P LY
2090-K6CK-D
xxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Auxiliary Feedback
1606-XL
xxx
24V DC
Control Power
Control Power
Supply Input
(To retain logic control when main DC power is removed.)
Full Regenerative
Input
Allen-Bradley
1606-XL
P o w e r S u p p l y
DC Bus
Fusing
Motor Power Cable
HPK-Series Motors
2090-K6CK-D
xxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Auxiliary Feedback.
1606-XL
xxx
24V DC
Control Power
Control Power
Supply Input
(To retain logic control when main DC power is removed.)
DC Bus
Input
Allen-Bradley
1606-XL
P o w e r S u p p l y
DC Bus
Fusing
Encoder Feedback Cable
Motor Power Cable
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165
xx
and MPM-
B215
xx
, and MPL-B5
xxx
, MPL-B6
xxx
,
MPL-B8
xxx
, and MPL-B9
xxx
(shown)
Servo Motors
Encoder
Feedback
Cable
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
17
Chapter 1
Start
Catalog Number Explanation
Kinetix 7000 drive catalog numbers and descriptions are listed in the table below.
Kinetix 7000
Drive
Kinetix 7000, 460V, 22 kW, 40 A continuous output
Kinetix 7000, 460V, 30 kW, 52 A continuous output
Kinetix 7000, 460V, 37 kW, 65 A continuous output
Kinetix 7000, 460V, 56 kW, 96 A continuous output
Kinetix 7000, 460V, 75 kW, 125 A continuous output
Kinetix 7000, 460V, 112 kW, 180 A continuous output
Kinetix 7000, 460V, 149 kW, 248 A continuous output
Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Agency Compliance
If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply.
ATTENTION:
Meeting CE requires a grounded system, and the method of grounding the AC line filter and drive must match. Failure to do this renders the filter ineffective and may cause damage to the filter.
For grounding examples, see
Grounded Power Configurations on page 75
.
For more information on electrical noise reduction, see the System Design for
Control of Electrical Noise Reference Manual, publication GMC-RM001 .
18
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Start
Chapter 1
CE Requirements - System without LIM
To meet CE requirements when your Kinetix 7000 system does not use a 2094 line interface module to supply AC line and DC control power, the following requirements apply:
•
Install an 8720MC-RF180 line filter as close to the 8720MC-RPS unit as possible, and the AC line filter (2090-XXLF-TC
xxxx
) as close to the
Kinetix 7000 drive as possible.
•
For MP
x
motors, use 2090 series motor power cables or use connector kits.
Terminate cable shields at the chassis and the motor terminal block with a
360° connection.
•
For HPK-Series motors, use UL Approved 4 wire, 600V AC, shield, VFD cabling. Terminate cable shields at the chassis and the motor with a 360° connection.
•
Combined motor power/feedback cables must not exceed 90 m (295.3 ft).
•
Use 2090 series motor feedback cables or connector kits and terminate the feedback shield as shown in Chapter 4 for wiring instructions and
Appendix B for motor feedback connector kit catalog numbers. Drive to motor feedback cables must not exceed 90 m (295.3 ft).
•
Install the Kinetix 7000 system inside an enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure.
Separate signal and power cables.
•
Output power, control (I/O), and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation.
•
All shielded cables should terminate with a properly shielded connector.
See the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , for information on electrical noise reduction and grounding practices.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
19
Chapter 1
Start
CE Requirements - System with LIM
To meet CE requirements when your Kinetix 7000 system includes the line
interface module (LIM), follow all the requirements as stated in CE
Requirements - System without LIM on page 19
and these additional requirements that also apply to the AC line filter:
•
Install the LIM, 2094-XL75S-C
x
or 2094-BL50/75S, and line filter
(2090-XXLF-TC
xxx
) as close to the Kinetix 7000 drive as possible.
IMPORTANT
The full rated current on the AC input line should not exceed that of the line interface module.
Catalog numbers 2094-XL75S-C
x
or 2094-BL50S for 2099-BM06-S and
2099-BM07-S Kinetix 7000 drives, or 2094-BL75S for 2099-BM08-S Kinetix
7000 drives.
IMPORTANT
CE requires use of a grounded secondary or source with a 2099-BM
xx
-S drive.
Never use a LIM in an ungrounded input, due to the potential for high lineto-neutral voltages damaging components within the line filter.
CE Requirements - System with DC Common Bus through 8720MC-RPS
To meet CE requirements when your Kinetix 7000 system includes a common
DC bus with an 8720MC-RPS, follow all the requirements as stated in the CE
Requirements - System without LIM on page
19 , the recommended installation and wiring in the 8720MC Regenerative Power Supply Reference Manual, publication 8720MC-RM001 , and these additional requirements:
•
Install a three-phase line filter on the AC input power line of the RPS as
indicated in Interconnect Diagrams beginning on page 163
.
•
Install a single-phase line filter when attaching an AC line input to the
RPS MC1/2 circuit as indicated in the Interconnect Diagrams beginning
on page
20
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Chapter
2
Install the Kinetix 7000 Drive System
This chapter describes system installation guidelines in preparation for mounting your Kinetix 7000 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 any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
21
Chapter 2
Install the Kinetix 7000 Drive System
System Design Guidelines
To design your enclosure and plan where to mount the system components on the panel, use this section and the information in the Kinetix Servo Drives
Specifications Technical Data, publication GMC-TD003 .
For online product selection and system configuration tools, including
AutoCAD (DXF) drawings of the product, go to: http://www.rockwellautomation.com/en/e-tools/ .
System Mounting Requirements
Follow these system mounting requirements.
•
To comply with UL and CE requirements, the Kinetix 7000 drive system must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to NEMA/UL Type IP2X such that they are not accessible to an operator or unskilled person. A
NEMA/UL Type 4X enclosure exceeds these requirements providing protection to IP66.
•
The panel you install inside the enclosure for mounting your system components must be on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors (as
specified in Environmental Specifications on page 156
).
•
Size the drive enclosure so as not to exceed the maximum ambient temperature rating. Consider heat dissipation specifications for all drive components.
•
Segregate input power wiring and motor power cables from control wiring and motor feedback cables. Use shielded cable for power wiring and provide a grounded 360° clamp termination.
•
Use high-frequency (HF) bonding techniques to connect the modules, enclosure, machine frame, and motor housing, and to provide a lowimpedance return path for HF energy and reduce electrical noise.
See the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , to better understand the concept of electrical noise reduction.
Transformer Selection
The Kinetix 7000 drive does not require an isolation transformer for three-phase input power. However, a transformer may be required to match the voltage requirements of the controller to the available service.
22
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Install the Kinetix 7000 Drive System
Chapter 2
To size a transformer for the AC power inputs to devices peripheral to the
Kinetix 7000 drive, refer to the manufacturer continuous output power specification.
IMPORTANT
If using an autotransformer, make sure that the phase to neutral/ground voltages do not exceed the input voltage ratings of the drive.
IMPORTANT
Use a form factor of 1.5 for three-phase power (where form factor is used to compensate for transformer, drive module and motor losses, and to account for utilization in the intermittent operating area of the torque speed curve).
For example: using a secondary of 480 VAC and a 2099-BM06-S with a rated power output = 22 kW continuous:
22 * 1.5 = 33 kVA transformer
Circuit Breaker/Fuse Selection
The Kinetix 7000 drive uses internal solid-state motor short-circuit protection and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 200,000 A. Fuses or circuit breakers, with adequate withstand and interrupt ratings, as defined in NEC or applicable local codes, are permitted.
The 2094-BL50 and 2094-BL75S LIMs contain supplementary protection devices, but require a customer-supplied external line filter. See the Line Interface
Module Installation Instructions, publication 2094-IN005 , for power specifications and more information on using the LIM module.
The Bulletin 140M motor protection circuit breakers are another acceptable means of protection. As with fuses and circuit breakers, you must make sure that the selected components are properly coordinated and meet applicable codes including any requirements for branch circuit protection. When applying the
140M product, evaluation of the short circuit available current is critical and must be kept below the short circuit rating of the 140M product.
In most cases, fuses selected to match the drive input current rating will meet the
NEC requirements and provide the full drive capabilities. Dual element, time delay (slow acting) fuses should be used to avoid nuisance trips during the inrush current of power initialization.
See Circuit Breaker/Fuse Specifications on page 153
for recommended circuit breakers and fuses.
See Power Specifications on page 152 for input current and inrush current
specifications for your Kinetix 7000.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
23
Chapter 2
Install the Kinetix 7000 Drive System
Enclosure Selection
To assist you in sizing an enclosure, the following example is provided. The example system consists of the following components.
•
2-axis Kinetix 7000 servo drive system
•
ControlLogix chassis and modules
Size the Kinetix 7000 servo drive using Motion Analyzer software, version 4.2 or later, and use the results to predict the amount of heat dissipated into the enclosure. You will also need heat dissipation data from other equipment inside the enclosure (such as ControlLogix). Once the total amount of heat dissipation
(in watts) is known, the minimum enclosure size can be calculated. It is recommended that you also contact the enclosure manufacturer for the best enclosure fit, including possible cooling methods to help reduce enclosure size.
Using Motion Analyzer to Determine Heat Dissipation
To obtain Motion Analyzer software, go to: http://ab.rockwellautomation.com/Motion-Control/Motion-Analyzer-
Software
Complete the Motion Analyzer Axis View data to find an acceptable Kinetix
7000 drive and motor solution to meet the application needs. In the Axis View
Solutions window find the Drive Capacity value. In this example, the
2099-BM11-S Drive Capacity characteristic can be used for the estimation of the
Rated Power Output used for the percentage of watts dissipated.
24
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Install the Kinetix 7000 Drive System
Chapter 2
Table 2 - Kinetix 7000 System Heat Dissipation Example
Enclosure
Component
Description
2099-BM08-S
2099-BM11-S
Kinetix 7000 Servo Drive
Kinetix 7000 Servo Drive
Total Wattage of Kinetix 7000 system
Loading
(1)
(Motion Analyzer)
50%
50%
Heat Dissipation
Watts
452
1275
1727
(1) Loading determined using Motion Analyzer software.
(2) To determine heat dissipation specifications for the Kinetix 7000 drive, see Power Dissipation
on page
.
(2)
Table 3 - ControlLogix Heat Dissipation Example
Enclosure
Component
Description
1756-M08SE
1756-L5563
1756-IB16D
1756-OB16D
8-axis SERCOS interface module
L63 ControlLogix processor
16-point input module
16-point output module
EtherNet/IP communication module 1756-EN
x
T
x
Backplane total
1756-PB72
1756-A7
24V DC ControlLogix power supply
7-slot mounting chassis
Total ControlLogix system wattage
Backplane Power Load
(1)
Watts
3.2
4.5
0.84
4.64
4.0
17.18
N/A
N/A
(2)
(1) For ControlLogix module specifications, see the ControlLogix Selection Guide, publication 1756-SG001 .
Heat Dissipation
(1)
Watts
0.0
0.0
5.8
3.3
0.0
N/A
25.0
(2)
N/A
34.1
Figure 6 - ControlLogix Real Power
1756-P B72
1756-P B75
DC
Backplane
Power Load
(Watts)
75
60
45
30
15
0
0 20 40 60 80
Real Power (Watts)
100
For backplane power loading requirements of other ControlLogix power supplies, see the ControlLogix Selection Guide, publication 1756-SG001 .
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
25
Chapter 2
Install the Kinetix 7000 Drive System
In this example, the amount of power dissipated inside the cabinet is the sum of the Kinetix 7000 drive (2099-BM08-S and 2099-BM11-S) system value (1727
W) and the ControlLogix value (34.1 W) for a total of 1761 W.
With no active method of heat dissipation (such as fans or air conditioning) either of the following approximate equations can be used.
Metric Standard English
A
=
0.38
Q
1.8
T
–
1.1
A
=
T
4.08
–
Q
1.1
Where T is temperature difference between inside air and outside ambient (°C), Q is heat generated in enclosure
(Watts), and A is enclosure surface area (m
2
). The exterior surface of all six sides of an enclosure is calculated as
Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in enclosure
(Watts), and A is enclosure surface area (ft2). The exterior surface of all six sides of an enclosure is calculated as
A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height) are in meters. Where d (depth), w (width), and h (height) are in inches.
The maximum ambient rating of the Kinetix 7000 drive is 50 °C (122 °F) and if the maximum environmental temperature is 30 °C (86 °F) then Q=1761 and
T=20 in this equation.
A =
0.3
8 (1761)
1.
8 (20) - 1.1
A = 19.2 m
2
In this example, the enclosure must have an exterior surface of 19.2 m
2
. If any portion of the enclosure is not able to transfer heat, it should not be included in the calculation. For instance, if an externally-mounted shunt system is used with the Kinetix 7000 system, it should not be included in the equation.
The minimum enclosure size must take into account the physical size and minimum clearance requirements of the two Kinetix 7000 drives and the additional ControlLogix and other devices required to meet the application needs.
If the enclosure size is considerably larger than what is necessary to house the system components, it may be more efficient to provide a means of cooling in a smaller enclosure. Contact your enclosure manufacturer for options available to cool your enclosure.
26
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Install the Kinetix 7000 Drive System
Chapter 2
Minimum Clearance Requirements
This section provides information to assist you in sizing your cabinet and positioning your Kinetix 7000 system components.
IMPORTANT
Mount the module in an upright position as shown. Do not mount the module on its side.
Figure 7 - Minimum Clearance Requirements
101.6 mm (4.0 in.) clearance for airflow and installation
50.8 mm (2.0 in.) clearance left of module is required
50.8 mm (2.0 in.) clearance right of module is required
Minimum cabinet depth = 300 mm (11.8 in.)
Cable bend radius requires a minimum of
60 mm (2.4 in.) from the front panel connections.
101.6 mm (4.0 in.) clearance for airflow and installation
See page
154 for power dissipation specifications.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
27
Chapter 2
Install the Kinetix 7000 Drive System
Minimizing Electrical Noise
This section outlines best practices that minimize the possibility of noise-related failures as they apply specifically to Kinetix 7000 drive installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, see the System Design for Control of
Electrical Noise Reference Manual, publication GMC-RM001 .
Bonding Modules
Bonding is the practice of connecting metal chassis, assemblies, frames, shields, and enclosures to reduce the effects of electromagnetic interference (EMI).
Unless specified, most paints are not conductive and act as insulators. To achieve a good bond between the drive and subpanel, surfaces need to be unpainted or plated. Bonding metal surfaces creates a low-impedance return path for highfrequency energy.
IMPORTANT
To improve the bond between the drive and subpanel, construct your subpanel out of zinc-plated (unpainted) steel.
Improper bonding blocks the direct return path and routes high-frequency energy to elsewhere in the cabinet. Excessive high-frequency energy can effect the operation of other microprocessor controlled equipment.
Figure 8 shows details of recommended bonding practices for painted panels, enclosures, and mounting brackets.
28
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Install the Kinetix 7000 Drive System
Chapter 2
Subpanel
Star Washer
Nut
Figure 8 - Recommended Bonding Practices for Painted Panels
Stud-mounting the Subpanel to the Enclosure Back Wall
Back Wall of
Enclosure
Stud-mounting a Ground Bus or Chassis to the Subpanel
Mounting Bracket or
Ground Bus
Welded Stud
Use a wire brush to remove paint from threads to maximize ground connection.
Flat Washer
Nut
Use plated panels or scrape paint off front of panel.
Star Washer
Subpanel
Welded Stud
Flat Washer
Scrape Paint
If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole.
Ground Bus or
Mounting Bracket
Bolt-mounting a Ground Bus or Chassis to the Back-panel
Subpanel
Tapped
Hole
Nut
Flat Washer
Nut
Star Washer
Bolt
Star
Flat Washer
Washer
Star Washer
Scrape paint on both sides of panel and use star washers.
If the mounting bracket is coated with a non-conductive material (anodized, or painted for example), scrape the material around the mounting hole.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
29
Chapter 2
Install the Kinetix 7000 Drive System
Bonding Multiple Subpanels
Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels.
Figure 9 - Multiple Subpanels and Cabinet Recommendations
Bond the top and bottom of each subpanel to the cabinet using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Cabinet ground bus bonded to the subpanel.
Scrape the paint around each fastener to maximize metal to metal contact.
Establish Noise Zones
When designing a panel for a Kinetix 7000 system, observe the following guidelines with additional attention to zone locations.
30
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Clean Wireway (C
x
)
C1
Kinetix 7000 Drive
Install the Kinetix 7000 Drive System
Chapter 2
Noise Zones when Using Regenerative Power Supplies (with/without a Line Filter Unit)
Observe the following guidelines when laying out a Kinetix 7000 system panel if a regenerative power supply (8720-RPS
xxxxx
) is used (see
regenerative power supply and line filter unit are used (see
•
Mount the regenerative power supply to the right of the drive.
•
The clean zone (C) is beneath and left of the Kinetix 7000 drive. This zone includes the motor feedback, auxiliary feedback and registration signals from the IOD connector (grey wireway).
•
The dirty zone (D) is to the right of the Kinetix 7000 drive. This zone includes the motor power, GPIO, GPR, SO, and IOD connections (black wireway).
•
The very dirty zone (VD) includes both the 8720MC-RPS DC output to the Kinetix 7000 drive and the fuses, contactors, circuit breakers, and AC line input to the EMC line filter to the right of the 8720MC-RPS.
Shielded cable is required only if the very dirty cables enter a wireway.
•
The SERCOS fiber-optic cables are immune to electrical noise.
Figure 10 - Establishing Noise Zones (Regenerative Power Supply)
GPIO, GPR, and SO Cables Dirty Wireway (D
x
) Dirty Wireway (D
x
)
D1
D3
8720MC-RPS065BM-HV2
Regenerative Power Supply
No sensitive equipment within
150 mm (6.0 in.)
Registration I/O
Encoder Feedback
24V DC I/O
Shielded Cable
Shield Clamps
(beneath cover)
A
V k W
R T PRG
ENT
8720 MC
REGENERATI V E PO V W ER S UPPLY S U P P LY
Varistor
V D
C1
24V DC
Shielded Cable or
Conduit
24V DC
Power
Supply
D2
Motor Power
Shielded Cable
Route Encoder/Analog/Registration
Shielded Cable
DC Bus
2 m (78.7 in.)
V D
8720MC
Line Reactor
Keep very dirty (VD) connections as short as possible and segregated (not in wireway)
Magnetic
Contactor
Harmonic
Filter
Line
Fuses
Circuit
Breaker
AC
Line
Filter
D2
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
31
Chapter 2
Install the Kinetix 7000 Drive System
Clean Wireway (C
x
)
C1
Kinetix 7000 Drive
No sensitive equipment within
150 mm (6.0 in.)
Registration I/O
Encoder Feedback
Figure 11 - Establishing Noise Zones (Regenerative Power Supply with Line Filter Unit)
GPIO, GPR, and SO Cables Dirty Wireway (D
x
)
8720MC-RPS190BM-HV2
Regenerative Power Supply
D3
Dirty Wireway (D
x
)
D1
24V DC I/O
Shielded Cable
Shield Clamps
(beneath cover)
A
V k W
S T PRG ENT
8720
MC
REGENERATI V E PO W ER S UPPLY S U P P LY
1.5 m
(5 ft)
V D
RST PRG ENT
8720
MC
REGENERATIVE POWER SUPPLY
Line
Fuses
Circuit
Breaker
8720MC-EF190-VB
EMC Line Filter
V D
C1
24V DC
Shielded Cable or
Conduit
24V DC
Power
Supply
D2
Route Encoder/Analog/Registration
Shielded Cable
DC Bus
2 m (78.7 in.)
V D
V D
Keep very dirty connections as short as possible and segregated (not in wireway)
Line
Reactor
V D
Line
Reactor
8720MC -LR10-100B
Line Reactors
Motor Power
Shielded Cable
D2
32
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Clean Wireway (C)
Install the Kinetix 7000 Drive System
Chapter 2
AC Power Noise Zones
Observe the following guidelines when laying out a Kinetix 7000 system panel, if an AC power supply is used (and regenerative power will not be used).
•
The clean zone (C) is beneath and left of the Kinetix 7000 drive. This zone includes the motor feedback, auxiliary feedback and registration signals from the IOD connector (grey wireway).
•
One dirty zone (D) is beneath and right of the Kinetix 7000 drive. This zone includes fuses, contactors, circuit breakers, AC line input to the
EMC line filter (black wireway).
•
The very dirty zone (VD) is limited to where the AC line output exits from the EMC line filter and connects to the Kinetix 7000 drive. Shielded cable is required only if the very dirty cables enter a wireway.
•
The SERCOS fiber-optic cables are immune to electrical noise.
Figure 12 - Establishing Noise Zones (AC Power)
Dirty Wireway (D)
Kinetix 7000 Drive
No sensitive equipment within 150 mm (6.0 in.)
(1)
24V DC I/O Shielded
Cable
Shield Clamps
(beneath cover)
Motor Power
Shielded Cable
C
V D
D
Keep very dirty connections as short as possible and segregated (not in wireway)
AC Line
Filter
Line
Fuses
Circuit
Breaker
Contactor
C
Route Encoder/Analog/Registration
Shielded Cable
D
Shielded Clamps
Shielded Cable or
Conduit
(1)
When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, see the System
Design for Control of electrical Noise Reference Manual
,
publication GMC-RM001 .
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Chapter 2
Install the Kinetix 7000 Drive System
1756-MxxSE SERCOS Interface Module Noise Zones
Observe the following guidelines when installing your 1756-M
xx
SE SERCOS interface module.
•
The clean zone (C) is beneath the less noisy I/O modules (analog, encoder, registration) - - (grey wireway).
•
The dirty zone (D) is above and below the power supply and noisy modules (black wireway).
•
The SERCOS fiber-optic cables are immune to electrical noise.
Figure 13 - Establishing Noise Zones (ControlLogix)
Dirty Wireway (D)
D
Route dirty wireways directly above the ControlLogix rack
(shielded by the chassis).
Clean Wireway (C)
AC Line
Filter
D
Spare Slot(s)
C
Line Filter/Power Supply
Connections Segregated
(not in wireway)
Dirty I/O
(24V DC I/O, AC I/O)
Clean I/O
(Analog, Encoder
Registration)
34
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Install the Kinetix 7000 Drive System
Chapter 2
Cable Categories for Kinetix 7000 Systems
The table below indicates the zoning requirements of input power cables connecting to the Kinetix 7000 drive.
Table 4 - Kinetix 7000 Drive
Wire/Cable
Control Power
DC-/DC+
L1, L2, L3 (shielded cable)
L1, L2, L3 (unshielded cable)
DPI
Connector Zone
Very
Dirty
CP
X
PTB
X
DPI
Dirty
X
X
Clean
Method
Ferrite
Sleeve
Shielded
Cable
X
X
X
The table below indicates the zoning requirements of power and control cables connecting to the Kinetix 7000 system.
Table 5 - Kinetix 7000 System
Wire/Cable Connector Zone
Very
Dirty
MP
GPR
Dirty
X
X
Method
Clean Ferrite
Sleeve
Shielded
Cable
X U, V, W (Motor Power)
GPR+, GPR- (Motor Brake)
24V DC (PWR), COM, filtered
24V DC (PWR), COM, unfiltered
24V DC (PWR), COM, safety enable, and feedback signals for safe-off feature
Motor Feedback
Auxiliary Feedback
Registration and Analog Outputs
Others
Fiber-optic
GPIO, GPR
SO
MF
AF
X
X
IOD
Rx and Tx No Restrictions
X
X
X
X
X
X
X
X
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Chapter 2
Install the Kinetix 7000 Drive System
36
Table 6 - Line Interface Module
Wire/Cable
VAC line (main input)
230V AC input
VAC load (shielded option)
VAC load (unshielded option)
Control power output
MBRK PWR, MBRK COM
Status I/O
Auxiliary 230V AC
Connector Zone
Very
Dirty
IPL
APL
OPL
CPL
P1L/PSL
IOL
P2L
X
Table 7 - External Shunt Resistor Kit
Wire/Cable Connector Zone
Very
Dirty
COL, DC+ (shielded option)
COL, DC+ (unshielded option)
Thermal switch
Fan (if present)
RC
TS
N/A
X
Dirty
X
X
X
X
X
X
X
X
X
Method
Clean Ferrite
Sleeve
Shielde d Cable
X
X
Method
Dirty Clean Ferrite
Sleeve
X
Shielded
Cable
X
Noise Reduction Guidelines for Drive Accessories
When mounting an AC (EMC) line filter or external shunt resistor refer to the sections below for guidelines designed to reduce system failures caused by excessive electrical noise.
AC Line Filters
Observe the following guidelines when mounting your AC (EMC) line filter.
See the Establishing Noise Zones (AC Power) on page 33 for an example.
•
Mount the AC line filter on the same panel as the Kinetix 7000 drive and as close to the power input as possible.
•
Good HF bonding to the panel is critical.
For painted panels, refer to the examples on page 29.
•
Segregate input and output wiring as far as possible.
IMPORTANT
CE test certification applies only to AC line filter and single drive. Sharing a line filter with multiple drives may perform satisfactorily, but the user takes legal responsibility.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Install the Kinetix 7000 Drive System
Chapter 2
Clean Wireway
C1
No sensitive equipment within
150 mm (6.0 in.)
Shunt Resistor
Observe the following guidelines when mounting your external shunt resistor outside the enclosure.
•
Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI.
•
Mount resistors (other than metal-clad) in a shielded and ventilated enclosure outside the cabinet
•
Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.
•
Route thermal switch and fan wires separate from shunt power.
Figure 14 - External Shunt Resistor Outside the Enclosure
Customer-supplied metal enclosure
Minimum of 150 mm (6.0 in.) of clearance on all sides of the shunt module
Metal conduit
(where required by local code)
Route Encoder/Analog/
Registration
Shielded Cables Dirty Wireway
D3
D1
Shunt Power Wiring Methods:
Twisted pair in conduit (1st choice)
Shielded twisted pair (2nd choice)
Twisted pair, 2 twists per foot min. (3rd choice)
I/O and Feedback
Cables
C1
Route 24V DC I/O
Shielded Cable
D2
Kinetix 7000 drive
V D
Very dirty connections segregated (not in wireway)
V D
V D
Motor Power Cables
Enclosure
D2
D1
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Chapter 2
Install the Kinetix 7000 Drive System
Clean Wireway
C1
No sensitive equipment within
150 mm (6.0 in.)
C1
I/O and Feedback
Cables
Route 24V DC I/O
Shielded Cable
D2
When mounting your shunt module inside the enclosure, follow these additional guidelines.
•
Metal-clad modules can be mounted anywhere in the dirty zone, but as close to the Kinetix 7000 system as possible.
•
Shunt power wires can be run with motor power cables.
•
Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.
•
Separate shunt power cables from other sensitive, low voltage signal cables.
•
The shunt module watts dissipation must be included in the Kinetix 7000 system heat dissipation calculation for selecting an enclosure.
Figure 15 - External Shunt Resistor Inside the Enclosure
Dirty Wireway
Route Encoder/Analog/Registration
Shielded Cables
Shunt Module
D3
Observe minimum clearance requirements for shunt module spacing.
D1
Kinetix 7000
V D
Shunt Wiring Methods:
Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
Twisted pair, 2 twists per foot min.
(3rd choice).
V D
V D
AC Line
Filter
Very dirty connections segregated (not in wireway)
Motor Power Cables
Enclosure
D2
D1
38
Motor Brake and Thermal Switch
The thermal switch and brake are mounted inside the motor, but how you connect to the axis module depends on the motor series.
See Wire Motor Output Power on page 93
for wiring guidelines specific to your
drive/motor combination, and to Interconnect Diagram Notes on page 164 for
the interconnect diagram of your drive/motor combination.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Install the Kinetix 7000 Drive System
Chapter 2
Mount the Kinetix 7000 Drive
SHOCK HAZARD:
To avoid hazard of electrical shock, perform all mounting and wiring of the drive prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.
ATTENTION:
Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.
Follow these steps to install your Kinetix 7000 drive.
1.
Layout and mark the position for your drive in the enclosure.
Follow the Kinetix 7000 mounting information provided in
. Clearance requirements on page 27
must also be followed.
2.
Attach the drive to the cabinet.
The recommended mounting bolts are listed in the table on page 40
.
Follow the recommended high-frequency (HF) bonding techniques as
shown in Bonding Modules beginning on page 28 .
Follow the lifting instructions found in the Kinetix 7000 High Power
Servo Drive Installation Instructions, publication 2099-IN003 .
3.
Tighten all mounting fasteners.
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Chapter 2
Install the Kinetix 7000 Drive System
Figure 16 - Kinetix 7000 Approximate Mounting Dimensions
B
M2 M3 C
A
M1
2099-BM07 shown
Kinetix 7000 Drive
Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Dimensions in mm (in.)
A B
517.5 (20.37) 254.12 (10.0)
644.5 (25.37)
690.3 (38.47)
977.1 (38.47)
331.9 (13.07)
331.9 (13.07)
429.2 (16.90)
C
224.3 (8.83)
286.7 (11.29)
286.7 (11.29)
282.7 (11.13)
M1
495.0 (19.49)
M2
192.0 (7.56)
625.0 (24.61)
625.0 (24.61)
824.0 (32.44)
225.0 (8.86)
225.0 (8.86)
300.0 (11.81)
M3
15.3 (0.60)
37.5 (1.48)
37.5 (1.48)
49.6 (1.95)
Mounting Screw Size
M6 (0.25)
M6 (0.25)
M6 (0.25)
M8 (0.3125)
IMPORTANT
Each Kinetix 7000 drive requires four mounting screws.
40
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Chapter
3
Kinetix 7000 Connector Data
This chapter provides power, feedback, and I/O connector locations and signal descriptions for a Kinetix 7000 drive.
Topic
Locate and Identify Connectors and Indicators
Motor (MF) and Auxiliary Feedback (AF) Connections
Page
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Chapter 3
Kinetix 7000 Connector Data
Locate and Identify
Connectors and Indicators
9
Although the physical size of the drives vary, the location of the connectors and indicators is identical.
Figure 17 - Kinetix 7000 Front Panel Connectors and Displays
SERCOS
Node Address
1
SERCOS
Node Address
Fault/Status
Fault/Status
Drive
Comm
Bus
2
Drive
Comm
Bus
3
4
5
I/O
Motor
Feedback
Auxiliary
Feedback
I/O
Motor
Feedback
Auxiliary
Feedback
6
7
8
10
Power terminal block located behind protective cover.
42
CP
2099-BM08-S shown
8
9
10
6
7
4
5
2
3
Item Designator/Label Description
1 Node Address SERCOS Node Address Switches
Fault/Status
Drive
Fault Status Display
Drive Status Indicator
Comm
Bus
AF
MF
Communication Status Indicator
Bus Status Indicator
Auxiliary Feedback Connector
Motor Feedback Connector
IOD
–
PTB
Connector
–
–
–
Digital and Analog Input/Output Connector 26-pin high-density D-shell
Control Power Status Indicator –
Power Terminal Block Terminal block
See Page
Chapter 6
Chapter 7
Chapter 7
–
–
15-pin high-density D-shell (male)
15-pin high-density D-shell (female)
Chapter 7
Chapter 7
Chapter 7
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Top View
Kinetix 7000 Connector Data
Chapter 3
Figure 18 - Kinetix 7000 Top Panel Connectors and Switches
2099-BM08-S shown
SO
DO1
DO2 N/C N/C
GPIO
GPR2GPR2+
COM
GPR1-GPR1+24VDC
1
SO
DO1
DO2
N/C N/C
GPIO
GPR2-
GPR2+
COM
GPR1-GPR1+24VDC
GPR
2 3 4 5 6 7
6
7
4
5
2
3
Item Designator/Label Description
1 SO Safe-off Terminal Block
GPIO
GPR
General Purpose I/O Terminal Block
General Purpose Relay Terminal Block
Rx
DPI
Tx
Baud Rate
SERCOS Fiber-optic Receive Port
Device Peripheral Interface Connector
Connector
SERCOS fiber-optic
–
SERCOS Fiber-optic Transmit Port SERCOS fiber-optic
SERCOS Baud Rate and Optical Power Switches –
See Page
9-position plug/header
8-position plug/header
6-position plug/header
–
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Chapter 3
Kinetix 7000 Connector Data
1
Figure 19 - Kinetix 7000 Bottom Panel Connectors
2
Bottom View 2099-BM06-S and 2099-BM07-S shown
Item Designator/Label
1 CP
2 PTB
Description
Control Power Terminal Block
Power Terminal Block Access
Connector
2-position terminal
Terminal block
See Page
44
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Pin 19
Pin 10
Kinetix 7000 Connector Data
Chapter 3
Digital and Analog Input/Output (IOD) Connector Pinout
The following diagram and table provide the signal description and pin-out information for the 26-pin Digital and Analog Input/Output connector.
See Kinetix 7000 Front Panel Connectors and Displays on page
location of the 26-pin connector. IOD signals are described in greater detail later in this chapter.
Figure 20 - Pin Orientation for 26-pin I/O (IOD) Connector
Pin 18
Pin 9
Pin 26
Pin 1
8
9
10
6
7
4
5
2
3
Pin
1
11
12
13
Description
Drive supplied +24V DC
Hardware Enable Switch Input
Hardware Enable Common
Signal Name
HW_Enable_Pwr
HW_Enable_In
HW_Enable_Com
Drive supplied +24V DC
Home Switch Input
Home Common
Drive supplied +24V DC
Home_Switch_Pwr
Home_Switch_In
Home_Switch_Com
Pos_OverTravel_Pwr
Positive Overtravel Limit Switch Input Pos_ OverTravel_In
Positive Overtravel Common Pos_OverTravel_Com
Drive supplied +24V DC Neg_OverTravel_Pwr
Negative Overtravel Limit Switch Input Neg_OverTravel_In
Negative Overtravel Common Neg_OverTravel_Com
Drive supplied Registration 1 Output
Power
Reg_1_Pwr
Table 8 - Digital and Analog Input/Output 26-pin (IOD) Connector
21
22
23
19
20
17
18
15
16
Pin
14
24
25
26
Description
Registration 1 Input
Registration 1 Common
Drive supplied Registration 2 Output
Power
Signal Name
Reg_1_In
Reg_1_Com
Reg_2_Pwr
Registration 2 Input
Registration 2 Common
Reg_2_In
Reg_2_Com
Differential Analog Channel 1 Input Analog_Input_1
Differential Analog Channel 1 Common Analog_Input_1_Ret
Differential Analog Channel 2 Input Analog_Input_2
Differential Analog Channel 2 Common Analog_Input_2_Ret
Programmable Analog Channel 1
Output
Analog_Out_1
Analog Channel 1 Common
Programmable Analog Channel 2
Output
Analog Channel 2 Common
Analog_Out_1_Ret
Analog_Out_2
Analog_Out_2_Ret
IMPORTANT
The Drive supplied +24V DC and Common source signals (at pins 1, 3, 4, 6,
7, 9, 10, and 12) can only be used for the inputs listed above.
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Chapter 3
Kinetix 7000 Connector Data
46
General Purpose I/O (GPIO) Terminal Block Connections
The following diagram and table provide the orientation and signal description for the General Purpose Input/Output terminal block.
Figure 21 - Orientation for General Purpose I/O (GPIO) Terminal Block
DO1
DO2
N/C N/C
GPIO
Table 9 - General Purpose I/O (GPIO) Terminal Block
6
7
4
5
8
2
3
Terminal Description
1 Digital Output 1
+24V DC for digital output 1 (customer-supplied)
+24V DC for digital output 2 (customer-supplied)
Digital Output 2
Reserved
Reserved
Regenerative power supply OK (customer supplied)
Common for Regenerative power supply OK
Signal Name
Digital_Out_1
DO_24VDC_1
DO_24VDC_2
Digital_Out_2
N/C
N/C
Regen_OK+
Regen_OK-
General Purpose Relay (GPR) Terminal Block Connections
The following diagram and table provide the orientation and signal description for the General Purpose Relay terminal block.
Figure 22 - Orientation for General Purpose Relay (GPR) Terminal Block
Note: The GPR terminal number orientation is rotated 180 degrees relative to the other I/O connectors.
GPR2-
GPR2+
COM
GPR1-GPR1+24VDC
GPR
Table 10 - General Purpose Relay (GPR) Terminal Block
4
5
6
2
3
Terminal Description
1 24V DC customer-supplied power input for Relay 1
Programmable N.O. Relay 1 output
Programmable Relay 1 common
24V DC customer-supplied power supply common
Programmable N.O. Relay 2 output
Programmable Relay 2 common
Signal Name
24VDC
GPR1+
GPR1-
COM
GPR2+
GPR2-
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Kinetix 7000 Connector Data
Chapter 3
Motor Feedback (MF) Connector Pinouts
The following diagram and tables provide the orientation and signal description for the Motor Feedback (MF) connector for each applicable feedback device.
Figure 23 - Pin Orientation for 15-pin Motor Feedback (MF) Connector
Pin 15
Pin 11
Pin 6
Pin 10
Pin 5
Pin 1
Table 11 - Motor Feedback (MF) Connections for Stegmann Hiperface (SRS/SRM)
6
7
4
5
8
2
3
Pin
1
Description
Sine differential input+
Sine differential input-
Cosine differential input+
Cosine differential input-
Hiperface data channel
Common
Encoder power (+9V)
Reserved
(1) Not applicable unless the motor has integrated thermal protection.
(2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.
Signal
SIN+
SIN-
COS+
COS-
DATA+
ECOM
EPWR_9V
(2)
—
14
15
12
13
Pin
9
10
11
Description
Reserved
Hiperface data channel
Motor thermal switch (normally-closed)
(1)
Reserved
Reserved
Encoder power (+5V)
Reserved
Signal
—
DATA-
TS
—
—
EPWR_5V
(2)
—
Table 12 - Motor Feedback (MF) Connections for TTL or Sine/Cosine with Index Pulse and Hall
Commutation
6
7
4
5
8
2
3
Pin
1
Description
AM+ / Sine differential input+
AM- / Sine differential input-
BM+ / Cosine differential input+
BM- / Cosine differential input-
Index pulse+
Common
Encoder power (+9V)
Single-ended 5V hall effect commutation
(1) Not applicable unless motor has integrated thermal protection.
(2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.
Signal
AM+ / SIN+
AM- / SIN-
BM+ / COS+
BM- / COS-
IM+
ECOM
EPWR_9V
(2)
S3
14
15
12
13
Pin
9
10
11
Description
Reserved
Index pulse-
Motor thermal switch (normally-closed)
(1)
Single-ended 5V hall effect commutation
Single-ended 5V hall effect commutation
Encoder power (+5V)
Reserved
Signal
—
IM-
TS
S1
S2
EPWR_5V
(2)
—
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47
Chapter 3
Kinetix 7000 Connector Data
Kinetix 7000 drives do not natively support Heidenhain EnDat high-resolution feedback. However, you can use the drive motor feedback connection with the
2090-K7CK-KENDAT feedback module to convert Heidenhain EnDat 2.1 high-resolution feedback from an RDD motor. Use the table below to connect the motor feedback wires to the 2090-K7CK-KENDAT feedback module.
IMPORTANT
Only 2099-BM
xx
-S drives with firmware revision 1.104 or higher support the use of 2090-K7CK-KENDAT feedback modules.
6
7
4
5
2
3
Pin
1
Description
Sine differential input+
Sine differential input-
Cosine differential input+
Cosine differential input-
Encoder power (+5V)
Common
Serial data clock signal +
(1) Not applicable unless motor has integrated thermal protection.
Table 13 - Connections for Heidenhain EnDat
Signal
SIN+
SIN-
COS+
COS-
EPWR_5V
ECOM
CLK+
11
12
13
9
10
Pin
8
Description
Serial data clock signal -
Serial data differential signal+
Serial data differential signal -
Motor thermal switch+
(1)
Reserved
Reserved
TS+
—
—
Signal
CLK-
DATA+
DATA-
IMPORTANT
Drive-to-motor power cables must not exceed 90 m (295.3 ft).
48
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Kinetix 7000 Connector Data
Chapter 3
Auxiliary Feedback (AF) Connector Pinouts
For TTL devices, the position count will increase when A leads B. For sinusoidal devices, the position count will increase when cosine leads sine.
Figure 24 - Pin Orientation for 15-pin Auxiliary Feedback (AF) Connector
Pin 6
Pin 11
Pin 15
Pin 1
Pin 5
Pin 10
Table 14 - Stegmann Hiperface (SRS and SRM only)
6
7
4
5
8
2
3
Pin
1
Description
Sine differential input+
Sine differential input-
Cosine differential input+
Cosine differential input-
Hiperface data channel
Common
Encoder power (+9V)
Reserved
(1) Encoder power supply uses either 5V or 9V DC based on encoder used.
Signal
SIN+
SIN-
COS+
COS-
DATA+
ECOM
EPWR_9V
(1)
—
14
15
12
13
10
11
Pin
9
Table 15 - TTL or Sine/Cosine with Index Pulse
Description
Reserved
Hiperface data channel
Reserved
Reserved
Reserved
Encoder power (+5V)
Reserved
6
7
4
5
8
2
3
Pin
1
Description
A+ / Sine differential input+
A- / Sine differential input-
B+ / Cosine differential input+
B- / Cosine differential input-
Index pulse+
Common
Encoder power (+9V)
Reserved
(1) Encoder power supply uses either 5V or 9V DC based on encoder used.
Signal
A+ / SIN+
A- / SIN-
B+ / COS+
B- / COS-
I+
ECOM
EPWR_9V
(1)
—
14
15
12
13
10
11
Pin
9
Description
Reserved
Index pulse-
Reserved
Reserved
Reserved
Encoder power (+5V)
Reserved
Signal
—
I-
—
—
—
EPWR_5V
(1)
—
Signal
—
DATA-
—
—
—
EPWR_5V
(1)
—
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
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Chapter 3
Kinetix 7000 Connector Data
Safe-off (SO) Terminal Block Connections
Figure 25 - Safe-off (SO) Terminal Block
6
7
4
5
8
9
Table 16 - Safe-off (SO) Terminal Block
Terminal Description
1 Normally-closed monitoring contact for safety relay 2
2 Return for safety relay 2
Return for safety relay 1
Coil of safety relay 2
Common for safety relays 1 and 2
Coil of safety relay 1
24V DC, 500 mA max., power for Safe Off circuit
Common for 24V power Safe off circuit
SO
Signal Name
FDBK2+
FDBK2-
FDBK1+
FDBK1-
ENABLE2+
ENABLE-
ENABLE1+
SO_24VDC
SO_COM
IMPORTANT
Terminals 8 and 9 (24V+ and Common) are only used by the motionallowed jumper. When using the Safe-off feature, the 24V supply must come from an external source.
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Kinetix 7000 Connector Data
Chapter 3
Control Power (CP) Terminal Block Connections
Kinetix 7000 drives must be wired to a 24V DC control power source through the Control Input Power (CP) connector. The Control Power input terminal is
located on the bottom of the drive as illustrated in Figure 19 on page 44
.
IMPORTANT
An external power supply provides the ability to retain control of the drive’s logic independent of its bus power status.
Figure 26 - Control Power (CP) Terminal Block Detail
Terminal Block
(on bottom of drive)
Label
(on front of drive)
CP_24VDC CP_COM
CP
Table 17 - Control Power (CP) Terminal Block
Terminal Description
1
Control Power 24V DC Input
2
Signal Name
CP_24VDC
CP_COM
Power Terminal Block (PTB) Connections
The power terminals are located behind the lower front panel of the drive. The figures below identify the input power, motor power, DC bus, ground, and cooling fan input terminals.
The 2099-BM09-S or 2099-BM10-S drives (frame 5), and the 2099-BM11-S or
2099-BM12-S drives (frame 6) provide connections for you to supply 120V AC or 240V AC to power an internal cooling fan. The fan VA rating is 100 VA for
2099-BM09-S and 2099-BM10-S, and 138 VA for the 2099-BM11-S and 2099-
BM12-S drives.
The 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S drives (frame 3) use the internal power supply for fan power and thus no terminals are provided.
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Chapter 3
Kinetix 7000 Connector Data
Figure 27 - 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S
PS-
PS+
Cable clamps for
Motor and AC inputs.
Figure 28 - 2099-BM09-S
PS-
PS+
Figure 29 - 2099-BM10-S
PS-
Motor
AC Line
Fan Terminals
Enlarged View
Fan Terminals
Enlarged View
PS+
Motor AC Line
52
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Figure 30 - 2099-BM11-S and 2099-BM12-S
PS-
Kinetix 7000 Connector Data
Chapter 3
Fan Terminals
Enlarged View
PS+
FAN
Motor AC Line
Table 18 - Power Terminal Block
Terminal Description
DC+ DC Bus Power
DC-
PE
GND
U-T1
V-T2
W-T3
R-L1
S-L2
T-L3
120VAC
240VAC
0VAC
PS-
PS+
Main Ground of the Drive System
Motor Ground
Motor Phase U Output
Motor Phase V Output
Motor Phase W Output
Main 380…480V AC +/-10% Input Power, Three-phase to R, S and T Input Terminals R
+120V AC Input for Fan Power
+240V AC Input for Fan Power
Fan Common
For factory use only
For factory use only
Name
DC Bus (+)
DC Bus (-)
PE Ground
Motor Ground
U (T1)
V (T2)
W (T3)
S
T
VAC_FAN_1
VAC_FAN_2
GND_FAN
–
–
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Control Signal Specifications
This section provides specifications for the Kinetix 7000 drive input/output
(IOD), SERCOS, motor feedback (MF), auxiliary feedback (AF) and brake
(BC) connectors.
Digital Inputs (IOD Connector)
Two fast registration inputs and four other inputs are available for the machine interface on the Kinetix 7000 drive. The drive supplies 24V DC @ 300 mA for the purpose of registration, home, enable, over-travel positive, and over-travel negative inputs. These are sinking inputs that require a sourcing device. A 24V
DC power and common connection is provided for each input.
IMPORTANT
To improve registration input EMC performance, see the System Design for
Control of Electrical Noise Reference Manual, publication GMC-RM001 .
IOD Pin Signal
IOD-2
IOD-5
IOD-14
IOD-17
IOD-8
IOD-11
ENABLE
HOME
REG1
REG2
OT+
OT-
Table 19 - Digital Input Descriptions
Description
Single optically isolated, single-ended active high signal. Current loading is nominally 10 mA. A 24V DC input is applied to this terminal to enable each axis.
Capture Time Edge/Level
Sensitive
20 ms Level
Single optically isolated, single-ended active high signal. Current loading is nominally 10 mA. Home switch (normally-open contact) inputs for each axis require 24V DC (nominal).
20 ms Level
Fast registration inputs are required to inform the motor interface to capture the positional information with less than 3
s uncertainty. Single optically isolated, singleended active high signal. Current loading is nominally 10mA. A 24V DC input is applied to this terminal to enable each axis.
500 ns
Overtravel detection is available as a dual-input, optically isolated, single-ended active high signal. Current loading is nominally 10 mA per input. The pos/neg limit switch
(normally-closed contact) inputs for each axis require 24V DC (nominal).
20 ms
Edge
Level
Table 20 - Digital Input Specifications
Parameter Description
ON-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an ON-state.
ON-state current Current flow to guarantee an ON-state
OFF-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an OFF-state.
Min
10.8V
3.0 mA
-1.0V
Max Leakage
26.4V
—
10.0 mA
3.0V
—
<1.5 mA
24V I/O Power
IMPORTANT
Signals +24V_PWR and +24V_COM are a 24V DC source that can be used only for the inputs listed below.
The Kinetix 7000 drive provides 24V DC power @ 300 mA total for the
HW_Enable_Pwr, Home_Switch_Pwr, Pos_OverTravel_Pwr,
Neg_OverTravel_Pwr, Reg_1_Pwr, and Reg_2_Pwr inputs on the specific drive.
The supply is protected with an automatically reset fuse. A temperature versus time curve automatically controls closing of the fuse.
A common mode choke filters the registration power connection. An additional common mode choke is provided for the remaining inputs.
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Chapter 3
Hardware Enable
The Hardware Enable input is an optically isolated (500V), single-ended, active high signal. A 24V DC input applied to this pin enables the drive.
The status of this digital input can be monitored in the axis servo drive tag in
RSLogix.
I/O SUPPLY
INPUT
IO_COM
Customer-supplied Input Device
If the Drive Hardware Enable option is selected in Logix, an MSO (Motion
Servo On) instruction must be executed in RSLogix software. This causes IOD-1 to supply 24V DC to IOD-2, and completes the enable circuit for servo loop and drive power structure.
If the Drive Hardware Enable option is not selected in Logix, an MSO instruction will enable the drive without the need for a Drive Enable signal confirmation.
This input is level sensitive. See Table 19 - Digital Input Descriptions and
Table 20 - Digital Input Specifications starting on page 54 for On/Off signal voltages and current levels.
Kinetix 7000 drive Hardware Enable functions and faults actions are programmed through RSLogix software. Kinetix 7000 dive firmware provides an additional 50 ms of debounce.
ATTENTION:
Overvoltage protection is not provided for the Hardware Enable input signal.
It is recommended to use the on-drive power to power the Hardware Enable signal.
If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.
IOD-1
IOD-2
The schematic below depicts the Hardware Enable circuit. It is provided as a reference only.
Figure 31 - Hardware Enable Digital Input Circuit Diagram
+24V DC
(1)
VCC
2k
Ω
0.1
μ
F
511
Ω
IOD-3
1k
Ω
CTRL_INPUT
Kinetix 7000 Drive
(1) +24V DC source (range) = 21.6V…26.4V (supplied by the drive, not to exceed 300 mA total).
Maximum current input = 10 mA.
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Home
The Home input is an optically isolated (500V), single-ended, active high signal.
A 24V DC input applied to this pin by a normally-open contact indicates this axis is in the home position. Firmware provides an additional 50 ms of debounce.
You can configure the required Home type in the axis servo drive properties in
RSLogix. You can monitor the Home input “on/off ” status in the axis servo drive tag.
I/O SUPPLY
INPUT
IO_COM
Customer-supplied Input Device
IOD-4
IOD-5
This input is level sensitive. See Table 19 - Digital Input Descriptions and
Table 20 - Digital Input Specifications starting on page 54 for On/Off signal voltages and current levels.
ATTENTION:
Overvoltage protection is not provided for the Home input signal.
It is recommended to use the on-drive power to power the Home signal. If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.
The schematic below depicts the Home circuit. It is provided as a reference only.
Figure 32 - Home Digital Input Circuit Diagram
24V DC
(1)
VCC
2k
Ω
0.1
μ
F
511
Ω
IOD-6
1k
Ω
CTRL_INPUT
Kinetix 7000 Drive
(1) +24V DC source (range) = 21.6…26.4V (supplied by the drive, not to exceed 300 mA total).
Maximum current input = 10 mA.
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Positive and Negative Overtravel
The Positive and Negative Overtravel detection is provided by two optically isolated (500V), single-ended, normally-closed, active high signals. Breaking the
24V DC input at either pin indicates an overtravel condition.
You can enable hard travel limits on the axis servo drive Limit tab in RSLogix.
Hard travel limits require power to both the positive and negative overtravel inputs. You can monitor the positive and negative overtravel input status in the axis servo drive tag.
Notes:
•
A status of “1” indicates a normally closed input and a drive ready for movement.
•
Hard overtravel limits can only be selected in a linear conversion selection.
This input is level sensitive. See Table 19 - Digital Input Descriptions and
Table 20 - Digital Input Specifications starting on page 54 for On/Off signal voltages and current levels.
IMPORTANT
Overtravel limit input devices must be normally-closed.
Kinetix 7000 drive Positive and Negative Overtravel functions and faults actions are programmed through RSLogix software. Kinetix 7000 drive firmware provides an additional 50ms of debounce.
ATTENTION:
Overvoltage protection is not provided for the Positive and
Negative Overtravel input signal.
It is recommended to use the on drive power to power the Positive and Negative
Overtravel signals. If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.
The schematic below depicts the Positive and Negative Overtravel circuits. It is provided as a reference only.
Figure 33 - Positive and Negative Overtravel Input Diagram
+24V DC
(1)
I/O SUPPLY
INPUT
IOD-7, 10
IOD-8, 9
IO_COM
Customer-supplied Input Device
IOD-9, 12
2k
Ω
Kinetix 7000 Drive
0.1
μ
F
511
Ω
VCC
1k
Ω
Positive Overtravel or
Negative Overtravel
(1) +24V DC source (range) = 21.6…26.4V (supplied by the drive, not to exceed 300 mA total).
Maximum current input = 10 mA.
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Registration
The two fast Registration inputs are provided on the Kinetix 7000 drive, Reg 1
(IOD-14) and Reg 2 (IOD-17). Unlike the Drive Enable, Home, and Overtravel signals, these inputs are either positive-edge or negative-edge triggered. They are based on the user-defined MAR (Motion Axis Registration) configured using
RSLogix software.
Figure 34 - MAR (Motion Axis Registration) Entry in RSLogix Software
58
The MAR instruction captures position data within a 3 μs uncertainty. The position is directly input to the axis_servo_drive.Registration_Position register in Logix software.
Figure 35 - Logix Position Register Entry
Power for the inputs is supplied by an internally supplied 24V DC supply.
See Table 19 - Digital Input Descriptions and Table 20 - Digital Input
Specifications starting on page 54 for On/Off signal voltages and current levels.
Registration functions and faults actions are programmed through RSLogix software. Kinetix 7000 firmware provides an additional 50 ms of debounce.
ATTENTION:
Overvoltage protection is not provided for the Registration input signal.
It is recommended to use the on drive power to power Registration. If an external power source is used, you must take responsibility to be sure that the voltage/ current does not exceed the rating of the input.
The schematic below depicts the Registration circuits. It is provided as a reference only.
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Chapter 3
Figure 36 - Registration Digital Input Circuit Diagram
+24V DC
(1)
I/O SUPPLY
IOD-13, or -16
INPUT
IOD-14, or -17
3k
Ω
0.001
μ
F
511
Ω
IO_COM
IOD-15, or -18
Customer-Supplied
Registration Input Device
Kinetix 7000 Drive
HCPL-0631
(1) +24V DC source (range) = 21.6V…26.4V (supplied by the drive, not to exceed 300 mA total).
Maximum current input = 10 mA.
VCC
1k
Ω
REG_INPUT
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IOD-20
Analog_Input_1_Ret
IOD-19
Analog_Input_1
IOD-22
Analog_Input_2_Ret
IOD-21
Analog_Input_2
Customer-supplied
Input Device
0.1
μ
F
0.1
μ
F
Kinetix 7000 Drive
Analog Inputs (IOD Connector)
IMPORTANT
RSLogix 5000 software, version 15, does not support analog input utilization.
Two analog inputs are provided, with 14-bit resolution (13 data bits, plus sign).
The analog data streamed to RSLogix by these inputs is useful for managing dynamic machine operations, for example tension transducers in an outer tension control loop.
The input range of these inputs is ±10V, and overvoltage protection is ±12V.
Inputs are updated at the drive every 125 μs. Frequency response of the input is up to 4 kHz, and input impedance is 12 k
.
Analog inputs are available as a real time attribute and Get System Value (GSV) within RSLogix software.
ATTENTION:
Gain and offset attributes are not provided for the Analog Inputs input signals, and no drive faults are issued.
The schematic below depicts the Analog Input circuits. It is provided as a reference only.
Figure 37 - Analog Input Circuit Diagram
0.1
μ
F
0.1
μ
F
–
+
V+
V–
Sense
Out
Ref
100
Ω
Anlg In 1
–
+
V+
V–
Sense
Out
Ref
100
Ω
Anlg In 2
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Chapter 3
Reading Analog Input Voltage Values
When connecting to the Kinetix 7000 drive via DriveExecutive™ or
DriveExplorer™, the input voltage is displayed as a percentage in parameters 691
[AnaInput 1 Value] and 692 [AnaInput 2 Value].
In the example above, analog input 1 displays 69.79%. This value equals 100% of
±10V DC. Therefore the actual value of analog input 1 is 6.98V DC.
When viewed in RSLogix 5000 using a real time attribute on the Drive/Motor tab on the Module Properties dialog, the corresponding bit value displays as in the example below.
Divide the value displayed by 100 to determine the actual voltage on the input.
6978 / 100 = 69.78% or 6.98V DC.
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VDD
SCLK
SDIN
SYNC
LDAC
SDO
CLR
GND
RFSA
IOUT1A
IOUT2A
RFSB
IOUT1B
IOUT2B
VRBFA
VRBFB
–
V+
+
V–
Analog Outputs (IOD Connector)
The two analog outputs (Analog_Out_1 and Analog_Out_2) are strictly for troubleshooting and cannot be used to drive other loads.
The analog outputs provide 12-bit resolution (11 data bits, plus sign) of the gain and filtering parameters within RSLogix software. In this way a data stream can be displayed by a meter or scale as velocity, torque, or following error information.
The ±10V outputs provide positive and negative direction range, with a null setting of 0V. For example, ±10V range, with 0V = 0. The drive update rate for these outputs is 125 μs, and is current limited to 25 mA.
Analog output functions are programmed in RSLogix software using a message instruction. The default pin assignments and the default gain values for the velocity, torque, and following error parameters are listed below.
Signal
Analog_Out_1
Analog_Out_2
Default Pin
IOD-23
IOD-25
Parameter
Velocity
Torque
Gain Value
0.0060
0.1
Analog Output
1V = 1000 rpm
1V = 100% torque
A single pole low pass digital filter is provided for each analog output. The digital filter frequency range is 1…4 kHz.
The schematic depicts the Analog Output circuits. It is provided as a reference only.
Figure 38 - Analog Outputs Circuit Diagram
10 k
Ω
10 k
Ω
3.9
μ
F
0.1
μ
F 0.1
μ
F
4.09 k
Ω
–
+
V+
V–
100 k
Ω
2.2
μ
F
10
k
Ω
10 k
Ω
IOD-23
Analog_Out_1
IOD-24
Analog_Out_1_Ret
10 k
Ω
10 k
Ω
3.9
μ
F
–
V+
+
V–
4.09 k
Ω
–
V+
+
V–
100
k
Ω
2.2
μ
F
10 k
Ω
10 k
Ω
IOD-25
Analog_Out_2
IOD-26
Analog_Out_2_Ret
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Chapter 3
4
5
6
2
3
Pin
1
Signal
Digital_Out_1
DO_24VDC_1
DO_24VDC_2
Digital_Out_2
Reserved
Description
General Purpose I/O (GPIO Connector)
Two 24V digital outputs are user programmable. You can monitor the status the an optional regenerative power supply. An isolated, external 24V DC power source must be customer supplied to power the digital outputs.
Table 21 - General Purpose I/O Digital Output Specifications
Optically isolated to 500V, current sourcing up to 75 mA
24V DC power source to digital inputs (customer-supplied)
Optically isolated to 500V, current sourcing up to 75 mA
On Condition
24…40V DC
—
Off Condition Leakage
<0.25 mA
—
24…40V DC <0.25 mA
Dig_Out_1
1 k
Ω
The two DC current sourcing outputs default settings are Zero_Speed
(Digital_Out_1) and In_Position (Digital_Out_2). Zero_Speed is the motor at
0 rpm velocity. In_Position can be set to the commanded position by the Position
Lock Tolerance (set in Axis Properties/Limits). Default parameter selections can also be set with an IDN function.
Figure 39 - General Purpose I/O Digital Output Diagram
DO_24VDC_1
0.1
μ
F
3.32
k
Ω
10
Ω
Digital_Out_1
Dig_Out_2
1 k
Ω
DO_24VDC_2
0.1
μ
F
3.32
k
Ω
10
Ω
Digital_Out_2
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Pin
7
8
Signal
Regen_OK+
Regen_OK-
Regen_OK+
Regen_OK-
2 k
Ω
The regenerative power supply OK provides status on the regenerative converter; in doing so, provides status to the Kinetix 7000 drive that there is DC bus power.
Selecting the 8720MC-RPSxxx on the Power tab in the Kinetix 7000 drive I/O configuration in RSLogix requires the customer to provide a 24V DC power source to GPIO pins 7 and 8 as shown in
and in the interconnect
diagrams in Appendix B. A failure to do so will cause a Regen_PS_OK (E111)
fault, which indicates that he Regen_OK signal is missing at pins 7 and 8 of the
GPIO connector. Kinetix 7000 drive firmware provides an additional 50 ms debounce.
Table 22 - General Purpose I/O Regenerative Power Supply OK Specifications
Description
Optically isolated (500V), single-ended active high signal
On Condition
12…38V DC @
3.3…12 mA
Off Condition
less than 6.6V DC, less than 1.5 mA
Figure 40 - General Purpose I/O Regenerative Power Supply OK Diagram
VCC
0.1
μ
F
511
Ω
Regen_OK
1 k
Ω
General Purpose Relay (GPR Connector)
Two general purpose relay connections are accessed through the GPR connector.
GPR1+ is a normally-open, dry relay contact, supporting 2 A at 30V DC ±10% with suppression. This relay defaults to Motor Brake control, and specifically provides suppression. GPR2+ is a normally-open, dry relay contact, supporting 2
A at 250V AC or 2 A at 30V DC without suppression. This relay defaults to
Drive OK. An external 24V DC power source must be supplied.
The following are default values for the general purpose relays.
Table 23 - General Purpose Relay Outputs Descriptions
Output:
GPR1+
Default Relay Setting in
RSLogix Software
Motor Brake
Description
Turn-on and turn-off delays are specified by the Brake
Engage Delay Time and Brake Release Delay Time in
RSLogix software.
GPR2+ Drive OK (DROK)
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Chapter 3
SERCOS Connections
Two fiber-optic connectors (transmit and receive) are provided on the Kinetix
7000 drive.
Table 24 - SERCOS Communication Specifications
Specification
Data Rates
Node Addresses
Description
4 and 8 Mbps
01…99
(1)
(1) Node addresses for additional axes on the same system are assigned by sequentially incrementing each additional axis. See Node
Addressing Examples on page
Safe-off (SO Connector)
Kinetix 7000 drives provide safety functions and system integrity.
The Kinetix 7000 drive ships with a (9-pin) wiring-plug header having a motionallowed jumper installed in the safe-off (SO) connector. With the motionallowed jumper installed, the safe-off feature is disabled.
For safe-off wiring information, see the Kinetix Safe-off Feature Safety Reference
Manual, publication GMC-RM002 .
Figure 41 - Safe-Off, Motion-allowed Jumper
Motion-allowed Jumper
FDBK2+
FDBK2-
FDBK1+
FDBK1-
ENABLE2+
ENABLE-
ENABLE1+
SO_24VDC
SO_COM
SO
Safe-off
(SO) Connector
1
1 2
3 4
FDBK2+
FDBK2-
FDBK1+
FDBK1-
5 6
7 8
9
ENABLE2+
ENABLE-
ENABLE1+
SO_24VDC
SO_COM
SO
Wiring Plug Header
Control Power Specifications
The following table provides specifications for the Control Power (CP) connector.
Attribute
Auxiliary DC input voltage
Value
24V DC, 3 A max, range 18…30 V DC
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Motor (MF) and Auxiliary
Feedback (AF) Connections
The motor interface and auxiliary feedback interfaces are consistent across the
Kinetix product line. This section provides information on motor and auxiliary feedback connections.
The Kinetix 7000 motor (MF) and auxiliary (AF) feedback ports can accept the following encoder types:
•
SRM/SRS Stegmann Hiperface encoders
•
5V TTL differential line driver with index pulse and hall commutation
•
Sin/Cos differential input with index pulse and hall commutation
Motor feedback requires RSLogix 5000 motion.db file to properly commutate the motor. Motors available in RSLogix software include feedback types designated as S and M in Allen-Bradley catalog numbers. Following are further definitions of these feedback types.
•
S type - single-turn 1024 cycles per rotation (interpolated to over 2 million counts in the drive) For example, the MPL-B980D-SJ72AA has this feedback type.
•
M type - multi-turn 1024 cycles per rotation (interpolated to over 2 million counts in the drive). For example, the MPL-980D-MJ72AA has this feedback type. The “M” type allows for 4096 cycles absolute retention when the encoder is powered down.
RDD motor feedback from Heidenhain EnDat high-resolution encoders is also accepted, but only when using drive firmware revision 1.104 or higher and the
2090-K7CK-KENDAT low-profile feedback module.
Third-party motor requests must be pre-qualified and a custom motor file developed. Contact your local distributor or Rockwell Automation Sale
Representative for more information.
Kinetix 7000 drives cannot drive open loop (no feedback) or other motor types not defined in the Kinetix motor database.
Motor and Auxiliary Feedback Specifications
AM, BM, and IM input encoder signals are filtered using analog and digital filtering. The inputs also include illegal state change detection.
schematic of the AM, BM, and IM inputs.
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+
-
1k
Ω
Drive
Kinetix 7000 Connector Data
Chapter 3
Figure 42 - AM, BM, and IM Motor Encoder Inputs
1k
Ω
+5 V
10k
Ω
56 pF
+
1k
Ω
1k
Ω
1k
Ω
56 pF
100 pF
10k
Ω
1k
Ω
56 pF
1k
Ω
56 pF
-
10k
Ω
100 pF
Drive
AM and BM Channel Inputs
Table 25 - Motor Encoder Feedback Specifications
10k
Ω
1k
Ω
1k
Ω
Attribute
Encoder Types
Maximum Input Frequency
Commutation Feedback
Value
Incremental, A quad B, Sine/Cosine, Intelligent, and Absolute
5.0 MHz (TTL input) per channel
250 kHz (Sine/Cosine input)
Hall sensor
provides a description of the AM, BM, and IM inputs for TTL encoders.
Table 26 - TTL Encoder Specifications
Parameter
AM, BM, and IM
ON-state
Input Voltage
AM, BM, and IM
OFF-state
Input Voltage
Common Mode
Input Voltage
DC Current Draw
AM, BM Input
Signal Frequency
Description
Input voltage difference between the + input and the - input that is detected as an ON-state.
Minimum
+1.0V
Input voltage difference between the + input and the - input that is detected as an OFF-state.
-1.0V
Potential difference between any encoder signal and logic ground.
Current draw into the + or - input.
-7.0V
Frequency of the AM or BM signal inputs. The count frequency is 4 times this frequency, since the circuitry counts all four transitions.
-30 mA
—
56 pF
56 pF
IM Channel Input
Maximum
+7.0V
-7.0V
+12.0V
30 mA
5.0 MHz
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68
Parameter
IM Pulse Width
AM, BM Phase Error
2.5 MHz Line
Frequency
AM, BM Phase Error
1 MHz Line
Frequency
Description
Pulse width of the index input signal. Since the index is active for a percentage of a revolution, the speed will determine the pulse width.
Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.
Minimum
125 nS
-22.5°
Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.
-45°
Maximum
—
+22.5°
+45°
The table provides a description of the AM and BM inputs for Sine/Cosine encoders.
Table 27 - AM, BM and IM Input Specifications for Sine/Cosine Encoders
Parameter
Sine/cosine
Input Signal
Frequency
Sine/cosine
Input Voltage
Description
Frequency of the Sine or Cosine signal inputs.
Peak-to-peak input voltages of the Sine or Cosine inputs.
Table 28 - Specifications for Heidenhain EnDat Encoders
Command Set
EnDat 2.1
Order
Designation
EnDat 01
Description
1V (p-p) Sin/Cos, <2 MHz clock frequency
Minimum
—
0.5V (p-p)
Maximum
250 kHz
2.0V (p-p)
Auxiliary Feedback (AF)
These requirements apply to the Auxiliary Feedback signals.
•
For TTL devices, the position count increases when A leads B.
•
For sinusoidal devices, the position count increases when cosine leads sine.
•
TTL devices must be 5V devices within the input voltage specification.
•
Use the Low Profile Connector Kit, catalog number 2090-K6CK-D15F to access the Auxiliary Feedback signals. You must supply cabling that has shielding, and other EMI protection for motor feedback cables.
Feedback Power Supply
The power circuit board generates the +5V and +9V DC for the motor and auxiliary feedback power supplies. Short-circuit protection and separate common mode filtering for each channel is included.
•
MP
x
-B, and HPK-B and -E motors all use 9V power sources from the MF connector.
•
Compatible Auxiliary Feedback devices include Stegmann Hiperface,
Sine/Cosine, and 5V TTL encoder types. Note: Heidenhain EnDat 2.1 encoders are only compatible when using the 2090-K7CK-KENDAT feedback module, however an interface module does not exist for the auxiliary encoder input.
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Chapter 3
•
See the Kinetix Motion Control Selection Guide, publication GMC-
SG001 , for cables compatible with the Kinetix 7000 drive and motor.
•
Low profile connector let you develop a custom cable for the Motor
Feedback (MF) or Auxiliary Feedback (AF) connectors.
The following table details power supply specifications for the motor and auxiliary feedback connectors.
Table 29 - Motor and Auxiliary Feedback Power Supply Specifications
Power
Supply
Signal Name Voltage (V DC) Current (mA)
(1) 400 mA on the 5V supply split in any manner between the channels with no load on the 5V supply.
(2) 275 mA on the 9V supply split in any manner between the channels with no load on the 9V supply.
(3) 300 mA on the 5V supply on one channel with 150 mA on the 9V supply on the second channel.
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Kinetix 7000 Connector Data
Notes:
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Chapter
4
This chapter provides procedures for wiring your Kinetix 7000 drive system components and making cable connections.
Topic
Determine the Input Power Configuration
Set the Ground Jumper in Select Power Configurations
Grounding the Kinetix 7000 Drive System
Input Power Wiring Requirements
Wire the Kinetix 7000 Drive Connectors
Feedback and I/O Cable Connections
Wire Feedback and I/O Connectors
External Shunt Module Connections
SERCOS Fiber-optic Cable Connections
Page
Basic Wiring Requirements
This section contains basic wiring information for the Kinetix 7000 drive.
ATTENTION:
Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, that can result in damage to components.
IMPORTANT
SHOCK HAZARD:
To avoid hazard of electrical shock, perform all mounting and wiring prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.
This section contains common PWM servo system wiring configurations, size, and practices that can be used in a majority of applications. National
Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.
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Building Your Own Motor Cables
IMPORTANT
Factory-made cables are designed to minimize EMI and are recommended over hand-built cables to optimize system performance.
•
Connect the cable shield to the connector shells on both ends of the cable with a complete 360° connection. If separate power wires are used in a customer-supplied power cable, the shield may alternatively be connected to a ground terminal.
•
Use a twisted pair cable whenever possible. Twist differential signals with each other and twist single-ended signals with the appropriate ground return.
•
Discrete power cables require 360° shielding. Connect the shield to a ground terminal.
See the Kinetix Motion Control Selection Guide, publication GMC-SG001 , for low-profile connector kit, drive-end (mating) connector kit, and motor-end connector kit catalog numbers.
Shielded Motor Cable
The use of a four-wire type Variable Frequency Drive (VFD), 600 volt, UL listed cable is strongly recommended for all motor currents at or below 130 Amperes.
The illustration below illustrates the type of cable required.
Figure 43 - Type of Cable Required for Kinetix 7000 Drive Interconnects
Stranded Drain Wire
Foil Shield
Cable Jacket
Tinned Copper Braid with 85% Coverage
Stranded Tinned Copper
Conductors
Oversized Insulation
Required Cable Types
You should always use shielded motor cable. The shield must connect to the drive chassis (PE) connection and the motor frame. Make the connection at both ends to minimize the external magnetic field. If you use cable trays or large conduits to distribute the motor leads for multiple drives, use shielded cable to reduce noise from the motor leads.
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Chapter 4
55 A
65 A
95 A
130 A
12 A
17 A
21 A
30 A
Cable Sizes
In the table below the appropriate VFD shielded cable to use based on 150% overload capability and 25 °C (77 °F) operating temperature is shown.
For applications above 130 Amps, use thick insulation lead wire, such as RHW-2 or equal. Make sure you thread the four wires (U, V, W, and ground) through a single, grounded, metal conduit.
Table 30 - 1.5x Rated Continuous Motor Current Cable Size
Motor Current
10
16
4
6
mm
2
Cable Size
AWG
1.5
2.5
16
14
25
35
4
2
8
6
12
10
Conduit
For applications above 130 Amperes, metal conduit is required for cable distribution. Follow these guidelines:
•
Drives are normally mounted in cabinets, and ground connections are made at a common ground point in the cabinet. If the conduit is connected to the motor junction box and the drive end is connected to the ground panel in the cabinet, you do not need any additional conduit connections.
•
Route no more than three sets of motor leads and a ground wire through a single conduit. This minimizes cross talk that also reduces the effectiveness of the noise reduction methods described. If more than three drive/motor connections per conduit are required, use shielded cable. If practical, each conduit should contain only one set of motor leads.
•
You should use a thick insulation lead wire, such as type RHW-2 or equal.
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General Wire Guidelines
Observe all applicable safety and national and local regulations when selecting the appropriate wire size for your system. Due to the drive overload capacity of
150% of the continuous current rating, the conductors for the transformer primary and secondary must be sized (at a minimum) for 125…160% of the maximum continuous input current for the motor selected. The motor conductors must also be rated for a minimum of 125…160% of the full load motor continuous current. If less than 150% overload is required the torque limit parameters must be set in the drive accordingly. The distance between the drive and motor may affect the size of the conductors used. To protect against interference, use shielded wire in motor and control circuits. A shielded cable is required for all feedback signal wires.
ATTENTION:
To avoid a possible shock hazard caused by induced voltages, ground unused wires in the conduit at both ends.
For the same reason, if a drive sharing a conduit is being serviced or installed, disable all drives using this conduit. This removes the possible shock hazard from cross-coupled drive motor leads.
Routing the Power and Signal Cables
Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic drives can be induced into motor or encoder feedback signals, input/output communication, or other sensitive low voltage signals. This can cause system faults and communication problems.
See Minimizing Electrical Noise on page 28 for examples of routing high and low
voltage cables in wireways, and to the System Design for Control of Electrical
Noise Reference Manual, publication GMC-RM001 , for more information.
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Chapter 4
Determine the Input Power
Configuration
Before wiring input power to your Kinetix 7000 drive system, you must determine the type of input power within your facility. The drive is designed to operate in both grounded and ungrounded environments.
ATTENTION:
When you are using a LIM module with your Kinetix 7000 drive, the AC line input power must come from a grounded power configuration.
When you are not using a LIM module with your Kinetix 7000 drive, ungrounded, corner-grounded, and impedance-grounded input power configurations are permitted, but you must set the ground jumper as indicated in
addition, set the ground jumper when an active converter supplies the DC-bus voltage.
See
Set the Ground Jumper in Select Power Configurations on page 79 for
additional information.
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 44 - Grounded Three-phase Power Configuration - (WYE Secondary)
2099-BM08-S shown with
Lower Front Panel Removed
Three-phase
Input VAC
Transformer (WYE) Secondary
Transformer
L1
L2
L3
Line
Filter
Phase Ground
Bonded Cabinet
Ground
Ground Grid or
Power Distribution Ground
To Ground Stud
IMPORTANT
If you determine that you have grounded power distribution in your facility, you do not need to set the ground jumper.
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Figure 45 - Corner-grounded Power Configuration
2099-BM08-S Shown with Lower
Front Panel Removed
Transformer (Delta) Secondary
Transformer
L1
L2
L3
Bonded Cabinet
Ground
Ground Grid or
Power Distribution Ground
Line
Filter
To Ground Stud
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Figure 46 - Impedance-grounded Power Configuration (WYE Secondary)
Three-phase
Input VAC
2099-BM08-S shown with
Lower Front Panel Removed
Transformer (WYE) Secondary
Transformer
L1
L2
L3
Line
Filter
Phase Ground
Bonded Cabinet
Ground
Ground Grid or
Power Distribution Ground
To Ground Stud
IMPORTANT
Even though impedance-grounded and corner-grounded power configurations have a ground connection, treat them as ungrounded when installing
Kinetix 7000 drives.
See Interconnect Diagrams beginning on page 163
for input power interconnect diagrams.
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Ungrounded Power Configurations
Kinetix 7000 drives contain protective MOV devices and common-mode capacitors that are referenced to ground. Disconnect the protective MOV devices and capacitors if the drive has an ungrounded, impedance-grounded, or cornergrounded power configuration where the line-to-ground voltages on any phase exceeds 125% of the nominal line-to-voltage.
ATTENTION:
To avoid unstable operation and/or drive damage, these devices must be disconnected if the drive has an ungrounded, impedance-grounded, or corner-grounded power configuration.
Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground.
A Kinetix 7000 drive application using an active converter for DC-bus voltage is considered an ungrounded power distribution system.
Figure 47 - Ungrounded Power Wiring
78
2099-BM08-S Shown with Lower
Front Panel Removed
Three-Phase Input
VAC
Ground
Conduit/4-Wire Cable
L1
L2
L3
Bonded Cabinet
Ground
Ground Grid or Power
Distribution Ground
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Connect the Kinetix 7000 Drive System
Chapter 4
Set the Ground Jumper in
Select Power Configurations
Setting the ground jumper is necessary when using an ungrounded, cornergrounded, and impedance-grounded power configuration. Also, set the ground jumper when you are using the Bulletin 8720MC regenerative power supply, or any active converter, for DC-bus voltage. Setting the ground jumper involves accessing the power chassis and removing jumper plugs or disconnecting wires on the power terminals.
ATTENTION:
To avoid personal injury, the ground jumper access area 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 DCbus voltage exists before accessing the ground jumper.
Because the unit no longer maintains line-to-neutral voltage protection, risk of equipment damage exists when you remove the ground jumper.
Example Diagram
Table 31 - Ground Jumper Configurations
Ground Jumper Configuration Ground Configuration
Grounded (wye)
•
Corner grounded
•
Impedance grounded
•
AC-fed ungrounded
DC-bus from active converter
Installed (default setting)
Removed
Benefits of Correct Configuration
•
UL and EMC compliance
•
Reduced electrical noise
•
Most stable operation
•
Reduced voltage stress on components and motor bearings
•
Helps avoid severe equipment damage when ground faults occurs
•
Reduced leakage current
Drive
2099-BM06-S, 2099-BM07-S and
2099-BM08-S
Jumper/Wire
PEA
PEB
2099-BM09-S and
2099-BM10-S
2099-BM11-S and
2099-BM12-S
Green/yellow wire
Green/yellow wire
Table 32 - Jumper/Wire Location and Removal Instructions
ID No.
Component
Common mode capacitor
1
Location
Remove the two jumpers located above the power terminal block. See
Remove the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and 2099-
.
MOVs
2
3
4
5
Common mode capacitor
MOVs/input filter cap
Common mode capacitor
MOVs
Remove DC-DC converter and drive top cover, and disconnect the green/ yellow wire from the drive chassis. Insulate and secure the wire to prevent
unintentional contact with the chassis or components. See Remove the
Ground Wires on 2099-BM09-S and 2099-BM10-S Drives on page 81
.
Disconnect the green/yellow wire next to the power terminal block. Insulate and secure the wire to prevent unintentional contact with the chassis or
components. See Remove the Ground Wires on 2099-BM09-S and 2099-
.
Disconnect the two green/yellow wires from the PE terminals on the power terminal block. Insulate and secure each of these wires to prevent
unintentional contact with the chassis or components. See Remove the
Ground Wires on 2099-BM11-S and 2099-BM12-S Drives on page 81
.
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Remove the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and
2099-BM08-S Drives
Figure 48 shows the location of the jumpers in 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S drives on the power chassis. The common mode capacitor jumper is indicated by callout 1 (PEA) and the MOV jumper is indicated by callout 2 (PEB).
Remove each jumper by carefully pulling it straight out.
Figure 48 - Ground Jumper Location on 2099-BM06-S, 2099-BM07-S, and
2099-BM08-S
2
1
MOV
PE B
CM Cap
PE A
PE B
PE A
AUX IN
+ –
WIRE
STRIP
BR1 BR2
75C Cu Wire
6 AWG [10MM2] Max.
12 IN. LBS.
1.4 N-M
} TORQUE
3 AWG [25MM
2
] Max.
16 IN. LBS.
1.8 N-M
} TORQUE
BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3
PE
SHLD
SHLD
Important:
Do not discard or replace the grounding hardware.
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Chapter 4
Remove the Ground Wires on 2099-BM09-S and 2099-BM10-S Drives
Figure 49 shows the locations of the common mode capacitor and MOV/input filter capacitor ground wires in 2099-BM09-S and 2099-BM10-S drives. The common mode capacitor ground wire is indicated by callout 3 and the MOV/ input filter cap ground wire is indicated by callout 4.
Figure 49 - Ground Wire Locations on Terminal Block of 2099-BM09-S and 2099-BM10-S
3
CM Cap - Newer Drives
Note: You must remove the DC-DC converter and drive top cover to access and remove the common mode capacitor ground wire. See the Kinetix
7000 DC-DC Converter and Control Board
Kits Installation instructions, publication
2099-IN002 , for instructions.
MOV
4
MOV/Input
Filter Cap
3
CM Cap -
Older Drives
Remove the Ground Wires on 2099-BM11-S and 2099-BM12-S Drives
Figure 50 shows the locations of the common mode capacitor and MOV ground wires in 2099-BM11-S and 2099-BM12-S drives. The common mode capacitor ground wire is indicated by callout 5 and the MOV ground wire is indicated by callout 6.
Figure 50 - Ground Wire Location on Power Terminal Block of 2099-BM11-S and 2099-BM12-S
DO NOT REMOVE
5
CM Cap
U
T1
V
T2
OUTPUT
MOV
W
T3
PE PE R
L1
S
L2
INPUT
T
L3
6
PE PE
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Grounding the Kinetix 7000
Drive System
All equipment and components of a machine or process system must have a common earth ground point connected to their chassis.
A grounded system provides a ground path for short-circuit protection.
Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short-circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.
See Agency Compliance on page 18 for CE grounding requirements.
IMPORTANT
To improve the bond between the drive and subpanel, construct your subpanel out of zinc-plated (paint-free) steel.
Grounding Your System to the Subpanel
, the drive is shown properly grounded to the bonded cabinet ground on the subpanel.
ATTENTION:
The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system.
See the Interconnect Diagram Notes diagrams beginning on page 164 .
Figure 51 - Drive Chassis Ground Connection
82
Bonded Cabinet Ground *
Kinetix 7000
Drive
Braided Ground Strap *
Ground grid or power distribution ground *
* Indicates customer-supplied item.
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Chapter 4
Grounding Multiple Subpanels
To extend the chassis ground to multiple subpanels, see
IMPORTANT
HF bonding is not illustrated. For HF bonding information, see Bonding
Multiple Subpanels on page 30 .
Figure 52 - Subpanels Connected to a Single Ground Point
Always follow NEC and applicable local codes
Bonded Ground Bus
Ground grid or power distribution ground
Motor Power Cable Shield Termination
Factory-supplied motor power cables for MP-series motors are shielded, and the braided cable shield must terminate at the drive when installed. A small portion of the cable jacket must be removed to expose the shield braid. The exposed area must be clamped (using the clamp provided on the 2099-BM06-S, -BM07-S and
-BM08-S drives) to the drive to provide a 360° termination. Factory-supplied power cables must also be terminated in the motor power (MP) connector plug.
ATTENTION:
To avoid hazard of electrical shock, be sure the shielded power cables are grounded at a minimum of one point for safety.
Customer-supplied power cables must be shielded, and the braided cable shield or conduit must terminate at the drive when installed. An area of the power cable shield must be exposed and terminated for 360° at the drive. In a similar manner, conduit enclosing discrete power cables must be terminated for 360° at the drive.
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Figure 53 - Power Cable Shielding Techniques Recommended for Kinetix 7000 Drives
Conduit or Cable Braid Clamped at Drive Frame Provides 360° Shield Termination.
Clamp Also Connects to the Nearest Available Bonded Cabinet Ground.
Drive
Enclosure
Wire Restraint
Enclosure Clamp Terminates
360° Shield at Enclosure
(1)(2)
Conduit in Contact with Clamp
Cable Shield Under
Clamp
Metallic Conduit with Wires
Cable with Braided Shield
1) For examples of shield clamp attachment, see the System Design for Control of Electrical Noise Reference Manual, publication
GMC-RM001 .
2) If enclosure is painted, remove paint to provide metal-to-metal contact.
Junction Box Beneath
Drive
(2099-BM10-S,
2099-BM11-S, and
2099-BM12-S Only)
Three-phase Power with
Ground
MP-Series (Bulletin MPL) Motor Connectors
Bayonet Connectors with Brake
Bulletin MPL motors equipped with circular DIN connectors (specified by 7 in the catalog number) are not compatible with cables designed for motors equipped with bayonet connectors (specified by 2 in the catalog number). The motors with bayonet connectors are being discontinued.
Bayonet connectors can be mounted facing the motor shaft or end plate and provide a separate connector for power, feedback, and brake connections.
Circular DIN connectors rotate up to 180° and combine power and brake wires in the same connector, eliminating the brake connector.
Figure 54 - Bayonet and Circular DIN Motor Connectors
Bayonet Connectors without Brake
Circular DIN Connectors
Feedback / Power / Brake
Motor Connectors
Feedback / Power
Motor Connectors Power and Brake
Motor Connector
Feedback Motor
Connector
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Table 33 - Motor Power Cable Compatibility
Motor/Actuator
MP-Series (Bulletin MPL)
Connector
Circular DIN
Motor/Actuator Cat. No.
MPL-B5
MPL-B9
xxx xxx
, MPL-B6
xxx
, MPL-B8
xxx,
and
Motor Power Cables
(with brake wires)
2090-CPBM7DF-
xx
AA
xx
or
2090-XXNPMF-
xx
S
xx
(standard, non-flex)
2090-CPBM7DF-
xx
AF
xx
(1)
(continuous-flex)
N/A
Motor Power Cables
(without brake wires)
2090-CPWM7DF-
xx
(standard, non-flex)
AA
xx
2090-CPWM7DF-
xx
AF
xx
(1)
(continuous-flex)
MP-Series (Bulletin MPM)
Bayonet
Circular DIN
MPL-A/B5
xxx
, MPL-B6
xxx
, and
MPL-B8
xxx
MPL-B960B, MPL-B960C,
MPL-B980B, and MPL-B980C
MPL-B960D and MPL-B980D
MPM-B165 and MPM-B215 2090-CPBM7DF-
xx
AA
xx
or
2090-XXNPMF-
xx
S
xx
(standard, non-flex)
2090-CPBM7DF-
xx
AF
xx
(1)
(continuous-flex)
N/A
2090-XX
x
PMP-
xx
2090-CPWM7DF-
S
xx
2090-MCNPMP-6S
xx xx
(standard, non-flex)
(2)
AA
xx
2090-CPWM7DF-
xx
AF
xx
(1)
(continuous-flex)
RDD-Series Circular DIN RDB-B
xxxx
2090-CPWM7DF-
xx
AA
xx
(standard, non-flex)
2090-CPWM7DF-
xx
AF
xx
(1)
(continuous-flex)
HPK-Series N/A HPK-B
xxxxx,
HPK-E
xxxxx
Customer-supplied
(1) You must remove the motor-side o-ring when using 2090-CP
x
M7DF-
xx
A
xxx
cables.
(2) For Bulletin MPL motors equipped with bayonet connectors. These cables are available as standard, non-flex (catalog number 2090-XXNPMP-xxSxx) and continuous-flex (catalog number 2090-XXTPMPxxSxx).
Motors may have a separate brake connector or need routing of thermal switch wires. These are often separately shielded and routed in an existing cable.
See Wiring Examples beginning on page
for interconnect diagrams, and the
Power Terminal Block (PTB) Connections diagram on page 51
for the location of the U, V, W, and ground (PE) motor power terminals.
IMPORTANT
Securing the cable shield in the clamp with a tie wrap is recommended to improve stress relief.
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Input Power Wiring
Requirements
National codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices.
ATTENTION:
To avoid personal injury and/or equipment damage, make sure installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code
(NEC) and local codes outline provisions for safely installing electrical equipment.
To avoid personal injury and/or equipment damage, make sure motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.
To avoid personal injury and/or equipment damage, make sure shielded power cables are grounded to prevent potentially high voltages on the shield.
86
Acceptable Cable Types
Do not use cable with an insulation thickness less than or equal to 15 mils (0.4 mm/0.015 in.). Use copper wire only. Wire gauge requirements and recommendations are based on 75
C. Do not reduce wire gauge when using higher temperature wire.
As an approximate guide, provide spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided.
Shielded/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communication and networking are also good candidates for shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks.
Consideration should be given to the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least
75%. An additional foil shield can greatly improve noise containment.
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Chapter 4
A good example of recommended cable is Belden/E 295
xx
(
xx
determines gauge). This cable has four XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a
PVC jacket.
Other types of shielded cable are available, but the selection of these types may limit the allowable. Particularly, some of the newer cables twist four conductors of THHN wire and wrap them tightly with a foil shield. This construction increases the cable charging current required and reduces the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.
The table below describes the recommended shielded cables.
Table 34 - Shielded Cable Ratings and Types
Location
Standard
(Option 1)
Standard
(Option 2)
Class I & II;
Division 1 & II
Rating/Type
600V, 90 °C (194 °F),
XHHW2/RHW-2
Anixter B209500-B209507,
Belden B29501-B229507, or equivalent
600V, 90 °C (194 °F),
RHH/RHW-2
Anixter OLF-7
xxxxx
, or equivalent
Tray rated 600V, 90 ° C (194 ° F),
XHHW2/RHW-2
Anixter 7V-7
xxxxx
-3g, or equivalent
Description
•
Four tinned copper conductors with XLPE insulation
•
Copper braid/aluminum foil combination shield and tinned copper drain wire
•
PVC jacket
•
Three tinned copper conductors with XLPE insulation
•
5 mil single helical copper tape (25% overlap minimum) with three bare copper grounds in contact with shield
•
PVC jacket
•
Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor
•
Black sunlight resistant PVC jacket overall
•
Three copper grounds on 5 mm
2
(10 AWG) and smaller
Contactors
A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed four cycles per minute maximum, or damage will occur to the drive precharge circuit.
The start/stop/enable control circuitry for the drive includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional stop circuitry may be required to remove the AC line to the drive. An auxiliary braking method also may be required.
IMPORTANT
It is recommended that the drive safe-off function be used to minimize contactor cycling.
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Power Wire Specifications
Wire should be copper with 75 °C (167 °F) minimum rating. Phasing of main
AC power is arbitrary and earth ground connection is required for safe and proper operation.
For additional information see Power Specifications on page 152
, and
Interconnect Diagram Notes on page 164
for interconnect diagrams.
ATTENTION:
This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures.
See publication 8000-4.5.2
, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook.
ATTENTION:
To avoid personal injury and/or equipment damage, be sure the installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code
(NEC) and local codes outline provisions for safely installing electrical equipment
To avoid personal injury and/or equipment damage, be sure the motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.
To avoid personal injury and/or equipment damage, be sure the shielded power cables are grounded to prevent potentially high voltages on the shield.
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Power Wiring Guidelines
Connect the Kinetix 7000 Drive System
Chapter 4
Use these guidelines when wiring the power connectors on your Kinetix 7000 drive (without a LIM).
IMPORTANT
To achieve system performance, run wires and cables in the wireways as
.
IMPORTANT
To limit coil switching transients generated by the LINE contactor, use of a surge suppressor is recommended. For an example, see
This procedure assumes you have separate power supply/line filter components mounted on your panel and are ready to wire the AC input power to the drive.
1.
Prepare the wires for attachment to each connector by removing insulation equal to an acceptable strip length.
The actual strip length will vary based on the wire gauge and terminal size of the Kinetix 7000 drive.
2.
Route the wires to your Kinetix 7000 drive.
3.
Insert the wires into the connector or connect the wires to the terminals.
4.
Tighten the terminal screws/nuts to the recommended torque for the specific terminal.
5.
Pull on each wire to make sure it does not come out of its terminal. If any wires are loose, reinsert/connect and tighten the wire to the recommended torque.
Wire the Kinetix 7000 Drive
Connectors
for all Kinetix 7000 drive interconnect diagrams.
Wire the Control Power (CP) Connector
Wire the 24V DC control power supply to your Kinetix 7000 drive as described in
. See Control Power (CP) Terminal Block Connections for more
information.
Table 35 - Control Power Connections
Signal
CP_24VDC
CP_COM
Terminal
1
2
Recommended Wire Size mm
2
(AWG)
0.75 (18)
(stranded wire with ferrule)
1.5 (16)
(solid wire)
Strip Length mm
2
(in.)
7.0 (0.275)
Torque
N
• m (lb
• in)
0.235 (2.0)
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Wire AC Input Power
Wire 460V AC input power to your Kinetix 7000 drive as described in
.
See Power Terminal Block (PTB) Connections for more information.
Table 36 - AC Input Power Connections
Kinetix 7000
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Signal
L1
L2
L3
Ground
L1
L2
L3
Ground
L1
L2
L3
Ground
L1
L2
L3
Ground
Terminal
R
S
T
PE
R
S
T
R
S
T
PE
PE
R
S
T
PE
Recommended Wire Size mm
2
(AWG)
25…2.5 (3…14)
50…4 (1/0…12)
50…4 (1/0…12)
70…10 (2/0…8)
50…4 (1/0…12)
100…10 (4/0…8)
50…4 (1/0…12)
Torque
N
• m (lb
• in)
1.8 (16)
3.6 (32)
5 (44)
15 (133)
5 (44)
12 (104)
5 (44)
Wire DC Input Power (Common Bus Configurations Only)
Wire the DC input power from a leader regenerative power supply (8720MC-
RPS) to a Kinetix 7000 drive as described in
(PTB) Connections on page 51 for more information.
IMPORTANT
DC power from the regenerative power supply (8720MC-RPS) is typically routed to a power distribution box. Fusing will be placed before and after the distribution box, providing protection for both the 8720MC-RPS and
Kinetix 7000 drive.
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Connect the Kinetix 7000 Drive System
Chapter 4
Table 37 - DC Input Power Connections
Kinetix 7000
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
DC+
DC-
DC+
DC-
DC+
DC-
Signal Description
DC+
DC-
DC+
DC-
DC+
DC-
DC+
DC-
Terminal(s) Recommended Wire Size mm
2
(AWG)
DC+
DC25…2.5 (3…14)
50…4 (1/0…12)
70…10 (2/0…8)
100…10 (4/0…8)
Torque
N
• m (lb
• in)
1.8 (16)
3.6 (32)
15 (133)
12 (104)
Wire the Safe-off (SO) Connector
Wire the Safe-off connections to your Kinetix 7000 drive as described in
. See Safe-off (SO) Terminal Block Connections for more information.
IMPORTANT
Terminals 8 and 9 (24V+ and Common) are only used by the motionallowed jumper. When using the Safe-off feature, the 24V supply must come from an external source.
Table 38 - Safe-off Connections
Signal
FDBK2+
FDBK2-
FDBK1+
FDBK1-
ENABLE2+
ENABLE-
ENABLE1+
SO_24VDC
SO_COM
Terminal
7
8
5
6
9
3
4
1
2
Recommended Wire Size mm
2
(AWG)
0.75 (18)
(stranded wire with ferrule)
1.5 (16)
(solid wire)
Strip Length mm
2
(in.)
Torque
N
• m (lb
• in)
7.0 (0.275) 0.235 (2.0)
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Wire the General Purpose Relay (GPR) and General Purpose I/O (GPIO)
Connectors
Wire the control and interface signals on the General Purpose Relay (GPR) and
General Purpose I/O (GPIO) connectors as described in
See General Purpose I/O (GPIO) Terminal Block Connections on page 46 and
General Purpose Relay (GPR) Terminal Block Connections on page 46 for more
information.
ATTENTION:
Wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your safety control string.
In common bus configurations, a REGEN connection on the General Purpose Input/
Output connector is also required for the drives. This connection must be wired in series to the safety control string, and also wired from the 8720MC-RPS to the
Kinetix 7000 drive to indicate bus voltage is present.
Signal
DRIVE OK+
DRIVE OK-
5
6
Terminal Description
Table 39 - General Purpose Relay Connections
Recommended Wire Size mm
2
(AWG)
Programmable N.O. Relay 2 output
Programmable Relay 2 common
0.75 (18)
(stranded wire with ferrule)
1.5 (16)
(solid wire)
Signal
Regen_OK+ 7
Regen_OK8
Terminal Description
Table 40 - General Purpose I/O Connections
Recommended Wire Size mm
2
(AWG)
Regenerative power supply status
Regenerative power supply status common
0.75 (18)
(stranded wire with ferrule)
1.5 (16)
(solid wire)
Strip Length mm (in.)
7.0 (0.275)
Strip Length mm (in.)
7.0 (0.275)
Torque Value
N•m (lb•in)
0.235 (2.0)
Torque Value
N•m (lb•in)
0.235 (2.0)
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Connect the Kinetix 7000 Drive System
Chapter 4
Wire Motor Output Power
Wire motor output power as described in
(PTB) Connections on page 51 for more information.
Table 41 - HPK-Series and MP-Series Servo Motor Power Connections
Kinetix 7000
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Signal
U / Brown
V / Black w / Blue
Green/Yellow
U / Brown
V / Black w / Blue
Green/Yellow
U / Brown
V / Black w / Blue
Green/Yellow
U / Brown
V / Black w / Blue
Green/Yellow
U
V
W
U
V
W
U
V
W
Terminal
U
V
W
Recommended Wire Size mm
2
(AWG)
25…2.5 (3…14)
50…4 (1/0…12)
50…4 (1/0…12)
70…10 (2/0…8)
50…4 (1/0…12)
100…10 (4/0…8)
50…4 (1/0…12)
Torque
N
• m (lb
• in)
1.8 (16)
3.6 (32)
5 (44)
15 (133)
5 (44)
12 (104)
5 (44)
Wire the Motor Brake
Wire the motor brake (if applicable) as described in
Terminal Block (PTB) Connections on page 51 for more information on the
motor power connections.
IMPORTANT
Use surge suppression when controlling a brake coil.
Table 42 - Motor Brake Connections
Motor Brake Terminal (Signal)
Bulletin MPL w/Bayonet Connector
Bulletin MP
x
w/Circular DIN Connector
A (BR+)
C (BR-)
F (BR+)
G (BR-)
Drive Terminal
(Signal)
2 (GPR1+)
3 (GPR1-)
Recommended Wire Size mm
2
(AWG)
2.5 (14)
Strip Length mm (in.)
10 (0.38)
Torque Value
N•m (lb•in)
0.5…0.6
(4.4…5.3)
Notes: HPK-Series motor brake terminations are BR+ and BR-. RDD-Series motors do not have a motor brake.
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Connect the Kinetix 7000 Drive System
Feedback and I/O Cable
Connections
Motor brake wiring varies slightly, depending on the motor connector type. The table below identifies the brake wire option for your servo motor and the appropriate brake cable or connector kit catalog number required.
Motor Series Connector
Type
Bulletin MPL
Bayonet The motor has a separate brake connector and requires a brake power cable.
Bulletin MPM Circular DIN The brake terminals are in the motor power connector. Drive to motor power cables must be ordered with the brake option.
HPK-Series
Circular DIN
N/A
Brake Wire Option
The brake terminals are in the motor power connector. Drive to motor power cables must be ordered with the brake option.
The motor has a separate brake wiring connection.
Cable Cat. No.
2090-CPBM7DF-
xx
AA
xx
(1)
2090-XXNPMF-
xx
S
xx
(standard, non-flex)
2090-CPBM
x
DF-
xx
AF
xx
(1)
(continuous-flex)
2090-UX
x
BMP-18S
xx
brake cable
(2)
2090-CPBM7DF-
2090-XXNPMF-
xx
S
xx
(standard, non-flex)
(continuous-flex)
xx
Customer-supplied
AA
xx
(1)
2090-CPBM
x
DF-
xx
AF
xx
(1)
(1) You must remove the motor-side o-ring when using 2090-CP
x
M7DF-
xx
A
xxx
cables.
(2) For Bulletin MPL motors equipped with bayonet connectors. These cables are available as standard, non-flex (catalog number 2090-
UXNBMP-18Sxx) and continuous-flex (catalog number 2090-UXTBMP-18Sxx).
Factory-made cables with premolded connectors are designed to minimize EMI and are recommended over hand-built cables to improve system performance.
However, other options are available for building your own feedback and I/O cables.
Table 43 - Motor Feedback Cable Compatibility - Bayonet Connectors
Motor/Actuator
MPL-B
xxxx
-S
Connector
Type
Bayonet
Feedback Type
Premolded
Feedback Cable
Flying-lead
High-resolution encoder 2090-UXNFBMP-S
xx
2090-XX
x
FMP-S
xx
(1)
(1) For Bulletin MPL and 1326AB (M2L/S2L) motors equipped with bayonet connectors. These cables are available as standard, non-flex
(catalog number 2090-XXNFMP-Sxx) and continuous-flex (catalog number 2090-XXTFMP-Sxx).
Table 44 - Motor Feedback Cable Compatibility - Circular Threaded DIN
Motor/Actuator
HPK-Series
Connector
Type
Feedback Type
Premolded
Circular
Threaded DIN
High-resolution encoder N/A
Feedback Cable
Flying-lead
2090-XXNFMF-S
xx
(standard, non-flex)
2090-CFBM4DF-CDAF
xx
(continuous-flex)
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Connect the Kinetix 7000 Drive System
Chapter 4
Table 45 - Motor Feedback Cable Compatibility - SpeedTec DIN Connectors
Motor/Actuator
Connector
Type
Feedback Type
Premolded
Feedback Cable
(1)
Flying-lead
MPL-B5
xxx
-S/M
x
7
x
AA,
MPL-B6
xxx
-S/M
x
7
x
AA,
MPL-B8
xxx
-S/M
x
7
x
AA
MPL-B9
xxx
-S/M
x
7
x
AA
MPM-B
xxxxx-
S/M
HPK-Series
SpeedTec DIN
High-resolution encoder
2090-CFBM7DD-CEAA
xx
(standard, non-flex) or
2090-CFBM7DD-CEAF
xx
(continuous-flex)
2090-CFBM7DF-CEAA
xx
(standard, non-flex) or
2090-CFBM7DF-CEAF
xx
(continuous-flex)
RDB-B
xxxx
-7/3 N/A
2090-XXNFMF-S
xx
(standard, non-flex) or
2090-CFBM7DF-CDAF
xx
(continuous-flex)
(1) You must remove the motor-side o-ring when using 2090-CFBM7
xx
-
xx
A
xxx
cables.
Flying-lead Feedback Cable Pinouts
Table 46 - 2090-XX
x
FMP-S
xx
Feedback Cable
(1)
Motor Bayonet
Connector Pin
T
U
V
R
S
N
P
K
L
E
F
C
D
A
B
Rotary Motors with High Resolution Feedback:
MPL-B5
xxxx-
M/S
x
2
x
AA, MPL-B6
xxxx
-M/S
x
2
x
AA,
MPL-B8
xxxx-
M/S
x
2
x
AA, and MPL-B9
xxxx
-M/S
x
2
x
AA
Signal
Sine+
Sine-
Cos+
Cos-
Data+
Data-
Reserved
Reserved
EPWR_9V
ECOM
TS+
TS-
Reserved
Reserved
Reserved
Drive MF
Connector Pin
1
2
3
4
5
10
–
–
7
6
11
–
–
–
–
(1) The 2090-XX
x
FMP-S
xx
cables are available as standard, non-flex (catalog number 2090-XX
N
FMP-S
xx
) and continuous-flex (catalog number 2090-XX
T
FMP-S
xx
).
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Table 47 - 2090-XXNFMF-S
xx
and 2090-CFBM
x
DF-CDAF
xx
Feedback Cable
16
17
14
15
12
13
10
11
6
9
4
5
1
2
3
Motor
Circular DIN
Connector Pin
Motors with High Resolution Feedback:
MPL-B5
xxxx
-M/S
x
7
x
AA, MPL-B6
xxxx
-M/S
x
7
x
AA,
MPL-B8
xxxx
-M/S
x
7
x
AA, MPL-B9
xxxx
-S/M-M/S
x
7
x
AA,
HPK-B
xxxx
-S/M, and HPK-E
xxxx
-S/M
Signal
Sine+
Sine-
Cos+
Cos-
Data+
Data-
Reserved
Reserved
EPWR_9V
ECOM
TS+
TS-
Reserved
Reserved
Reserved
Drive MF
Connector Pin
–
–
–
–
6
11
–
7
10
–
4
5
1
2
3
14
15
12
13
16
17
10
11
8
9
6
7
4
5
1
2
3
Table 48 - 2090-XXNFMF-S
xx
and 2090-CFBM
x
DF-CDAF
xx
Feedback Cable
Motor Circular DIN
Connector Pin
RDB-B
xxxxx
-3/7 Motors 2090-K7CK-KENDAT
Pin
Signal
Sine+ 1
ECOM
Reserved
Reserved
TS+
TS-
Reserved
Reserved
Reserved
Sine-
Cos+
Cos-
Data+
Data-
CLK+
CLK-
EPWR_5V
–
–
–
–
–
11
6
–
8
5
10
7
4
9
2
3
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Wire Feedback and I/O
Connectors
Connect the Kinetix 7000 Drive System
Chapter 4
Wire your feedback and I/O cables.
To make this type of connection
Premolded Cable
Panel-mounted Breakout Board
Low-profile Connector
Go to
Connect Premolded Motor Feedback Cables below.
Wire Panel-mounted Breakout Board Kits on page 98 .
Wire Low-profile Connectors on page 100 .
Connect Premolded Motor Feedback Cables
Motor feedback cables (with premolded connectors) plug directly into 15-pin motor feedback (MF) connectors on Kinetix 7000 drive (no wiring is necessary).
IMPORTANT
When using Bulletin 2090 cables with premolded connectors, tighten the mounting screws (finger tight) to improve system performance.
Figure 55 - Premolded Motor Feedback Cable Connection
Kinetix 7000 Drive
(Side View)
Premolded Connector Cable:
2090-CFBM7DD-CEAAxx (standard, non-flex) or
2090-CFBM7DD-CEAF
xx
(continuous flex)
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Wire Panel-mounted Breakout Board Kits
The panel-mounted breakout board kit (catalog number 2090-UXBK-D15
xx
) includes a (DIN rail) terminal block and cable. The cable connects between the terminal block and the motor feedback (MF) connector. Wires from your flyinglead motor feedback cable connect to the terminals.
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Connect the Kinetix 7000 Drive System
Chapter 4
Figure 56 - Panel-mounted Breakout Board Connection Example
Kinetix 7000 Drive
(Side View)
See the Motor Feedback Breakout Board
Installation Instructions, publication 2090-IN006 , for Connector Breakout Board Specifications.
2090-UXBB-D15xx
Panel-mounted Breakout Board
2090-UXBC-D15xx
Breakout Cable
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Connect the Kinetix 7000 Drive System
Connector Kit
Cat. No.
2090-K7CK-KENDAT
2090-K6CK-D15M
2090-K6CK-D15F
2090-K6CK-D26M
Wire Low-profile Connectors
Low-profile connectors (2090-K6CK-D
xxx
) are suitable for motor feedback
(MF), auxiliary feedback (AF), and I/O connections (IOD) on Kinetix 7000 drive.
Table 49 - Low-profile Connector Kits
Description Cable Compatibility
Low-profile feedback module for connecting to Heidenhain EnDat high-resolution feedback device (15-pin, male, D-sub).
Use with any Kinetix 7000 drive and Bulletin RDB direct-drive motor with EnDat high-resolution feedback.
NOTE:
Only 2099-BM
xx
-S drives with firmware revision 1.104 or higher support the use of this feedback module.
Low-profile connector kit for motor feedback (15-pin, male, D-sub). Use with any Kinetix 7000 drive and compatible motors.
Low-profile connector kit for auxiliary feedback (15-pin, female, D-sub). Use with any Kinetix 7000 drive for auxiliary feedback applications.
Low-profile connector kit for I/O (26-pin, male, D-sub). Use with any Kinetix 7000 drive or 2094-BL02 LIM module for making I/O connections.
2090-XX
x
FMP-S
xx,
2090-XXNFMF-S
xx,
2090-CFBM
x
DF-C
x
A
xxx
Customer supplied
Kinetix 7000 Drive
(Side View)
100
2090-Kxxx-Dxxx
Low-profile Connector Kit with Flying-lead Feedback or
I/O Cable
IMPORTANT
Tightening the mounting screws is essential to be sure of shield integrity between the low-profile connector covers and the drive feedback connector D-shells. Tightening torque is 0.4 N
• m
(35 lb
• in).
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Connect the Kinetix 7000 Drive System
Chapter 4
Figure 57 - Wiring (15-pin) Flying-lead Feedback Cable Connections
2090-K6CK-D15M and 2090-K6CK-D15F Connector Kits
15-pin (male) Motor Feedback
Low-profile Connector
15-pin (female) Auxiliary Feedback
Low-profile Connector
Bare wires
Wire insulation
Foil shield
Braided shield
Outer insulation
Mounting
Screws
Bulletin 2090
Feedback Cable
2090-K6CK-D15
x
Low-profile Connector Kit
Pin 10
Pin 5
Pin 1
Pin 15
Pin 11
Pin 6
Pin 1
Pin 5
Pin 10
Pin 6
Pin 11
Pin 15
Shield Clamp
Exposed Braid Under Clamp
Tie
Wrap
for Feedback Signal Descriptions.
See Appendix B for the Motor Feedback
Interconnect Drawing for Your Application.
See the Low Profile Connector Kit Installation
Instructions, Publication
2094-IN007 , for Connector Kit Specifications.
Bulletin 2090 Feedback Cable
Turn Clamp Over to Hold
Small Wires Secure
Bare Wires
Wire Insulation
Foil Shield
Braided Shield
Outer Insulation
Turn Clamp Over to Hold
Small Wires Secure.
Figure 58 - Wiring (15-pin) Flying-lead Feedback Cable Connections
2090-K7CK-KENDAT Feedback Module
Status
Indicator
15-pin (male) Motor Feedback
Low-profile Connector
Pin 10
Pin 5 Pin 15
Mounting
Screws
Pin 1
Pin 11
Pin 6
Bulletin 2090
Feedback Cable
2090-K7CK-KENDAT
Low-profile Feedback Module
Shield Clamp
Exposed Braid Under Clamp
See
Descriptions.
See
Appendix B for the Motor Feedback
Interconnect Drawing for Your Application.
Bulletin 2090
Feedback Cable
See the Low Profile Connector Kit Installation
Instructions, Publication
2094-IN007 , for Connector Lit Specifications.
IMPORTANT
The purpose of the cable shield clamp is to provide a proper ground and improve system performance, not stress relief.
Clamping the exposed braid under the shield clamp is critical. Turn the clamp over, if necessary, to be sure of a proper ground.
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Figure 59 - Wiring (26-pin) I/O Cable Connections
2090-K6CK-D26M Connector Kit
Mounting
Screws
2090-K6CK-D26M
Low-profile Connector Kit
12 11 10
Pin 18
Pin 9
Pin 26
Pin 1
Pin 19
Pin 10
26-pin (male) I/O
Low-profile Connector
See the Low Profile Connector Kit Installation
Instructions, Publication
2094-IN007 , for Connector Kit Specifications.
Tie Wrap Slot
Three Conductor
I/O Cable(s)
IMPORTANT
Turn Clamp Over to
Hold Small Wires
Secure
Discrete I/O Wire
The purpose of the cable shield clamp is to provide a proper ground and improve system performance, not stress relief.
Clamping the exposed braid under the shield clamp is critical. Turn the clamp over, if necessary, to be sure of a proper ground.
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External Shunt Module
Connections
Connect the Kinetix 7000 Drive System
Chapter 4
External active shunt modules listed in the table on page 158 are compatible with
Kinetix 7000 drives. Follow these guidelines when wiring your external active shunt module kit.
•
Refer to Shunt Resistor on page 37 for important wiring
recommendations.
•
Refer to
for the Kinetix 7000 drive interconnect diagrams.
•
Refer to the installation instructions provided with your shunt module.
IMPORTANT
When tightening screws to secure the wires to the DC bus terminals, see
Table 37 on page 91 for torque values.
SERCOS Fiber-optic Cable
Connections
This procedure assumes you have your Logix SERCOS interface module/PCI card and Kinetix 7000 drive mounted and are ready to connect the fiber-optic cables.
The SERCOS fiber-optic ring is connected using the SERCOS receive (Rx) and transmit (Tx) connectors.
See page
65 to locate the SERCOS connectors on your Kinetix 7000 drive. See
the figure below to locate the connectors on your SERCOS interface module or
PCI card.
Plastic cable is available in lengths up to 32 m (105 ft). Glass cable is available in lengths between 50 m (164 ft) and 200 m (656 ft).
IMPORTANT
When connecting Kinetix 7000 drives, use at least a 2090-SCEP1-0, 1 m (3 ft) or longer cable.
Larger drives may require longer cables.
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CompactLogix Platform
1768-M04SE SERCOS interface Module
Front View
Tx (rear)
Rx (front)
Bottom View
Figure 60 - CompactLogix, ControlLogix, and SoftLogix SERCOS Connector Locations
SERCOS interface TM
CP OK
ControlLogix Platform
1756-M
xx
SE SERCOS interface Module
RSLogix 5000 Software
D
E
F
9A
0
8
1
2
3
67
OK
CP
SoftLogix Platform
1756-PM16SE SERCOS interface PCI Card
(as viewed from the back of your personal computer)
TX
SERCOS Transmit Connector, Tx
RX
Tx (rear)
Rx (front)
Front View
SERCOS Receive Connector, Rx
SERCOS Receive Connector, Rx (front)
SERCOS Transmit Connector, Tx (rear)
Connect the cable from transmit on the Logix module to receive on the Kinetix
7000 drive, then transmit to receive (drive to drive), and from transmit on the last drive back to receive on the Logix module.
ATTENTION:
To avoid damage to the SERCOS Rx and Tx connectors use only finger-tight torque when attaching the fiber-optic cables to the Kinetix 7000 drive. Do not use a wrench or any other mechanical assistance.
For more information, see the Fiber-optic Cable Installation and Handling
Instructions, publication 2090-IN010 .
Figure 61 - Fiber-optic Cable Connections to a SoftLogix Module
Transmit
Receive
F
1
OK
CP
TX
RX
SoftLogix
1784-PM16SE SERCOS interface PCI Card
Receive
SERCOS Fiber-optic Ring
Transmit Receive
Transmit
Kinetix 6000 System
Kinetix 7000 Drive
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The following fiber-optic cable examples are shown using ControlLogix modules. CompactLogix modules connect in the same way, however the ring cannot include more than four drives.
Figure 62 - Fiber-optic Cable Connections to ControlLogix/CompactLogix Modules
1756-M
xx
SE SERCOS interface Module
SERCOS interface TM
CP
OK
Transmit
Tx (rear)
Rx (front)
Receive
Logix Chassis
(ControlLogix is shown)
Receive
SERCOS Fiber-optic Ring
Transmit
Receive
Transmit
Kinetix 6000 System
Kinetix 7000 Drive System
You can also mount the two Logix SERCOS modules in two separate chassis, or you can mount them in the same chassis.
IMPORTANT
Clean the fiber-optic cable connectors prior to installation. Dust in the connectors can reduce signal strength.
See the Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010 , for more information.
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The following example depicts the second Kinetix system, consisting of Kinetix
7000 drives, located in a separate cabinet and connected with bulkhead adapters.
IMPORTANT
To avoid signal loss, do not use bulkhead adapters to connect glass cables.
Use bulkhead adapters for making plastic-to-plastic cable connections only.
Figure 63 - Fiber-optic Cable Connections (ControlLogix/CompactLogix)
1756-M
xx
SE SERCOS
Interface Module
SERCOS interface TM
CP OK
Logix Chassis
(ControlLogix is shown)
Transmit
Tx (rear)
Rx (front)
Receive
SERCOS
Fiber-optic
Bulkhead
Adapter
SERCOS Fiber-optic Ring
Receive Transmit
SERCOS Ring
Receive
SERCOS
Fiber-optic
Bulkhead
Adapter
Transmit
Kinetix 6000 System
Kinetix 7000 Drive System
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5
Configure and Start the Kinetix 7000 Drive
System
This chapter provides procedures for configuring your Kinetix 7000 system components with the Logix SERCOS module.
Topic
Configure the Logix SERCOS interface Module
Configure Drive Parameters and System Variables
Page
Before you begin, make sure you know the characteristics of the following system components.
•
Logix processor
•
Logix module(s), including the SERCOS module
•
Kinetix 7000 drive(s) and accessories
•
Servo motor(s)/actuator(s)
•
transmission/load for the conversion constant
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Configure the Drive Modules
Follow these steps to configure the Kinetix 7000 drive.
1.
Verify that there is no power applied to the drive and that the SERCOS fiber-optic cables are plugged into the Tx and Rx connectors.
To verify your fiber-optic cable connections, refer to page
2.
Set the base node address for the drive by setting the SERCOS Node
Address switch.
Valid node addresses are 01...99. The left hand switch sets the most significant digit (MSD) and the right hand switch sets the least significant digit (LSD).
Refer to the table and figure below for switch operation.
Table 49 - Node Addressing Switch Settings
To
Increment the (MSD/LSD) node address
Decrement the (MSD/LSD) node address
Press
The plus (+) switch.
The minus (-) switch.
Figure 63 - N ode Addressing Switch Settings
Decrements MSD
MSD
Increments MSD
Decrements LSD
LSD
Increments LSD
IMPORTANT
When two or more drives are connected to the same SERCOS interface module, each node address must be unique.
Refer to the node addressing examples beginning on page
3.
Cycle control power to initialize the drive.
IMPORTANT
The base node address setting takes effect only after the drive is initialized.
4.
Set the SERCOS communication rate using DIP switches 2 and 3.
For This Communication Rate
4 Mbps
8 Mbps
Set Switch 2
OFF
ON
Set Switch 3
ON
OFF
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5.
Set the SERCOS optical power level to High using DIP switch 1.
For This Optical Power Level
Low
High
Set Switch 1
OFF
ON
IMPORTANT
All drives on the SERCOS ring must have the same baud rate and power setting.
Figure 64 - SERCOS DIP Switch Settings and Locations
SERCOS switch and connectors
(typical orientation around DPI connector)
DIP Switches Set for
4 Mbps Applications
(high-power setting)
3 2 1
ON
OFF
ON
OFF
DIP Switches Set for
8 Mbps Applications
(high-power setting)
3 2 1
Switch in OFF Position
SERCOS Baud Rate and Optical Power Switches
Note: 8 Mbps setting shown.
6.
Repeat Steps 4 and 5 for each Kinetix 7000 drive.
Switch in ON Position
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Node Addressing Examples
The examples below illustrate how each axis in the fiber-optic ring is assigned a node address. The ControlLogix platform is used in the examples, but the node addressing is typical for Logix platforms.
Figure 65 - Node Addressing Example 1
1756-M
xx
SE SERCOS interface Module 1
Logix Chassis/PCI Card
(ControlLogix chassis is shown)
SERCOS interface TM
CP OK
Tx (rear)
Rx (front)
Transmit Receive
SERCOS interface TM
CP OK
1756-M
xx
SE SERCOS interface Module 2
Logix Chassis/PCI Card
(ControlLogix chassis is shown)
Tx (rear)
Rx (front)
Transmit Receive
Receive
Transmit
SERCOS Fiber-optic Rings
Receive Transmit
Kinetix 7000 Drive
System
03 = Drive (axis 3) Node Address
02 = Drive (axis 2) Node Address
01 = Drive (axis 1) Base Node Address
In this example, SERCOS interface module 1 controls Kinetix 7000 axes 1 and 2.
SERCOS interface module 2 controls Kinetix 7000 axis 3.
TIP
You can mount the two SERCOS interface modules in two separate Logix chassis (as shown above) or you can mount them in the same chassis.
Utilizing two SERCOS interface modules to control axes from a single Kinetix
7000 drive lets you reduce cycle times.
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Kinetix 6000
(8-axis power rail)
Figure 66 - Node Addressing Example 2
ERCO S interface TM
CP OK
1756-M
xx
SE SERCOS interface Module
Logix Chassis/PCI Card
(ControlLogix chassis is shown)
Tx (rear)
Rx (front)
Transmit Receive
SERCOS Fiber-optic Ring
Configure and Start the Kinetix 7000 Drive System
Chapter 5
Kinetix 7000
(2-axis)
08 = Not Used (AM rightmost slot)
07 = AM (axis 4) Node Address
06 = Not Used (AM rightmost slot)
05 = AM (axis 3) Node Address
04 = Not Used (AM rightmost slot)
03 = AM (axis 2) Node Address
02 = Not Used (IAM rightmost slot)
01 = IAM (axis 1) Base Node Address
10 = Drive (axis 2) Node Address
09 = Drive (axis 1) Node Address
In this example, a Kinetix 6000 (8-axis) power rail contains a double-wide IAM, and three double-wide AMs.
The leftmost slot of a double-wide module determines the node address. So, in the example above, node addresses 02, 04, and 06 (the rightmost slots of the double-wide modules) are not used.
The Kinetix 7000 (2-axis) drive system contains two drives. The base node address of the system must be set for an address of
9.
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Configure the Logix SERCOS interface Module
This procedure assumes that you have wired your Kinetix 7000 system and set the
Kinetix 7000 baud rate and optical power switches.
IMPORTANT
For the Kinetix 7000 drive to communicate with the SERCOS interface module
(indicated by three solid-green status indicators on the SERCOS module), your
RSLogix 5000 software must be revision 15.0 or later.
For resources on using RSLogix 5000 software as it applies to configuring the
ControlLogix, CompactLogix, or SoftLogix SERCOS modules, refer to
Additional Resources on page 9 .
Configure the Logix Controller
Follow these steps to configure the Logix controller.
1.
Apply power to your Logix chassis containing the SERCOS interface module and open your RSLogix 5000 software.
2.
From the File menu, choose New.
The New Controller dialog box opens.
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3.
Configure the controller.
a. From the Type pull-down menu, choose the controller type.
b. From the Revision pull-down menu, choose the revision.
c. Type the file Name.
d. From the Chassis Type pull-down menu, choose the chassis.
e. Choose the Logix processor Slot.
4.
Click OK.
5.
From the Edit menu, choose Controller Properties.
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The Controller Properties dialog box opens.
6.
Click the Date/Time tab.
7.
Check Enable Time Synchronization.
This assigns the controller as the Grandmaster clock. The motion modules set their clocks to the module you assign as the Grandmaster.
IMPORTANT
You can assign only one module in the Logix chassis as the
Grandmaster clock.
8.
Click OK.
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Configure the SERCOS Module
Follow these steps to configure the SERCOS module.
1.
Right-click on I/O Configuration in the Controller Organizer and choose
New Module.
The Select Module dialog box opens.
114
2.
Expand the Motion category and select 1756-M
xx
SE, 1756-L60M03SE,
1768-M04SE, or 1784-PM16SE as appropriate for your actual hardware configuration.
In this example, the 1756-M16SE module is selected.
3.
Click OK.
The New Module dialog box opens.
4.
Configure the module.
a. Type the module Name.
b. Enter the Logix SERCOS module slot (leftmost slot = 0).
c. Check Open Module Properties.
5.
Click OK.
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Your new module appears under the I/O Configuration folder in the
Controller Organizer and the Module Properties dialog box opens.
6.
Click the SERCOS Interface tab and reference the table below.
Logix SERCOS Module
1756-M03SE or
1756-L60M03SE
1756-M08SE
1756-M16SE or
1784-PM16SE
1768-M04SE
Number of Axes
Up to 3
Up to 8
Up to 16
Data Rate
4 or 8 Mbps
Up to 4
7.
Verify that the Data Rate setting matches DIP switches 2 and 3
(communication rate) as set on the drive, or use the Auto Detect setting.
8.
From the Cycle Time pull-down menu, choose the Cycle Time according to the following table.
Data Rate
4 Mbps
8 Mbps
Number of Axes
Up to 2
Up to 4
Up to 8
No support for axes 9...16
Up to 4
Up to 8
Up to 16
Cycle Time
0.5 ms
1 ms
2 ms
0.5 ms
1 ms
2 ms
TIP
The number of axes/module is limited to the number of axes as shown in step 6 .
9.
Verify that the Transmit Power setting (high) matches the Optical Power
DIP switch 1 as set on the drive.
10.
Enter the Transition to Phase setting.
The Transition to Phase default setting is 4 (phase 4). The Transition to
Phase setting stops the ring in the phase specified.
11.
Click OK.
12.
Repeat steps 1...11 for each SERCOS module.
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Configure the Motion Group
Follow these steps to configure the motion group.
1.
Right-click Motion Groups in the Controller Organizer and choose New
Motion Group.
The New Tag dialog opens.
2.
Type the new motion group Name.
3.
Click OK.
The new motion group appears under the Motion Groups folder.
4.
Right-click the new motion group and select Properties.
The Motion Group Properties dialog box opens.
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No axis have been created yet. For this setup, a servo axis named Axis_1 and a feedback only axis named Axis_1_Aux will be created. Both axes will be assigned to the Kinetix 7000 axis in the Configure the Kinetix 7000
Drive Modules section.
5.
Right-click the Motion group name created and select New Axis.
6.
Select an Axis_Servo_Drive (SERCOS controlled axis).
The New Tag dialog opens.
7.
Type Axis_1 (or the name of your axis) in the Name field.
Axis_Servo_Drive is the correct Data Type.
8.
Click Ok.
9.
Repeat steps 5 and 6 above for the Axis_1_Aux Feedback Only axis.
10.
Right-click on the Motion Group name created and select Properties.
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Both Axis_1 and Axis_1_Aux are Assigned to the Motion Group. This means both axis will be part of the SERCOS and Motion planner updates from/to the controller/SERCOS card/drive.
11.
Open the Attribute folder.
The Motion Planner coarse update period must be set according to the application needs. Guidelines for the coarse update period for the processor used and the number of servo drive axes created in the motion group can be found in the following resources.
•
Rockwell Automation Knowledgebase at: http://www.rockwellautomation.com/knowledgebase/
•
SERCOS and Analog Motion Configuration and Startup User
Manual, publication MOTION-UM001
•
The various Logix controller user manuals
Only 1 Motion group per processor is allowed.
12.
Click Ok.
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Configure the Kinetix 7000 Drive Modules
Follow these steps to configure the Kinetix 7000 drive modules.
1.
Right-click the Logix module you just created and choose New Module.
The Select Module dialog box opens.
2.
Expand the Drives category and select your drive as appropriate for your actual hardware configuration.
IMPORTANT
In order for the Kinetix 7000 drive to communicate with the SERCOS interface module (indicated by three solid-green status indicators on the SERCOS module), your RSLogix 5000 software must be revision 15.0 or later.
3.
Click OK.
The New Module dialog box opens.
4.
Configure the new drive module.
a. Type the module Name.
b. Enter the Node address.
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Set the node address in the software to match the node setting on the
drive. Refer to Configure the Drive Modules,
step 2 , on page 108 .
c. Check Open Module Properties.
5.
Click OK.
6.
Select the Associated Axes tab.
7.
Assign Axis_1 to Node 1 in the Associated Axis folder. This assigns Axis 1 in the motion group to the Kinetix 7000 drive at node address 1. Select the
Associated Axes tab.
8.
Click Apply.
9.
Click next to Axis_1.
The Axis Properties dialog box opens on the General tab.
10.
Select the Units tab.
11.
Select the correct position units to be used in your application. This example uses load millimeter.
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12.
Select the Conversion tab. Based on the type of application, the system can be configured for a linear or rotary system. To simplify the setup, a linear system is utilized. The calculate tool on the Drive/Motor tab will be used to set the drive resolution and conversion constant. If a rotary system is used, the Drive/Motor tab calculate tool will be used to set the drive resolution, conversion constant, and position unwind.
13.
Click Apply.
14.
Select the Drive/Motor tab.
15.
Click Change Catalog in order to select the appropriate motor for configuration.
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16.
The Change Catalog Number dialog box appears.
17.
Select the appropriate motor catalog number for your application. It is important to verify the motor catalog number on the motor nameplate as well as in your design specification.
18.
Click OK.
19.
Click Calculate, to configure the drive resolution and conversion constant.
The position unwind is also calculated if rotary load is used.
20.
In this example, a linear load is used and a 25.4 mm (1 in.) movement on a ballscrew is made with every 1 motor revolution. The total position movement on the ballscrew is 254 mm (9.8 in.).
122
21.
Click Update.
22.
Click Close.
23.
The Drive Enable Input Checking is selected by default. When checked
(default) a hard drive enable input signal on the IOD connector (pin 2) is required. Uncheck Drive Enable Input Checking if a hard drive enable input signal is not required.
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The Drive/Motor tab and Conversion tabs should look similar to these examples or reflect your application configuration.
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24.
Click the Fault Actions tab.
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25.
Click Set Custom Stop Action.
The Custom Stop Action Attributes dialog box opens and lets you set delay times for servo motors with a brake and resistive brake modules. For recommended motor brake delay times, refer to refer to the Kinetix
Motion Control Selection Guide, publication GMC-SG001 .
26.
Configure the delay times.
a. Type the Brake Engage Delay Time.
b. Type the Brake Release Delay Time.
c. Set the Resistive Brake Contact Delay time (0…1000 ms range).
d. Click Close.
27.
Click OK.
28.
In the Module Properties > Associated Axes tab, select the auxiliary axis
Axis_1_Aux and click Apply.
TIP
The base node is the servo axis utilizing the motor feedback, and the base node (plus 128) is a feedback-only axis utilizing the auxiliary feedback port (as shown below).
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Axis_1_Aux is configured similar to Axis_1, except that only a feedback device is configured.
29.
Configure the Auxiliary Axis properties. Click next to Axis_1_Aux.
The Axis Properties dialog box opens on the General tab.
If an axis is associated to the auxiliary axis node, set the Axis Configuration on the General tab of the Axis Properties dialog box to Feedback Only.
30.
Select the Units tab and configure the same as in steps 10…13 of this procedure.
31.
Select the Conversion tab and configure the same as in steps 10…13 of this procedure.
32.
Select the Drive/Motor tab.
The Drive/Motor tab displays the amplifier being used and the Loop
Configuration is Aux Feedback Only. This is the only choice if the amplifier is using the primary node for Servo (motor) configuration.
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33.
Configure the drive resolution / conversion constant (position unwind, if rotary) as in step 19…22 of this procedure.
34.
Click the Aux Feedback tab.
IMPORTANT
The Aux Feedback tab must be configured for the auxiliary feedback type being used. In this example, an SRM feedback device is being used.
35.
From the Feedback Type pull-down menu, choose the feedback type appropriate for your auxiliary feedback motor.
36.
Click Apply.
37.
Click OK.
38.
In the Module Properties, click the Power tab.
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39.
From the Bus Regulator Configuration pull-down menu, choose the component appropriate for your actual hardware configuration. Note: The
Kinetix 7000 drive internal dynamic brake IGBT is not utilized by the drive main control for bus regulation therefore any type of regulation must come from an external source.
If your drive requires
No bus regulator configuration
External Shunt configuration
Then choose
<none>
1336-MOD-KB005, KB010 or KB050
1336-WB009, WB035 or WB110
(1)
8720MC-RPS027, 8720MC-RPS065, or 8720MC-RPS190
(2)(3)(4)
External regeneration power supply
(1) External shunt configuration 1336 MOD-KB
xxx
and 1336-WB
xxx
are no longer available for new sale but are selectable as of this manual release.
(2) 8720MC-RPS
xxx
is an external regenerative converter system used to regulate the DC bus connected to the Kinetix 7000
(3) 8720MC-RPS027BM-HV1 is no longer available for sale.
(4) 8720MC-RPS065BM-HV1 has been superseded by 8720MC-RPS065BM-HV2.
40.
Click OK.
41.
Repeat steps 1…27 for each additional axis.
42.
Verify your Logix program and save the file.
Download the Program
After completing the Logix configuration you must download your program to the Logix processor.
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Apply Power to the Drive
This procedure assumes that you have completed the following tasks:
•
Wired your Kinetix 7000 drive.
•
Connected your Logix controller, SERCOS interface module fiber-optic connections to your Kinetix 7000 drive.
•
Configured and verified a RSLogix 5000 program.
•
Connected the motor power and motor feedback cables to your Kinetix
7000 drive.
SHOCK HAZARD:
To avoid hazard of electrical shock, complete all mounting and wiring prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.
Refer to the Line Interface Module Installation Instructions, publication
2094-IN005 , when troubleshooting the LIM status indicators, and for the location of LIM circuit breakers, connectors, and status indicators.
Follow these steps to apply power to the Kinetix 7000 system.
ATTENTION:
To avoid personal injury or damage to equipment, disconnect the load to the motor. Make sure each motor is free of all linkages when initially applying power to the system.
1.
Determine your source of control power.
If Your Control Power
Is sourced from a LIM module
Is not sourced from a LIM module
Then
1. Verify that the LIM CB1, CB2, and CB3 are in the OFF position.
2. Apply three-phase input power to the LIM VAC Line connector.
3. Set CB3 to the ON position.
4. Set CB2 to the ON position.
5. Go to main step 2 .
1. Apply 24V DC control power to the drive (CP connector).
2. Go to main step 2 .
2.
Verify the status of the drive logic power status indicator.
Seven-segment Fault Status Indicator
Logic Power Status Indicator
If the Logic Power Status Indicator is Then
Not ON
1. Check your control power connections.
2. Go back to main
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3.
Define the three-phase input power as described below.
If Your Three-phase Power
Is sourced from a LIM module
Is not sourced from a LIM module
Then
1. Set the LIM CB1 to the ON position.
2. Verify that the LIM, IPL, and OPL connections for phase-tophase voltage is 324…528V AC (460V).
3. Verify that the input voltage at terminals R (L1), S (L2), and T
(L3) on the Kinetix 7000 drive is 324…528V AC (460V).
4. If used, verify that the Kinetix 7000 drive Hardware Enable
Input signal (IOD pin 2) for each axis is off.
5. Go to main step 4 .
1. Apply 324...528V AC (460V) input power to the Kinetix 7000 drive R (L1), S (L2), and T (L3) input terminals.
2. If used, verify that the Kinetix 7000 drive Hardware Enable
Input signal (IOD pin 2) is off.
3. Go to main step 4 .
4.
Observe the seven-segment fault status indicator display on the drive.
Kinetix 7000 Drive Status Indicator
Actively cycling (phase 0)
Displaying a fixed 1 (phase 1
Displaying a fixed 2 (phase 2)
Displaying a fixed 3 (phase 3)
Displaying a fixed 4 (phase 4)
Flashing an E followed by two numbers
The status indicator will first flash the SERCOS node address, then cycle through phases until final configuration (phase 4) is reached.
Status
The drive is looking for a closed SERCOS ring. Wait for phase 1 or take corrective action until you reach phase 1.
The drive is looking for active nodes. Wait for phase 2 or take corrective action until you reach phase 2.
The drive is configuring nodes for communication. Wait for phase 3 or take corrective action until you reach phase 3.
The drive is configuring device specific parameters. Wait for phase 4 or take corrective action until you reach phase 4.
The drive is configured and active.
Drive is faulted.
Do This
Check fiber-optic connections.
Check node addressing.
Check program motor and drive configuration against installed hardware.
Check motor catalog number against selection.
(1)
Go to step 5 .
.
(1) To get diagnostic information from the module, highlight the module name in RSLogix 5000 software. A Pseudo Key Failure often indicates that the motor selection does not match the motor installed.
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SERCOS Status Indicators
Flashing green and red
Steady green
Not flashing green and red/ not steady green
5.
Observe the three status indicators on the front of the drive.
Status Indicator
Drive
Comm
Bus
Condition
Off
Steady red
Flashing green
Steady green
Off
Steady green
Flashing green
(1)
Off
Status
Normal condition
Drive is faulted
Establishing communication with network
Communication is ready
No ring present
Axis is enabled when status should be disabled
Bus is up, axis is disabled (normal status)
DC bus is not present
Do This
Observe the Comm status LED.
Go to Status Indicators on page 145
.
Wait for steady green.
Observe the Bus status LED
Go to Interpret Error Codes and Status Indicators on page 140 .
1. Verify Hardware Enable Input (IOD-2) is open.
2. Verify MSO instruction is not commanded in RSLogix 5000 software.
3. Return to Apply Power to the Drive on page 128
.
Go to step 6 .
Go to Status Indicators on page 145
.
(1) The follower drive has a 2.5 second delay after DC bus voltage is applied before the Bus Status LED begins flashing. This provides the common bus leader time to complete precharge.
6.
Observe the three SERCOS status indicators on the SERCOS module.
Status
Establishing communication
Communication is ready
SERCOS module is faulted
Do This
Wait for steady green on all three LEDs.
Go to Test and Tune the Axes on page 131 .
Go to the appropriate Logix manual for specific instructions and troubleshooting.
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Configure and Start the Kinetix 7000 Drive System
Chapter 5
This procedure assumes that you have configured your Kinetix 7000 drive, your
SERCOS interface module, and applied power to the system.
For help using RSLogix 5000 software as it applies to testing and tuning your axes with ControlLogix, CompactLogix, or SoftLogix SERCOS modules, refer
to Additional Resources on page 9
.
Test the Axes
Follow these steps to test the axes.
1.
Verify the load was removed from each axis.
ATTENTION:
To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then reconnect the load and perform the tuning procedure again to provide an accurate operational response.
2.
Right-click an axis in your Motion Group folder and choose Properties.
The Axis Properties dialog box opens.
3.
Click the Hookup tab.
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4.
Type 2.0 as the number of revolutions for the test or another number more appropriate for your application.
This Test
Test Marker
Test Feedback
Test Command & Feedback
Performs this Test
Verifies marker detection capability as you rotate the motor shaft.
Verifies feedback connections are wired correctly as you rotate the motor shaft.
Verifies motor power and feedback connections are wired correctly as you command the motor to rotate. Also, lets you define polarity.
5.
If Drive Enable Input Checking was selected in step 18 of the Configure the Kinetix 7000 Drive Modules section, apply Hardware Enable Input signal (IOD-2) for the axis you are testing.
ATTENTION:
To avoid personal injury or damage to equipment, apply
24V ENABLE signal (IOD-2) only to the axis you are testing.
ATTENTION:
The drive will enable the power module at the appropriate time during hookup and autotune.
6.
Select the Test (Marker/Feedback/Command & Feedback) to verify connections.
The Online Command dialog opens. Follow the on-screen test instructions. When the test completes, the Command Status changes from
Executing to Command Complete.
132
7.
Click OK.
The Online Command - Apply Test dialog opens (Feedback and
Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.
8.
Click OK.
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9.
Determine if your test completed successfully.
If
Your test completes successfully, this dialog box opens.
Then
1. Click OK.
2. Remove Hardware Enable Input signal (IOD-2).
3. Go to Tune the Axes on page 133 .
Your test failed, this dialog box opens. 1. Click OK.
2. Verify the Bus Status LED turned solid green during the test.
3. Verify that the Hardware Enable Input signal (IOD-2) is applied to the axis you are testing.
4. Verify conversion constant entered in the Conversion tab.
5. Return to main step 6 and run the test again.
Tune the Axes
Follow these steps to tune the axes.
1.
Verify the load is still removed from the axis being tuned.
ATTENTION:
To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then reconnect the load and perform the tuning procedure again to provide an accurate operational response.
2.
Click the Tune tab.
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3.
Enter values for Travel Limit and Speed.
In this example, Travel Limit = 5 and Speed = 10. The actual value of programmed units depend on your application.
4.
From the Direction pull-down menu, choose a setting (Forward Unidirectional is default).
5.
Check Tune boxes as appropriate for your application.
6.
Apply Hardware Enable Input signal (IOD-2) for the axis you are tuning.
ATTENTION:
To avoid personal injury or damage to equipment, apply
24V ENABLE signal (IOD-2) only to the axis you are tuning.
7.
Click Start Tuning to auto-tune your axis.
The Online Command - Tune Servo dialog box opens. When the test completes, the Command Status changes from Executing to Command
Complete.
8.
Click OK.
The Tune Bandwidth dialog box opens.
134
Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.
9.
Record your bandwidth data for future reference.
10.
Click OK.
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The Online Command - Apply Tune dialog box opens. When the test completes, the Command Status changes from Executing to Command
Complete.
11.
Click OK.
12.
Determine if your test completed successfully.
If
Your test completes successfully, this dialog box opens.
Then
1. Click OK.
2. Remove the Hardware Enable Input signal (IOD-2) applied earlier.
3. Go to step 13 .
Your test failed, this dialog box opens. 1. Click OK.
2. Make an adjustment to motor velocity.
3. Refer to appropriate Logix motion module setup and configuration manual for more information.
4. Return to step 7 and run the test again.
13.
Repeat Test and Tune the Axes for each axis.
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Configure Drive Parameters and System Variables
This section provides information for accessing and changing parameters not accessible through RSLogix 5000 software.
Tools for Changing Parameters
Most parameters are accessible through RSLogix 5000 software. Alternatives include the DPI compatible Human Interface Module (HIM), and
DriveExplorer and DriveExecutive software.
Table 50 - Software For Changing Parameters
Method
DriveExplorer
Description
DriveExplorer software
(1)
Serial to SCANport adapter
Cat. No.
9306-4EXP02ENE
1203-SSS (Series B), or
1203-USB
20-HIM-A3
(2)
Drive HIM Full numeric LCD HIM
(1) Refer to DriveExplorer Getting Results Manual, publication 9306-GR001 , for instructions.
(2) Compatible catalog numbers include all 20-HIM-A
x
.
Firmware Revision
2.01 or later
3.004 or later
N/A
Change Parameters with DriveExplorer Software
To edit a parameter using DriveExplorer software, refer to the example dialog box below. In this example, the I/O Interface group folder is open and the Analog
Outputs file is selected in the tree view pane on the left. The parameters and corresponding elements are displayed in the pane to the right. Double-click on a parameter in the list to open the edit dialog box where you can change the value for the desired parameter.
Figure 67 - DriveExplorer Software Example
Double-click on a parameter in the list to open the edit dialog box.
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Change Parameters with the HIM Module
When using the HIM module to monitor or change parameters, use the up and down arrows (
and
) to arrive at selections. Refer to the instructions that came with your HIM module for more information.
Follow these steps to monitor or change parameters with the HIM module.
1.
Select parameter, and press
.
2.
Select I/O AM1 Group (for IAM module), and press
.
3.
Select Analog Outputs, and press
.
a. Analog Output 1 is displayed, and press
.
b. For Analog Output 2 use arrows to select, and press
.
4.
Press Sel.
5.
Enter parameter number, and press
.
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Notes:
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Safety Precautions
Chapter
6
Troubleshoot the Kinetix 7000 Drive System
This chapter provides troubleshooting tables for your Kinetix 7000 system components.
Topic
Interpret Error Codes and Status Indicators
Page
IMPORTANT
Equipment connected to the Kinetix 7000 drive may store error data, and may take precedence when troubleshooting the system.
For example, the regenerative power supply (8720MC-RPS
xxxxx
) should be examined first when the DC common bus is providing system power.
Refer to the product manuals listed in the Additional Resources section on
page 9 for troubleshooting information on other products.
Observe the following safety precautions when troubleshooting your Kinetix
7000 drive.
ATTENTION:
Capacitors on the DC bus may retain hazardous voltages after input power has been removed. Before working on the drive, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the front of the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION:
Do not attempt to defeat or override the drive fault circuits. You must determine the cause of a fault and correct it before you attempt to operate the system. Failure to correct the fault could result in personal injury and/or damage to equipment as a result of uncontrolled machine operation.
ATTENTION:
Provide an earth ground for test equipment (oscilloscope) used in troubleshooting. Failure to ground the test equipment could result in personal injury.
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Interpret Error Codes and
Status Indicators
Refer to these troubleshooting tables to identify faults, potential causes, and the appropriate actions to resolve the fault. If the fault persists after attempting to troubleshoot the system, please contact your Rockwell Automation sales representative for further assistance.
E04
MotorOvertemp Fault
Error Codes
Common hardware errors that prevent a drive from completing the power sequencing and fault assessment are listed first. Error codes that may appear on the Fault Status display immediately follow the start-up errors.
When a fault is detected, the seven-segment status indicator will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the error code is cleared.
Table 51 - Seven-segment Status Indicator Error Codes
Error
Code
Fault Message RSLogix Anomaly or Symptom Potential Cause
Power (PWR) indicator not
ON
No AC power or auxiliary logic power.
Internal power supply malfunction.
No Error Code Displayed
Motor jumps when first enabled
Digital I/O not working correctly
Motor wiring error.
Incorrect motor chosen.
I/O power supply disconnected.
Motor thermal switch tripped
High motor ambient temperature and/or excessive current.
Motor wiring error.
Incorrect motor selection.
Mechanical failure.
Possible Resolution
Verify AC control power is applied to the Kinetix 7000 system.
Call your Rockwell Automation sales representative to return module for repair.
Check motor wiring.
Run Hookup test in RSLogix 5000 software.
Verify the proper motor is selected.
Verify connections and I/O power source.
Operate within (not above) the continuous torque rating for the ambient temperature, 40 °C (104 °F) maximum.
Lower ambient temperature, increase motor cooling.
Check motor wiring at MF connector on the drive.
Verify the proper motor has been selected.
Check for motor bearing failure or machine jam.
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Table 51 - Seven-segment Status Indicator Error Codes (Continued)
Error
Code
Fault Message RSLogix Anomaly or Symptom Potential Cause
E05
E06
E07
E09
E10
E11
E16
DriveOvercurrent Fault
HardOvertravelFault
MotFeedbackFault
BusUndervoltageFault
DriveOvervoltageFault
MotFeedbackFault
SoftOvertravelFault
Possible Resolution
Inverter Overcurrent (IOC) indicates a major power related fault condition.
Axis moved beyond the physical travel limits in the positive/negative direction.
With three-phase power present, the DC bus voltage is below precharge limits.
Motor cables shorted.
Motor winding shorted internally.
Drive temperature too high.
Operation above continuous power rating and/or product environmental ratings.
Kinetix 7000 drive has a short-circuit, overcurrent, or failed component.
Dedicated overtravel input is inactive.
The feedback wiring is open, shorted, or missing.
Bus voltage for 460V system is below 275V
DC.
Verify continuity of motor power cable and connector.
Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced.
Check for clogged vents or defective fan.
Verify cooling is not restricted by insufficient space around the unit.
Verify ambient temperature is not too high.
Operate within the continuous power rating.
Reduce acceleration rates.
Remove all power and motor connections, and preform a continuity check from the DC bus to the U,
V, and W motor outputs. If a continuity exists, check for wire fibers between terminals, or send drive in for repair.
Check wiring.
Verify motion profile.
Verify axis configuration in RSLogix 5000 software.
Check motor encoder and wiring.
Run Hookup test in RSLogix 5000 software.
Verify voltage level of the incoming AC power.
Verify integrity and consistency of AC power source.
Install an uninterruptible power supply (UPS) on your AC input.
DC bus voltage fell below the undervoltage limit while an axis was enabled.
The DC bus voltage is above limits.
Bus voltage is at least 180V DC below the precharge level of 323… 525V DC.
Verify bus supply is OK.
Disable axis before removing input power.
One of more phases of AC input power failed.
Check AC input power on all phases.
Excessive regeneration of power.
When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the drive’s power supply. The system faults to save itself from an overload.
Change the deceleration or motion profile.
Use a larger system (motor and drive).
Install shunt module.
Install larger active shunt module or regenerative converter module.
Bus voltage for 460V system is over 800V DC.
Verify line input integrity and that it is within specification.
Verify the Hall wiring at the MF connector on the drive.
State of Hall feedback inputs is incorrect.
Improper connection.
Axis moved beyond the software axis position in either the positive or negative direction.
Verify 5V power supply to the encoder.
Check feedback device.
Verify motion profile.
Verify overtravel settings are appropriate.
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Table 51 - Seven-segment Status Indicator Error Codes (Continued)
Error
Code
Fault Message RSLogix
E18
E19
E20
E21
E23
E30
E34
E35
E37
OverSpeedFault
PositionErrorFault
MotFeedbackFault
AuxFeedbackFault
DriveOvertempFault
MotFeedbackFault
GroundShortFault
DriveUndervoltageFault
PowerPhaseLossFault
Anomaly or Symptom Potential Cause
Motor speed has exceeded 150% of maximum rated speed. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed.
Position error limit exceeded.
Motor encoder state error.
The motor encoder encountered an illegal transition.
Communication was not established with an intelligent encoder.
IPM thermal protection fault
Communication was not established with an intelligent encoder.
Excessive ground current detected in the converter.
Converter precharge cycle failed.
The internal filter protecting the drive from overheating has tripped.
Wiring error.
Motor internal ground short.
Internal malfunction.
Low AC input voltage.
Internal malfunction.
One or more phases of the AC input power is missing.
Possible Resolution
Check cables for noise.
Check tuning.
Check feedback device.
Verify velocity limit settings.
Increase the feed forward gain.
Increase following error limit or time.
Check position loop tuning.
Verify sizing of system.
Verify mechanical integrity of system within specification limits.
Use shielded cables with twisted pair wires.
Route the feedback away from potential noise sources.
Check the system grounds.
Replace the motor/encoder.
Check feedback device and wiring.
Verify auxiliary encoder wiring.
Reduce acceleration rates.
Reduce duty cycle (ON/OFF) of commanded motion.
Increase time permitted for motion.
Use larger Kinetix 7000 drive and motor.
Check tuning.
Verify motor selection.
Verify the motor supports automatic identification.
Verify motor encoder wiring.
Check motor power wiring.
Check input power wiring.
Replace motor.
Disconnect motor power cable from drive and enable drive with current limit set to 0. If fault clears, then a wiring error or motor internal problem exists. If fault remains, call your Rockwell Automation sales representative.
Remove ground from control power input.
Wire control power to use main power as shown in
.
Add isolation transformer for control power.
Check input AC voltage on all phases.
Call your Rockwell Automation sales representative.
Check input AC voltage and fusing on all phases and
DC bus.
Disable axis before removing power.
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Table 51 - Seven-segment Status Indicator Error Codes (Continued)
Error
Code
Fault Message RSLogix Anomaly or Symptom Potential Cause
E38
E39
E43
E49
E50
E54
E61
E62
E63
E64
E65
E66
E67
E68
SERCOSFault
DriveHardFault
DriveEnableInputFault
DriveHardFault
SERCOSFault
DriveHardFault
AuxFeedbackFault
AuxFeedbackFault
AuxFeedbackNoise
MotorFeedbackNoise
No Fault Message
(condition indicated by on-screen message)
No Fault Message
(condition indicated by on-screen message)
DriveHardFault
DriveHardFault
Possible Resolution
The SERCOS ring is not active after being active and operational.
Cable disconnected.
Self-sensing Commutation
Startup Error.
Check that fiber-optic cable is present and properly connected.
Verify that there are no impediments to motion at startup, such as hard limits.
Obstruction prevents motion required for selfsensing startup commutation.
Increase self-sensing current if high friction or load conditions exist.
Check motor or encoder wiring using wiring diagnostics.
Missing Drive Enable input signal.
Attempted to enable the axis through software while the Drive Enable hardware input was inactive.
The Drive Enable input transition from active to inactive occurred while the axis was enabled.
Disable the Drive Enable Input fault.
Verify that Drive Enable hardware input is active whenever the drive is enabled through software.
Verify wiring and shielding.
If error persists, return the drive to Rockwell
Automation.
Safe-off function mismatch.
Drive will not permit motion.
Loose wiring at SO connector.
Cable/header not seated properly in SO connector.
Safe-off circuit missing +24V DC.
Verify wire terminations, cable/header connections, and +24V DC.
Reset error and run proof test.
If error persists, return the drive to Rockwell
Automation.
Refer to the Kinetix Safe-off Feature Safety Reference Manual, GMC-RM002 , for additional troubleshooting information and proof test procedures.
Duplicate node address detected on SERCOS ring.
Excessive Current Feedback
Offset.
Auxiliary Encoder State
Error.
The feedback wiring is open, shorted, or missing.
Noise on auxiliary feedback cable.
Noise on motor feedback cable.
Defective current feedback sensing.
The auxiliary encoder encountered an illegal transition.
Recommended grounding, per installation instructions, has not been followed.
Verify that each SERCOS drive is assigned a unique node address.
If error persists, return the drive to Rockwell
Automation.
Use shielded cables with twisted pair wires.
Route the feedback away from potential noise sources.
Check the system grounds.
Replace the motor/encoder.
Check the motor feedback cable connectors/wiring to the drive and motor.
•
Verify grounding.
•
Route feedback cable away from noise sources.
•
Refer to System Design for Control of Electrical
Noise Reference Manual, publication GMC-
RM001 .
Check motor power/feedback wiring.
Hookup procedure failed.
Motor or feedback device malfunction.
Refer to displayed message for resolution.
Autotune procedure failed.
Operating system failed.
DPI communication failed.
Motor or feedback device malfunction.
Software initialization fault detected due to hardware failure.
The DPI device or cable is faulty.
Check motor power/feedback wiring.
Refer to displayed message for resolution.
Perform Hookup in RSLogix 5000 software.
Consult RSLogix 5000 help message.
Cycle power.
If fault persists, replace module.
Check DPI connections.
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Table 51 - Seven-segment Status Indicator Error Codes (Continued)
Error
Code
Fault Message RSLogix Anomaly or Symptom Potential Cause
E69
E70
E71
E72
E76
E78
E80
DriveHardFault
DriveHardFault
DriveHardFault
DriveOvertemp Fault
(Drive Overtemp)
DriveHardFault
DriveHardFault
(Sercos Init)
DriveHardFault
(CPLD Flt)
E109
IGBT_TempFault
E110
EEPROM_Fault
E111
Regen_PS_OK
Possible Resolution
Nonvolatile memory is corrupt due to control board hardware failure.
Nonvolatile memory is corrupt due to control board software error.
RAM or flash memory validation failure.
Load default parameters, save to nonvolatile memory, and recycle power or reset the drive.
If fault persists, replace module.
Load default parameters, save to nonvolatile memory, and recycle power or reset the drive.
If fault persists, replace module.
Cycle power.
If fault persists, replace module.
Replace the failed module.
Check the cabinet temperature. See System Design
.
Inverter thermal switch tripped
The drive fan failed.
The cabinet ambient temperature is above rating.
The machine duty cycle requires an RMS current exceeding the continuous rating of the controller.
The airflow access to the Kinetix 7000 drive is limited or blocked.
Change the command profile to reduce speed or increase time.
Check airflow and remove any fan blockage.
DPI hardware initialization fault detected.
Control board hardware failure.
Control hardware fault detected.
Control hardware fault detected.
Junction temperature of Insulated Gate Bipolar Transistor exceeded.
Reset System.
If fault persists, replace system module.
Cycle power.
If fault persists, replace module.
A-to-D conversion state machine error.
If fault persists, replace module.
Check for proper drive sizing.
Install larger kW rated drive.
EEPROM failed.
EEPROM data corrupted or bus not calibrated.
If fault persists, replace module.
The Regen_OK signal is missing at pins 7 and 8 of the GPIO connector.
Check error displays on RPS, and troubleshoot per error message.
Reset system.
All others RESERVED.
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Status Indicators
Table 52 - Drive Status Indicator
Drive Status LED
Off
Steady Red
Status
Normal, no faults
Drive faulted
Comm Status LED
Off
Flashing Green
Steady Green
Status
No communication
(1)
Establishing communication
Communication ready
Potential Cause
Loose fiber-optic connection.
Broken fiber-optic cable.
Receive fiber-optic cable connected to SERCOS transmit connector and vice versa.
System is still in the process of establishing SERCOS communication.
Node address setting on the drive module does not match SERCOS controller configuration.
No faults or failures.
(1) Refer to Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010 , for more information.
Table 54 - Bus Status Indicator
Possible Resolution
Verify proper fiber-optic cable connection.
Replace fiber-optic cable.
Check proper SERCOS fiber-optic cable connections.
Wait for steady green indicator.
Verify proper node switch setting.
N/A
Bus Status LED
Off
Alternating Red-Green
Flashing Green
Steady Green
Bus power not present.
24V DC control power is present.
Bus power is present, axis disabled.
No faults or failures.
Bus power is present, axis enabled.
No faults or failures.
Potential Cause
N/A
Possible Resolution
N/A
Seven-segment status indicator displays error code.
See the Error Codes on page 140 section and continue
troubleshooting.
Table 53 - Comm Status Indicator
Status
Bus power not present.
Bus power is present in follower drive.
Condition
•
Normal when bus power is not applied.
•
Fault exists, see the Interpret Error Codes and Status Indicators beginning on page 140 .
•
Follower drive is not configured as Common Bus Follow in RSLogix 5000 software.
•
After DC bus voltage is applied, a 2.50 second delay occurs before the indicator begins flashing green.
This is normal operation and provides the common bus leader time to complete precharge.
•
Normal when bus power is not applied. Verify 460V AC connections.
•
Fault exists, see the Interpret Error Codes and Status Indicators beginning on page 140 .
Normal when:
•
24V is not applied to Hardware Enable Input (IOD-2).
•
MSO instruction is not commanded in RSLogix 5000 software.
Normal when:
•
24V is applied to Hardware Enable Input (IOD-2).
•
MSO instruction is commanded in RSLogix 5000 software.
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Table 55 - SERCOS Status Indicator
SERCOS Status
Actively cycling
Phase 0
Displaying a fixed 1
Phase 1
Displaying a fixed 2
Phase 2
Displaying a fixed 3
Phase 3
Status
The drive is looking for a closed SERCOS ring. Wait for phase 1 to complete or take corrective action to reach phase 1.
Condition
Check fiber-optic connections.
Serial ring must enter at the Rx connector and exit TX connector.
Baud rate switch settings conflict.
Verify drive and Logix setup parameters.
Check node addressing on drive and in ControlLogix and RSLogix 5000.
The drive is looking for active nodes. Wait for phase 2 to complete or take corrective action to reach phase 2.
Logix is configuring nodes for communication.
Wait for phase 3 to complete or take corrective action to reach phase 3.
Check RSLogix programming to verify drive configuration against installed hardware.
Verify the appropriate drive model is selected in RSLogix software.
The drive is configuring device specific parameters. Wait for phase 4 to complete or take corrective action to reach phase 4.
Check RSLogix software programming to verify motor configuration against installed hardware.
Verify motor feedback cable connects to MF connector on the drive.
The drive is configured and the SERCOS ring is active.
If low profile connector is used, verify the connection for correct pinout, pinched insulation, and loose wires.
Verify motor feedback cable for continuity and shorts.
Replace the motor.
(1)
Displaying a fixed 4
Phase 4
Flashing an E followed by two numbers
Drive is faulted.
See the Error Codes section on page .
(1) You can access diagnostic information from the module by highlighting the module name in RSLogix 5000 software. A Pseudo Key Failure often indicates that the motor selection does not match the motor installed.
Table 56 - Control Power Status Indicator
CP Status LED
Off
Steady Green
Status
Control power not present.
Control power applied.
Condition
Normal when auxiliary power is not applied to the Control Power (CP) terminal.
Normal when auxiliary power is applied to the Control Power (CP) terminal.
General System Anomalies
These anomalies do not always result in a fault code, but may require troubleshooting to improve performance.
Condition
Axis or system is unstable.
Potential Cause
The position feedback device is incorrect or open.
Unintentionally in Torque mode.
Motor tuning limits are set too high.
Position loop gain or position controller accel/decel rate is improperly set.
Improper grounding or shielding techniques are causing noise to be transmitted into the position feedback or velocity command lines, causing erratic axis movement.
Possible Resolution
Check wiring.
Check to see what primary operation mode was programmed.
Run Tune in RSLogix 5000 software.
Run Tune in RSLogix 5000 software.
Check wiring and ground.
Motor Select limit is incorrectly set (servo motor is not matched to axis module).
Mechanical resonance.
•
Check setups.
•
Run Tune in RSLogix 5000 software.
Notch filter or output filter may be required.
Refer to Axis Properties dialog, Output tab in RSLogix 5000 software.
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Condition
You cannot obtain the motor acceleration/deceleration that you want.
Motor does not respond to a velocity command.
Presence of noise on command or motor feedback signal wires.
No rotation.
Motor overheating.
Potential Cause
Torque Limit limits are set too low.
Incorrect motor selected in configuration.
The system inertia is excessive.
The system friction torque is excessive.
Possible Resolution
Verify that current limits are set properly.
Select the correct motor and run Tune in RSLogix 5000 software.
•
Check motor size against the application need.
•
Review servo system sizing.
Check motor size against the application need.
Available current is insufficient to supply the correct accel/decel rate.
Acceleration limit is incorrect.
Velocity Limit limits are incorrect.
The axis cannot be enabled for 1.5 seconds after disabling.
Enable signal has not been applied or the enable wiring is incorrect.
The motor wiring is open.
The motor thermal switch has tripped.
•
Check motor size against the application need.
•
Review servo system sizing.
Verify limit settings and correct them, as necessary.
Verify limit settings and correct them, as necessary.
Disable the axis, wait for 1.5 seconds, and enable the axis.
•
Check the controller.
•
Check the wiring.
Check the wiring.
•
Check for a fault.
•
Check the wiring.
Repair or replace the motor.
The motor has malfunctioned.
The coupling between motor and machine has broken.
For example, the motor moves, but the load/machine does not.
Primary operation mode is set incorrectly.
Velocity or current limits are set incorrectly.
Recommended grounding per installation instructions have not been followed.
Line frequency may be present.
Check and correct the mechanics.
Check and properly set the limit.
Check and properly set the limits.
•
Verify grounding.
•
Route wire away from noise sources.
•
Refer to System Design for Control of Electrical Noise, publication
GMC-RM001 .
•
Verify grounding.
•
Route wire away from noise sources.
Variable frequency may be velocity feedback ripple or a disturbance caused by gear teeth, ballscrew balls, or other mechanical wear. The frequency may be a multiple of the motor power transmission components or ballscrew speeds resulting in velocity disturbance.
The motor connections are loose or open.
Foreign matter is lodged in the motor.
The motor load is excessive.
The bearings are worn.
The motor brake is engaged (if supplied).
•
Decouple the motor for verification.
•
Check and improve the performance of the gearbox, ballscrew, and other mechanical items.
Check motor wiring and connections.
Remove foreign matter.
Verify the servo system sizing.
Return the motor for repair.
•
Check brake wiring and function.
•
Return the motor for repair.
The motor is not connect to the load.
The duty cycle is excessive.
Check coupling.
Change the command profile to reduce accel/decel or increase time.
The rotor is partially demagnetized, causing excessive motor current.
Return the motor for repair.
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Troubleshoot the Kinetix 7000 Drive System
Condition
Abnormal noise
Erratic operation -
Motor locks into position, runs without control or with reduced torque.
Potential Cause
Motor tuning limits are set too high.
Loose parts are present in the motor.
Through bolts or coupling is loose.
The bearings are worn.
Mechanical resonance.
Motor power phases U and V, U and W, or V and W reversed.
Sine, Cosine or Rotor leads are reversed in the feedback cable connector.
Sine, Cosine, Rotor lead sets of resolver feedback are reversed.
Possible Resolution
Run Tune in RSLogix 5000 software again.
•
Remove the loose parts.
•
Return motor for repair.
•
Replace motor.
Tighten bolts.
Return motor for repair.
Notch filter may be required (refer to Axis Properties dialog, Output tab in RSLogix 5000 software).
Check and correct motor power wiring.
Check and correct motor feedback wiring.
Check and correct motor feedback wiring.
Logix/Drive Fault Behavior
These RSLogix 5000 fault actions are configurable from the Axis Properties dialog box, Fault Actions tab.
Table 57 - Drive Fault Action Definitions
Drive Fault Action
Shutdown
Disable Drive
Stop Motion
Status Only
Definition
The drive is disabled and the contactor enable relay opens. An uncontrolled stop occurs, and the motor coasts to a stop.
The drive is disabled. An uncontrolled stop occurs, and the motor coasts to a stop.
Logix configuration for velocity loop Kp/Ki is followed. When zero speed is reached or stopping time is exceeded, the drive is disabled. Stopping time and stopping torque are configurable parameters in RSLogix 5000 software.
Drive continues to operate. Status is provided by the seven-segment status indicator, drive status indicator, and DPI (if used).
Only selected faults are programmable. In Table 58 on page 149 , the controlling
attribute is given for programmable fault actions.
Figure 68 - RSLogix 5000 Axis Properties - Fault Actions Tab Example
Drive Fault Action/Attribute for
Motor Overtemp fault (E04).
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Troubleshoot the Kinetix 7000 Drive System
Chapter 6
Table 58 - Logix/Drive Fault Behavior Definitions
Logix Fault Message
(HIM)
MotorOvertempFault
(Motor Overtemp)
Error
Code
Description Drive Fault Action/
Attribute
RSLogix
Programmable
Fault Action?
E04
(1)
The motor thermal switch was tripped.
Firmware I
2 t protection does not generate a fault, rather it dynamically folds back current when 110% of motor rating is reached. Setting the Motor Thermal fault action to Status Only will bypass this function.
STOP MOTION / Motor
Thermal
Yes
DriveOvercurrentFault
(Power Fault)
HardOvertravelFault
(+/- Hard Overtravel)
MotFeedbackFault
(Motor Feedback Loss)
E05
E06
E07
An instantaneous overcurrent was detected in the inverter power section
Axis moved beyond the physical travel limits in the positive/negative direction. This fault can be configured for status only.
The feedback wiring is open, shorted or missing.
SHUTDOWN
STOP MOTION / Hard
Overtravel
DISABLE DRIVE
No
Yes
No
BusUndervoltageFault
(Bus Under Voltage)
E09
E10
With three-phase present, the DC bus voltage is below limits.
The trip point is 800V DC for 460 drives.
DC bus voltage is below limits when any axis on common-bus follower was enabled.
The DC bus voltage is above limits.
The trip point is 800V DC for 460 drives.
SHUTDOWN
SHUTDOWN
No
No
DriveOvervoltageFault
(Bus Overvoltage)
MotFeedbackFault
(Illegal Hall State)
SoftOvertravelFault
(+/- Software Overtravel)
OverSpeedFault
(Overspeed Fault)
PositionErrorFault
(Follow Error)
MotFeedbackFault
(Mtr Fdbk AQB)
AuxFeedbackFault
(Aux Feedback Comm)
DriveOvertempFault
(Drive Overtemperature Fault)
MotFeedbackFault
(Motor Feedback Comm)
GroundShortFault
(Ground Fault)
DriveUndervoltageFault
(Precharge Fault)
E11
E16
E18
E19
E20
E21
E23
E30
E34
E35
State of Hall feedback inputs in incorrect.
Axis position exceeded maximum software setting in the positive/negative direction.
This fault can be configured for status only.
Axis speed has reached 150% of the maximum rated setting. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed.
STOP MOTION / Soft
Overtravel
DISABLE DRIVE
Axis position error limit has been exceeded. This fault can be configured for status only.
STOP MOTION /
Position Error
Motor encoder has encountered an illegal state transition.
Communication was not established with an intelligent (Stegmann) encoder on the
Auxiliary feedback port.
An IPM thermal protection fault occurred.
Communication was not established with an intelligent (Stegmann) encoder on the motor feedback port.
Excessive ground current in the converter was detected.
The converter precharge cycle has failed.
DISABLE DRIVE
DISABLE DRIVE
STOP MOTION
DISABLE
Drive Thermal
STOP MOTION
SHUTDOWN
SHUTDOWN
No
Yes
No
Yes
No
No
Yes
No
No
No
PowerPhaseLossFault
(Phase Loss Flt)
E37
•
One or more phases of the input AC power is missing.
•
Axis was enabled when main (three-phase) power was removed.
•
Common bus follower axis was enabled when DC bus power was removed.
SHUTDOWN/ STOP
MOTION
No
SERCOSFault
(SERCOS Ring Flt)
DriveHardFault
(Self Sense Flt)
DriveEnableInputFault
(Drive Enable Flt)
E38
E39
E43
The SERCOS ring is not active after being active and operational.
Self-sensing commutation fault detected
Generated when Enable input switches off when drive is enabled.
STOP MOTION
DISABLE DRIVE
STOP MOTION
No
No
Yes
DriveHardFault
(Safe-Off HW Flt)
E49
Safe-off function mismatch. Drive will not permit motion. Refer to the Kinetix Safe-off
Feature Safety Reference Manual, publication GMC-RM002 , for more information. Only applies to drives with Safe-off feature.
SHUTDOWN No
SERCOSFault
(SERCOS Same ADDR)
DriveHardFault
(Ifbk HW Fault)
E50
E54
Duplicate node address detected on SERCOS ring.
Current feedback hardware fault detected.
STOP MOTION
SHUTDOWN
No
No
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Troubleshoot the Kinetix 7000 Drive System
Logix Fault Message
(HIM)
Error
Code
Description Drive Fault Action/
Attribute
RSLogix
Programmable
Fault Action?
AuxFeedbackFault
(Aux Fdbk AQB)
AuxFeedbackFault
(Aux Fdbk Loss)
AuxFeedbackNoise
(Aux Fdbk Noise)
MotorFeedbackNoise
(Mtr Fdbk Noise)
No Fault Message
(condition indicated by onscreen message)
(Hookup Fault)
No Fault Message
(condition indicated by onscreen message)
(Atune Flt)
DriveHardFault
(Task Init)
DriveHardFault
(SCANport Comm)
DriveHardFault
(Objects Init)
DriveHardFault
(NV Mem Init)
DriveHardFault
(Memory Init)
DriveOvertempFault
(Drive Overtemp)
DriveHardFault
(Can Init)
DriveHardFault
SERCOS Init
HardwareFault
(CPLD FLT)
IGBTTempFault
(IGBTFLT)
EEPROMFault
(CPLD FLT)
RegenPSOK
(CPLD FLT)
All Others RESERVED
E61
E62
E63
E64
E65
E66
E67
E68
E69
E70
E71
E72
E76
E78
E80
E109
E110
E111
Auxiliary encoder has encountered an illegal state transition.
The feedback wiring is open, shorted or missing.
Presence of noise on auxiliary feedback cable.
Presence of noise on motor feedback cable.
Hookup procedure failed.
Autotune procedure failed.
Operating system failed.
DPI communication failed.
Nonvolatile memory attribute out of range.
Nonvolatile memory corrupted.
RAM or flash memory validation failure.
Inverter temperature limit exceeded. Firmware I
2 t protection does not generate a fault, rather it dynamically folds back current when 110% of drive rating is reached.
Either DPI or backplane CAN initialization failure.
Control hardware fault detected.
Control hardware fault detected.
Junction temperature of IGBT exceeded.
EEPROM failure. EEPROM data corrupt or bus not calibrated.
Regenerative PS+/- missing at GPIO.
DISABLE DRIVE
DISABLE DRIVE
DISABLE DRIVE /
Feedback Noise
DISABLE DRIVE
DISABLE DRIVE
SHUTDOWN
STOP MOTION
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
No
No
Yes
No
No
No
No
No
No
No
Yes
No
No
No
No
No
No
(1) The Logix Motor Thermal Fault Action is tied to the motor thermostat fault. If this is set to Shutdown or Disable (in Logix), the drive will fold back the current when the I
2
T calculation indicates that the motor temperature has exceeded 10% of its rated temperature. If it is set to Stop Motion or Status Only, the drive will not fold back the current. The I
2
T calculation never generates a fault.
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Appendix
A
Specifications and Dimensions
This appendix provides product specifications and mounting dimensions for your Kinetix 7000 system components.
Topic
Power Dissipation Specifications
Precharge Capacities of the Regenerative Power Supply
Page
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Appendix A
Specifications and Dimensions
Power Specifications
This section contains power specifications for the Kinetix 7000 drive.
Attribute
AC input voltage
AC input frequency
Bandwidth
(1)
Velocity loop
Current loop
PWM frequency
Main AC input current
Nom (rms)
Max inrush (A peak)
DC input voltage
DC input current
Control power input Voltage
Control power DC input current
Nom (rms)
Maximum inrush (rms)
Continuous output current (rms)
Continuous output current (0-pk)
Peak output current (rms)
3 s duration
60 s duration
Peak output current (0-pk)
3 s duration
60 s duration
Bus overvoltage
Bus undervoltage
Continuous power output, nom
Continuous power output (Hp)
Maximum power cycles/minute
AC line
DC bus
DC bus discharge time
Efficiency
Total capacitance
(3)
Short circuit current rating
2099-BM06-S
342…528V AC rms three-phase (380…480V nom)
47…63 Hz
500 Hz
1300 Hz
4 kHz
36.7 A
18.0 A
450…750V DC
42.9 A
3.3 A
6.0 A
40.0 A
56.0 A
47.7 A
18.0 A
55.7 A
18…30V DC (24V DC, nom)
68.0 A
51.0 A
96.0 A
72.0 A
800V DC
275…560V DC
22 kW
30 Hp
(2)
2099-BM07-S
52.0 A
73.0 A
80.0 A
60.0 A
113 A
84.8 A
30 kW
40 Hp
2099-BM08-S
59.6 A
18.0 A
69.7 A
65.0 A
92.0 A
104 A
78.0A
147 A
110 A
37 kW
50 Hp
4 per minute (pre-charge provided by drive)
3 minutes after removal of main AC power
97.5%
1800
F 2400
F
200,000 A (rms) symmetrical
3000
F
2099-BM09-S
90.1 A
96.0 A
105 A
96.0 A
135 A
154 A
115 A
217.7 A
162.6 A
56 kW
75 Hp
2 per minute (DC pre-charge provided by the regenerative power supply)
4500
F
2099-BM10-S
117 A
118 A
137 A
125 A
176 A
163 A
138 A
230.5 A
195 A
75 kW
100 Hp
6000
F
2099-BM11-S
500 Hz
500 Hz
2 kHz
169 A
141 A
204 A
180 A
254 A
312 A
234 A
441 A
331 A
112 kW
150 Hp
8400
F
2099-BM12-S
233 A
141 A
281 A
248 A
351 A
372 A
273 A
526 A
386 A
149 kW
200 Hp
8400
F
(1) Bandwidth values vary based on tuning parameters and mechanical components.
(2) Bus undervoltage will vary based on input line voltage.
(3) If DC input is supplied to 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, or 2099-BM12-S drives, the precharge capability must be provided at the system level. Disconnect switches must not be used between the input of the drive and a common DC bus without the use of an external precharge device.
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Specifications and Dimensions
Appendix A
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Circuit Breaker/Fuse Specifications
While circuit breakers offer some convenience, there are limitations for their use.
Circuit breakers do not handle high current inrush as well as fuses.
Make sure the selected components are properly coordinated and meet acceptable codes including any requirements for branch circuit protection.
Evaluation of the short-circuit available current is critical and must be kept below the short-circuit current rating of the circuit breaker.
Use class CC, T, RK1, or J fuses, with current rating as indicated in the table below. The following fuse examples and short-circuit current ratings are recommended for use with the 2099-BM
xx
-S drives when the Line Interface
Module (LIM) is not used.
IMPORTANT
LIM modules (catalog numbers 2094-BL
xx
S and 2094-XL75S-C
x
) provide branch circuit protection to the Kinetix 7000 drive. Follow all applicable NEC and local codes.
Table 59 - 460V AC Input Drive Fuse and Motor Circuit Protector Specifications
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Bussmann
Fuse
LPJ-90SP
LPJ-110SP
LPJ-125SP
LPJ-200SP
LPJ-250SP
LPJ-400SP
LPJ-500SP
Dual Element Time Delay
Fuse (min/max)
A rms
50/90
60/110
80/125
125/200
150/250
225/400
300/550
Non-Time Delay
Fuse (min/max)
A rms
50/150
60/200
80/250
125/300
150/500
225/600
300/700
100
125
150
250
400
Motor Circuit
Protector (max)
A rms
50
70
Common DC Bus Fuse Specifications
Table 60 - Ferraz Shawmut Fuse Recommendations i2t (A2sec)
69.7
105
137
204
281
Drive Current
Rating (ADC)
42.9
55.7
Recommended
Fuse
HSJ80
HSJ90
HSJ100
HSJ175
HSJ200
HSJ400
HSJ400
100
175
200
400
400
Fuse Current
Rating
80
90
Pre-Arc
1600
2300
2700
8000
14000
63000
63000
Max. Clearing @
600V AC
15000
21000
23000
60000
92000
450000
450000
Peak Let-Through Current at 100 kA rms
7000 A
7400 A
7700 A
12000 A
13000 A
21000 A
21000 A
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Appendix A
Specifications and Dimensions
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Table 61 - Bussmann Fuse Recommendations i2t (A2sec)
69.7
105
137
204
281
Drive Current
Rating (ADC)
42.9
55.7
Recommended
Fuse
FWJ-80A
FWJ-100A
FWJ-125A
FWJ-175A
FWJ-200A
FWJ-500A
FWJ-500A
125
175
200
500
500
Fuse Current
Rating
80
100
Pre-Arc
1550
2800
4800
7500
11700
39500
39500
Max Clearing @
600V AC
9700
17500
35000
65000
80000
329000
329000
Peak Let-Through Current at 100 kA rms
6300 A
8000 A
10000 A
12000 A
13000 A
21000 A
21000 A
Contactor Ratings
The table below lists the recommended contactor ratings for Kinetix 7000 drives installed without a Line Interface Module (LIM).
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
Contactor
100-C43DJ01
100-D95EN11
100-D140EN11
100-D180EN11
100-D250EN11
(1) Electronic coil control power requirements = 24V DC @ 15 mA.
Safety Contactor
100S-C43-DJD4C
100S-D95EN22C
100S-D140EN22C
100S-D180EN22C
100S-D250EN22C
Coil Type
Standard with Diode
Electronic Coil
(1)
Coil Voltage Requirements
24V DC
24V DC for control and 480V AC for coil power
Power Dissipation
Specifications
Use this table to size an enclosure and calculate required ventilation for your
Kinetix 7000 drive system.
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
294
388
452
645
Usage as a % of Rated Power Output
W
50% 100%
465
619
730
1072
882
1275
1438
1479
2125
2437
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General Specifications
Specifications and Dimensions
Appendix A
Maximum Feedback Cable Lengths
Although motor power and feedback cables are available in standard lengths up to 90 m (295.3 ft), the drive/motor/feedback combination may limit the maximum feedback cable length. These tables assume the use of recommended
2090-series cables.
Table 62 - Cable Lengths for Compatible Rotary Motors
Motor Cat. No.
Absolute High-resolution (5V)
Encoder
m (ft)
Absolute High-resolution (9V)
Encoder
m (ft)
90 (295.3)
MPL-B5
xxx…
MPL-B9
xxx
-S/M
MPM-B165
xx…
MPM-B215
xx
-S/M
RDB-B215
xx
-7/3
RDB-B290
xx
-7/3 or
RDB-B410
xx
-7/3
HPK-B
xxxxx
-S/M or
HPK-E
xxxxx
-S/M
30 (98.4)
90 (295.3)
90 (295.3)
90 (295.3)
Weight Specifications
Weight, approx.
kg (lb)
Drive Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
18.55 (40.9)
37.2 (82.0)
71.4 (157.5)
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Appendix A
Specifications and Dimensions
Certifications
Agency Certification
c-UL-us
CE
C-Tick
KC
(2)
Functional Safety
(1)
Standards
UL Listed to U.S. and Canadian safety standards (UL 508C File E59272).
Solid-state motor overload protection provides dynamic fold-back of motor current when 110% of the motor rating is reached with a peak current limit based on the peak rating of the motor as investigated by UL to comply with UL 508C (UL File E59272, volume 1, section 22).
European Union 2004/108/EC EMC Directive compliant with:
•
EN 60034-1:2004: Rotating electrical machines - Part 1: Rating and performance
•
EN 61800-3:2004: Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods
European Union 2006/95/EC Low Voltage Directive compliant with:
•
EN 50178:1997 - Electronic equipment for use in power installations
•
EN 60204-1:2006 - Safety of Machinery - Electrical equipment of machines - Part 1: General requirements
•
IEC 61508 Part 1-7:2000 - Functional safety of electrical/electronic/programmable electronic safety-related systems
•
EN ISO 13849-1:2008 - Safety of machinery. Safety-related parts of control systems - Part 1: General principles for design
•
Radiocommunications Act: 1992
•
Radiocommunications (Electromagnetic Compatibility) Standard: 1998
•
Radiocommunications (Compliance Labelling - Incidental Emissions) Notice: 1998
•
AS/NZS CISPR 11: 2002 (Group 2, Class A)
Korean Registration of Broadcasting and Communications Equipment, compliant with:
•
Article 58-2 of Radio Waves Act, Clause 3
•
Registration Number: KCC-REM-RAA-2099
(1) When product is marked, refer to www.rockwellautomation.com/products/certification/ for Declarations of Conformity Certificates.
(2) Underwriters Laboratories Inc. has not evaluated the safe-off, safe torque-off, or safe speed-monitoring options in these products.
Attribute
Temperature, ambient
Relative humidity
Altitude
Vibration
Shock
Environmental Specifications
Operational Range
0…50
C (32…122
F)
5…95% noncondensing
1000 m (3281 ft)
3000 m (9843 ft) with derating
Storage Range (nonoperating)
-40…70
C (-40…158
5…95% noncondensing
F)
3000 m (9843 ft) during transport
5…55 Hz @ 0.35 mm (0.014 in.) double amplitude, continuous displacement; 55…500 Hz @ 2.0 g peak constant acceleration (10 sweeps in each of 3 mutually perpendicular directions).
15 g, 11 ms half-sine pulse (3 pulses in each direction of 3 mutually perpendicular directions)
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Specifications and Dimensions
Appendix A
AC Line Filter Specifications
Line filters compatible with a Kinetix 7000 drive sourcing input power from an
AC power supply are listed below.
Kinetix 7000 Drive
Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
AC Line Filter
Cat. No.
2090- XXLF-TC350
2090- XXLF-TC365
2090- XXLF-TC3100
2090- XXLF-TC3150
2090- XXLF-TC3200
2090- XXLF-TC3250
Line filters compatible with a Kinetix 7000 drive sourcing input power from a regenerative DC bus with a 8720MC-RPS unit are listed below.
8720MC-RPS
Cat. No.
8720MC-RPS065BM-HV2
8720MC-RPS190BM
AC Line Filter
Manufacturer and Cat. No.
Schaffner: FN3100-80-35
Soshin Electric: HF3080C-TOA
8720MC-EF190-VB
AC Line Reactors
380…480V, 50/60 Hz, three-phase, line reactors compatible with a Kinetix 7000 drive connected to a three-phase, AC input power source are listed below.
Table 63 - Compatible Kinetix 7000 Drives and AC Line Reactors
Kinetix 7000 Drive
Cat. No.
2099-BM06-S
2099-BM07-S
2099-BM08-S
2099-BM09-S
2099-BM10-S
2099-BM11-S
2099-BM12-S
3% Impedance Input Line Reactor
(1)
IP00 (Open Style)
Cat. No.
IP11 (NEMA/UL Type 1)
Cat. No.
1321-3R45-B
1321-3R55-B
1321-3R80-B
1321-3R100-B
1321-3R130-B
1321-3R200-B
1321-3RB250-B
1321-3RA45-B
1321-3RA55-B
1321-3RA80-B
1321-3RA100-B
1321-3RA130-B
1321-3RA200-B
1321-3RAB250-B
(1) Input line reactors were sized based on the NEC fundamental motor amps.
5% Impedance Input Line Reactor
(1)
IP00 (Open Style)
Cat. No.
IP11 (NEMA/UL Type 1)
Cat. No.
1321-3R45-C
1321-3R55-C
1321-3R80-C
1321-3R100-C
1321-3RA45-C
1321-3RA55-C
1321-3RA80-C
1321-3RA100-C
1321-3R130-C
1321-3R200-C
1321-3RB250-C
1321-3RA130-C
1321-3RA200-C
1321-3RAB250-C
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Appendix A
Specifications and Dimensions
External Shunt Modules
Line reactors compatible with a 8720MC-RPS Regenerative Power Supply sourcing input power from an AC power supply are listed below. They must be
configured as shown in the Regenerative Power Supply example on page 171
.
Table 64 - Compatible Kinetix 7000 Drives, 8720MC-RPS Regenerative Power Supplies and
8720MC Line Reactors
Kinetix 7000 Drive
Cat. No.
2099-BM07-S
2099-BM08-S
2099-BM09-S
8720MC-RPS Regenerative Power
Supply Cat. No.
(1)
8720MC-RPS065BM
8720MC Line Reactor
Cat. No.
8720MC-LR05-048B
2099-BM11-S
8720MC-RPS065BM and
8720MC-RPS065BS
8720MC-RPS190BM
8720MC-LR10-062B
8720MC-LR05-048B
(requires two units, one for the master
RPS unit and one for the slave RPS unit.)
8720MC-LR10-062B
(requires two units, one for the master
RPS unit and one for the slave RPS unit.)
8720MC-LR10-100B (required two units)
2099-BM12-S
(1) Regenerative Power Supply (RPS) selection is for a single motor/drive combination. When combining multiple drives on the same
RPS module, the selection will change.
Refer to this table for active shunt solutions for use with Kinetix 7000 drives from
Rockwell Automation Encompass Partners.
Rockwell Automation Encompass Partner
Powerohm Resistors, Inc.
Bonitron, Inc.
Contact Information
5713 13th Street
Katy, TX 77493
Tel: (800) 838-4694 http://www.powerohm.com
521 Fairground Court,
Nashville, TN 37211
Tel: (615) 244-2825 http://www.bonitron.com
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Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Specifications and Dimensions
Appendix A
Precharge Capacities of the
Regenerative Power Supply
Internal (built-in) and external precharge capacities of the regenerative power supply (RPS) are listed below.
Attribute 8720MC-RPS065B
x
-HV2
Rated Output kVa (750V DC bus)
(1)
45
8720MC-RPS190B
x
133
DC Amperes Continuous
(1)
64
DC Amperes Peak (1 minute)
(1)
190
96 285
Built-in Capacitor
Built-in Resistor (Resistance/W)
External Resistor (Min Resistance)
(2) (3)
External Circuit (Min Resistance)
(3)
1900 μF
7000 μF (22 Ohms/120 W)
110000 μF (20 Ohms)
220000 μF (4.7 Ohms)
7600 μF
25000 μF (10 Ohms/400 W)
165000 μF (10 Ohms)
495000 μF (1.5 Ohms)
(1) For 8720MC-RPS065-HV2 and 8720MC-RPS190, you may have up to two slave units with a master unit. Multiply these values by the number of slave units.
(2) Use this case only when the bus capacitance exceeds the internal precharge rating. You must use the specified resistor. Calculate rated wattage and surge resistivity for that resistor. See the 8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001 , for configuration details.
(3) Use this case only when the bus capacitance exceeds the external resistor rating. You must use the specified resistor. Calculate rated wattage and surge resistivity for that resistor. See the 8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001 , for configuration details.
IMPORTANT
Large levels of load capacitance may require modification of the 8720 regenerative power supply internal precharge/discharge circuit.
See the Wiring instructions in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , for information on how to determine the appropriate precharge/discharge resistance power value
(Ohms/Watt) to accommodate the capacitance of your system.
Product Dimensions
This section provides a quick reference table to common dimensions for Kinetix
7000 drives (height, width, depth, and mounting hole locations), and outline drawings with dimensions related to the specific frame sizes.
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159
Appendix A
Specifications and Dimensions
Ø 7.0
(0.28) X2
192
(7.56)
Figure 69 - 2099-BM06-S 2099-BM07-S, and 2099-BM08-S Approximate Dimensions
Dimensions are in millimeters (inches)
15.27
(0.60)
224.3
(8.82)
517.5
(20.37)
495.0
(19.49)
160
8.0
(0.31)
31.9
(1.26)
Ø 28.7
(1.13)
7.0
(0.28)
254.12
(10.00)
7.0
(0.28)
Ø 22.4
(0.88)
Ø 37.3
(1.47) X2
Important:
Additional clearance below the connector is necessary to provide the recommended cable bend radius.
Ø 47.0
(1.85) 2X
Ø 28.7
(1.13)
165.9
(6.53)
165.1
(6.50)
160.1
(6.30)
151.1
(5.95)
31.9
(1.26)
66.0
(2.60)
97.0
(3.82)
137.2
(5.40)
187.0
(7.36)
Bottom View
(2099-BM06-S and 2099-BM07-S)
165.9
(6.53)
165.1
(6.50)
160.1
(6.30)
31.9
(1.26)
66.0
(2.60)
130.0
(5.19)
186.0
(7.32)
Bottom View
(2099-BM08-S)
Ø 34.9
(1.37) 2X
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Ø 6.5
(0.26) 2X
Ø 15.0
(0.59) 2X
7.0
(0.28)
Specifications and Dimensions
Appendix A
225.0
(8.86)
Figure 70 - 2099-BM09-S and 2099-BM10-S Approximate Dimensions
Dimensions are in millimeters (inches)
37.5
(1.48)
286.7
(11.29)
644.5
(25.37)
625.0
(24.61)
644.5
(25.37)
2099-BM09
690.3
(27.18)
2099-BM10
12.0
(0.47)
31.9
(1.26)
259.1
(10.20) 2X
6.5
(0.26) 2X
300.0
(11.81)
Ø 34.9
(1.37) 2X
60.4
(2.38)
159.5
(6.28)
31.9
(1.26)
85.1
(3.35)
65.0
(2.56) 2X
130
(5.12)
170
(6.69)
20.4
(0.80) 2X
Ø 22.2 (0.87)
Ø 62.7 (2.47) 2X
45.5
(1.79)
70
(2.75)
35
(1.38)
31.8
(1.25)
24.5
(0.96) 2X
153.5
(6.04) 2X
Important:
Additional clearance below the connector is necessary to provide the recommended cable bend radius.
Ø 34.9
(1.37)
Ø 22.2
(0.87) 3X
Ø 62.7
(2.47) 2X
34.1
(1.34)
128.1
(5.04)
22.4
(0.88)
104.3
(4.10)
53.0
(2.08) 2X
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161
Appendix A
Specifications and Dimensions
8.5
(0.33) 2X
Ø 18.0
(0.71) 2X
7.9
(0.31)
300.0
(11.81)
Figure 71 - 2099-BM11-S and 2099-BM12-S Approximate Dimensions
Dimensions are in millimeters (inches)
49.6
(1.95)
282.8
(11.13)
850.0
(33.46)
824.0
(32.44)
849.97
(33.46)
977.1
(38.47)
162
14.5
(0.04)
30.0
(1.18)
8.5
(0.33) 2X
360.6
(14.20) 2X
399.2
(15.72)
Ø 22.2 (0.87) 4X
Ø 34.9
(1.37)
73.8
(2.90) 36.9 (1.45) 4X
148.4
(5.84)
31.69 (1.25)
22.0 (0.86) 2X
128
(5.04)
45.0
(1.77)
100
(3.94)
150 (5.90) 2X
200 (7.87)
67.2
(2.64)
151.7
(5.97)
Ø 62.7 (2.47) 2X
Important:
Additional clearance below the connector is necessary to provide the recommended cable bend radius.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Appendix
B
Interconnect Diagrams
This appendix provides wiring examples and system block diagrams to assist you in wiring your Kinetix 7000 system components.
Topic
Page
Figure 72 Kinetix 7000 Drive AC Power Wiring 165
Figure 73 Kinetix 7000 Drive AC Powered with a 8720MC-RPS065BM Regenerative Power Supply 166
Figure 74 8720MC-RPS065BM Regenerative Power Supply to a Single Kinetix 7000 Drive
Figure 75 8720MC-RPS065BM Regenerative Power Supply to Multiple Kinetix 7000 Drives
Figure 76 Dual 8720MC-RPS065Bx Regenerative Power Supplies to a Single Kinetix 7000 Drive 169
Figure 77 Kinetix 7000 Drive AC Powered with a 8720MC-RPS190BM Regenerative Power Supply 170
Figure 78 8720MC-RPS190BM Regenerative Power Supply to a Single Kinetix 7000 Drive
Figure 79 8720MC-RPS190BM Regenerative Power Supply to Multiple Kinetix 7000 Drives
Figure 80 Dual 8720MC-RPS190Bx Regenerative Power Supplies to a Single Kinetix 7000 Drive
Figure 81 Bulletin MPL Motors (Bayonet Style Connector)
Figure 83 Bulletin MPL and MPM Motors (Circular DIN Style Connector)
Figure 84 HPK-Series High-power Motors
Figure 86 Example with RDD-Series (Bulletin RDB-B) Motors
Figure 87
Kinetix Safe-off Feature Block Diagram
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163
Appendix B
Interconnect Diagrams
Interconnect Diagram Notes
The notes below apply to the Kinetix 7000 drive wiring examples on the following pages.
9
10
11
7
8
4
5
2
3
Note
1
Information
For power wiring specifications, refer to Power Wiring Requirements on page
.
For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Specifications on page 153
and 148.
Place AC (EMC) line filters as close to the drive as possible and do not route very dirty wires in wireway. If routing in wireway is unavoidable, use shielded cable with shields
. See Establish Noise Zones on page 30 for wire
routing guidelines.
for more information.
The default configuration for the ground jumper is for grounded power at the customer site. Ungrounded, impedance grounded, high resistive grounded, B phase grounded, or common DC bus power distribution system sites must disconnect the protective MOVs and Common Mode Capacitors to guard against unstable operation
6
ATTENTION:
Implementation of safety circuits and risk assessment is the responsibility of the machine builder. Please reference international standards EN 1050 and EN 954 estimation and safety performance categories. For more information, refer to Understanding the Machinery Directive, publication SHB-900 .
Use of an external 24V DC control power supply is recommended for energizing the main control board. This allows the SERCOS ring to remain active when main power is removed. The main control board is powered from the DC bus during drive operation and can be used in this manner, if necessary.
The General Purpose Relay outputs on the Kinetix 7000 drive are configured as follows: GPR1+ and GRP1- have noise suppression circuitry and should be used for the motor brake, if used. The default setting for GPR2+ and GPR2- is DROK or Drive_OK. The GPR2 contacts close when external 24V DC control power is applied to the Control
Power terminals and there are no shutdown faults.
External AC input power for the cooling fan is required only for 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, and 2099-BM12-S drives. The cooling fans on 2099-BM06-S,
2099-BM07-S, and 2099-BM08-S drives are powered internally.
Dual 8720MC-RPS
xxx
units use a ribbon cable to connect the master unit to the slave unit control. The ribbon cable is included with the slave unit.
Contact for use with a safety circuit or other system requirement.
164
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Power Wiring Examples
Figure 72 - Kinetix 7000 Drive AC Power Wiring
Interconnect Diagrams
Appendix B
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
165
Appendix B
Interconnect Diagrams
Figure 73 - Kinetix 7000 Drive AC Powered with a 8720MC-RPS065BM Regenerative Power Supply
IMPORTANT
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
166
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Interconnect Diagrams
Appendix B
Figure 74 - 8720MC-RPS065BM Regenerative Power Supply to a Single Kinetix 7000 Drive
IMPORTANT
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
167
Appendix B
Interconnect Diagrams
Figure 75 - 8720MC-RPS065BM Regenerative Power Supply to Multiple Kinetix 7000 Drives
IMPORTANT
168
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Interconnect Diagrams
Appendix B
Figure 76 - Dual 8720MC-RPS065B
x
Regenerative Power Supplies to a Single Kinetix 7000 Drive
PIFS CN2
PIFS CN3
IMPORTANT
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
169
Appendix B
Interconnect Diagrams
Figure 77 - Kinetix 7000 Drive AC Powered with a 8720MC-RPS190BM Regenerative Power Supply
BLK
RED
YLW
BLK
RED
YLW
IMPORTANT
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
170
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Interconnect Diagrams
Appendix B
Figure 78 - 8720MC-RPS190BM Regenerative Power Supply to a Single Kinetix 7000 Drive
BLK
RED
YLW
BLK
RED
YLW
IMPORTANT
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
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171
Appendix B
Interconnect Diagrams
Figure 79 - 8720MC-RPS190BM Regenerative Power Supply to Multiple Kinetix 7000 Drives
BLK
RED
YLW
BLK
RED
YLW
IMPORTANT
172
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Interconnect Diagrams
Appendix B
Figure 80 - Dual 8720MC-RPS190B
x
Regenerative Power Supplies to a Single Kinetix 7000 Drive
*Three-phase Input
(+10/-15%)
3 8 0V AC RMS, 50 Hz or 460V AC RMS, 60 Hz
See Note 1
*Circuit
Breaker
See Note 2
*Input
Fusing
See Note 2
TB1
L1
L2
L3
EMC Line Filter
8 720MC-EF190-VB
TB1
L4
L5
L6
MC1
MC2
+24V2
0V2
NC
+24V3
0V3
SENS-out
+24V
MC
CN1
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
CN2
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
R1
S1
T1
CN4
1
2
3
2
*Circuit
Breaker
See Note 2
*Input
Fusing
See Note 2
TB1
L1
L2
L3
EMC Line Filter
8 720MC-EF190-VB
TB1
L4
L5
L6
MC1
MC2
+24V2
0V2
NC
+24V3
0V3
SENS-out
+24V
MC
CN1
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
CN2
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
R1
S1
T1
CN4
1
2
3
1 2
L1
L2
L3
Line Reactor
8 720MC-LR10-100B
L4
L5
L6
Fan 2
TB1
L1
L2
L3
Regenerative
Power Supply
8 720MC-RPS190BM
DC Bus
Connections
TB1
DC+
DC-
*DC Line
Fuses
Kinetix 7000 Drive
2099-BM
xx
-S
Axis
n
* DC Line Fuses
(see table in
Appendix A)
TB
DC+
DC-
DC Bus
Connections
L1
L2
L3
Line Reactor
8 720MC-LR10-100B
L4
L5
L6
Fan 3
L1
L2
L3
Line Reactor
8 720MC-LR10-100B
L4
L5
L6
Fan 2
L1
L2
L3
Line Reactor
8 720MC-LR10-100B
L4
L5
L6
Fan 3
RED
WHT
BLU
TB2
L1 AUX
L2 AUX
L3 AUX
PR1
PR2
PR3
TB4
+24V3
0V3
SENS
+24V2
0V2
MC1
MC2
Fault Relay
Contact
TB3
MC
RDY
FR
FR
RST
PWR
0V
24V
COM
IP
CR1*
8
7
GPIO
REGEN COM
REGEN OK
RED
WHT
BLU
TB2
L1 AUX
L2 AUX
L3 AUX
PR1
PR2
PR3
TB4
+24V3
0V3
SENS
+24V2
0V2
MC1
MC2
See Note 10
1
1
2
Motion
Control I/O
See Note 11
IOD
24V DC
ENABLE
24V COM
5
6
GPR
GPR2+
GPR2-
See Notes 6 and 8
Additional connections required, but not shown in this diagram:
1. +24V DC Control Power
2. Motor Feedback, Brake (if used), and Power
3. Drive I/O and Communications
TB1
L1
L2
L3
Regenerative
Power Supply
8 720MC-RPS190BM
DC Bus
Connections
TB1
DC+
DC-
*DC Line
Fuses
120V/240V AC or
24V DC
*Single-phase
AC Line Filter
RPS Stop-Start String
CR1* STOP* START (RPS On)*
CR1*
* Indicates User Supplied Component
IMPORTANT
This configuration requires the power regenerative mode settings as described in the 8720MC Regenerative Power Supply
Installation Manual, publication 8720MC-RM001 , and setting of the power tab in RSLogix 5000 software is set to the appropriate bus regulator catalog number. Common mode capacitors should be disconnected on DC common bus drives.
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173
Appendix B
Interconnect Diagrams
Kinetix 7000 Drive/Rotary Motor Wiring Examples
IMPORTANT
The Bulletin MPL motor wiring example on this page applies to motors equipped with bayonet connectors.
Figure 81 - Bulletin MPL Motors (Bayonet Style Connector)
Kinetix 7000 Drive
MPL-B
xx
460V Servo Motors with High
Resolution Feedback
Cable Shield
Clamp
Motor Power
(MP) Connector
W
V
U
2
1
4
3
2090-XX
x
PMP-
xx
S
xx
Motor Power Cable
Green/Yellow
1/Blue
2/Black
3/Brown
D
C
B
A
Motor Connector Shell
W
V
U
GND
Motor Power (Three-phase)
(2)
K
General Purpose Relay
(GPR) Connector
GPR1-
GPR1+
COM
24VDC
Dashed lines denote an internal circuit
Motor Feedback
(MF) Connector
(3)
2090-K6CK-D15M connector kit
1
2
3
4
5
10
14
6
7
11
4
1
3
2
SIN+
SIN-
COS+
COS-
DATA+
DATA-
ECOM
+9VDC
TS+
2090-UX
x
BMP-18S
xx
Brake Cable
Black
White
Customer-supplied
24V DC (2A max)
(1)
C
A
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/GRAY
ORANGE
WHT/ORANGE
Cable shield clamp must be used to meet CE requirements. No external connection to ground required.
(3)
2090-XX
x
FMP-S
xx
Flying-lead Feedback Cable
BR-
BR+
Motor Brake
(2)
K
L
E
F
D
C
N
R
A
B
S
Motor Connector Shell
Motor Feedback
(2)
Thermostat
P
(1) See
Customer-supplied 24V DC Power Supply Notes on page 175
for important wiring information.
(2) See MP-Series (Bulletin MPL) Motor Connectors on page 84
for more information on bayonet and circular DIN connectors.
(3) See Wire Low-profile Connectors on page 100
for more information on grounding feedback cables when using low-profile connectors.
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Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Interconnect Diagrams
Appendix B
Customer-supplied 24V DC Power Supply Notes
•
The contact connected to GPR1+ and GPR1- is rated 2 Amps inductive
@ 250V AC/30V DC maximum.
•
MPx motors with a brake have various coil current requirements. Refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001 for coil current requirements.
•
For motors that utilize above 2 Amp coil current it is recommended that a customer-supplied external device, such as an interposing relay, be used between the drive and motor. See
•
A customer-supplied diode or metal oxide varistor (MOV) is recommended for use with an interposing relay to prevent an electrical arc that may occur before the brake coil power dissipates. Use of an MOV can also reduce the amount of time required to mechanically engage the brake.
Figure 82 - Customer-supplied 24V DC Power Supply Wiring Example
Kinetix 7000
Drive
*Dashed lines denote customer supplied components.
MPL Motor
GPR1-
GPR1+
COM
24VDC
3
2
4
1
C1
C
A
C1
BR-
BR+
+ -
24VDC
Supply
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
175
Appendix B
Interconnect Diagrams
IMPORTANT
The Bulletin MPL motor wiring example on this page applies to motors equipped with circular DIN connectors.
Figure 83 - Bulletin MPL and MPM Motors (Circular DIN Style Connector)
Kinetix 7000 Drive
Cable Shield
Clamp
Motor Power
(MP) Connector
W
V
U
4
3
2
1
2090-CPBM7DF-
xx
AA
xx
, or
2090-XXNPMF-xxS
xx
(standard, non-flex) or
2090-CPBM7DF-
xx
AF
xx
or
2090-CPBM4DF-
xx
AF
xx
(continuous-flex)
Motor Power Cable
Shield
Green/Yellow
Blue
Black
Brown
D/
C/W
B/V
A/U
MPL-B
xx
and MPM-B
xx
460V Servo Motors with High
Resolution Feedback
Motor Connector Shell
W
V
U
GND
Motor Power (Three-phase)
(2)
General Purpose Relay
(GPR) Connector
K
GPR1-
GPR1+
COM
24VDC
3
2
4
1
Black
White
Customer-supplied
24V DC (2A max)
(1)
G/-
F/+
BR-
BR+
Motor Brake
(2)
Dashed lines denote an internal circuit
Motor Feedback
(MF) Connector
(3)
2090-K6CK-D15M connector kit
1
2
3
4
5
10
14
6
7
11
SIN+
SIN-
COS+
COS-
DATA+
DATA-
ECOM
+9VDC
TS+
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/GRAY
ORANGE
WHT/ORANGE
9
10
5
6
3
4
11
13
1
2
Motor Feedback
(2)
Thermostat
TS-
BLUE
14
Cable shield clamp must be used to meet CE requirements. No external connection to ground required.
COM
12
2090-CFBM7DF-CEAA
xx
, or
2090-XXNFMF-S
xx
(standard, non-flex) or
2090-CFBM7DF-CEAF
xx,
or
CFBM4DF-CDAF
xx
(continuous-flex)
(1) See
Customer-supplied 24V DC Power Supply Notes on page 175
for important wiring information.
(2) See MP-Series (Bulletin MPL) Motor Connectors on page 84
for more information on bayonet and circular DIN connectors.
(3) See Wire Low-profile Connectors on page 100
for more information on grounding feedback cables when using low-profile connectors.
176
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Interconnect Diagrams
Appendix B
Figure 84 - HPK-Series High-power Motors
Kinetix 7000 Drive
K
Cable Shield
Clamp
Motor Power
(MP) Connector
W
V
U
4
3
2
1
GPR1-
GPR1+
COM
24VDC
Motor Power Cable
(customer-supplied)
Green/Yellow
1/Blue
2/Black
3/Brown
3
2
4
1
Customer-supplied
Interface to
460V AC Power
Customer-supplied
24V DC
(1)
Dashed lines denote an internal circuit
Motor Connector Shell
W
V
U
HPK-B/E
xxxx
460V High-power Servo Motors with High Resolution Feedback
BR-
BR+
GND
Motor Power (Three-phase)
Spring-set Brake
(Single-phase)
FAN-
FAN+
Blower Connections
(2)
Motor Feedback
(MF) Connector
2090-K6CK-D15M connector kit
3
4
5
10
14
6
7
11
1
2
Cable shield clamp must be used to meet CE requirements. No external connection to ground required.
SIN+
SIN-
COS+
COS-
DATA+
DATA-
ECOM
+9VDC
TS+
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/GRAY
ORANGE
WHT/ORANGE
2090-CFBM7DF-CEAA
xx
, or
2090-XXNFMF-S
xx
(standard, non-flex) or
2090-CFBM7DF-CEAF
xx,
or
CFBM4DF-CDAF
xx
(continuous-flex)
9
10
11
13
5
6
3
4
1
2
14
Motor Connector Shell
Motor Feedback
Thermostat
12
(1) See
(2) See
HPK-Series Motor Blower Connections on page 178 for more information.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
177
Appendix B
Interconnect Diagrams
178
Customer-supplied 24V DC Power Supply Notes (HPK-series motors)
•
HPK-series motors require a customer-supplied 460V AC single-phase supply, rather than a 24V DC supply. However, the brake current ratings required by HPK-series motors are higher than the contact rating of the
GPR connector. Therefore, if using an HPK-series motor with a brake, it is recommended that a customer-supplied, external interposing relay or equivalent circuit be used. See
•
The contact connected to GPR1+ and GPR1- is rated 2 Amps inductive
@ 250V AC/30 VDC maximum.
•
See the Kinetix Motion Control Selection Guide, publication
GMC-SG001 for HPK-series motor brake ratings.
Figure 85 - Customer-supplied HPK-Series Motor Brake Wiring Example
Kinetix 7000
Drive
*Dashed lines denote customer supplied components.
HPK-Series Motor
GPR1-
GPR1+
COM
24VDC
3
2
4
1
C1
C1
C
A
BR-
BR+
+ -
24V DC
Supply
L1 L2
460V AC
Supply
HPK-Series Motor Blower Connections
•
The HPK-series motor blower must be used to ensure proper motor performance.
•
The blower connections can use either a Star (460 V AC) or Delta (230V
AC) three-phase configuration. See the HPK-Series Asynchronous Servo
Motor Installation Instructions, publication HPK-IN001 , for connection diagrams.
•
HPK-series Motors with a brake and without a brake have different blower assemblies and, therefore, have different connection and electrical characteristics.
•
The HPK-series motor has a conduit box with terminals/leads for external power connections.
•
See the Kinetix Motion Control Selection Guide, publication
GMC-SG001 for HPK-series motors blower voltage and current specifications.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Interconnect Diagrams
Appendix B
Kinetix 7000 Drive
Cable Shield
Clamp
Motor Power
(MP) Connector
W
V
U
2
1
4
3
Figure 86 - Example with RDD-Series (Bulletin RDB-B) Motors
Shield
Green/Yellow
Blue
Black
Brown
2090-CPWM7DF-
xx
AA
xx
, or
2090-XXNPMF-
xx
S
xx
(standard, non-flex) or 2090-CPWM7DF-
xx
AF
xx
(continuous-flex)
Motor Power Cable
C/W
B/V
A/U
RDB-B
xxxx
Direct Drive
Servo Motors with
High Resolution Feedback
W
V
U
GND
Three-phase
Motor Power
Thermistor
Motor
Feedback
1
2
3
4
10
11
13
7
8
9
5
6
14
12
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
BROWN
WHT/BROWN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
BLUE
Refer to table on
note information.
SIN+
SIN-
COS+
COS-
DATA+
DATA-
CLK+
CLK-
+5VDC
ECOM
–
TS+
2090-K7CK-KENDAT
Feedback Module
3
4
1
2
5
6
7
8
9
10
11
TS-
COM
Cable shield clamp must be used in order to meet CE requirements. No external connection to ground is required.
2090-XXNFMF-S
xx
(standard, non-flex) or
2090-CFBM7DF-CDAF
xx
(continuous-flex)
Flying-lead Feedback Cable
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
179
Appendix B
Interconnect Diagrams
Kinetix Safe-off Feature
Block Diagram
Kinetix 7000 drives with the Safe-off feature installed ship with the wiring header and a motion-allowed jumper installed. In this configuration, the safe-off feature is disabled (not used).
Figure 87 - Kinetix Safe-off Feature
8
9
Safe-Off Option
Safe-Off (SO)
9-pin Connector
+24V
+24V_COM
K1-C
3
4
FDBK1+
FDBK1-
7
ENABLE1+
6
ENABLE-
5
ENABLE2+
1
2
FDBK2+
FDBK2-
K1
K2
K1-A
K2-A
Gate Control
Power Supply
Safety Monitor uC
Gate Control
Circuit (CCP)
K2-C
Motion Allowed Jumper
Wiring Header +24V
DRIVE ENABLE
+24V_COM
Gate Control
Enable Signal
M
180
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Before You Begin
Appendix
C
Upgrade Firmware
This appendix provides procedures for using ControlFLASH™ utility to upgrade the firmware in a Kinetix 7000 drive.
Topic
Page
Upgrading the firmware of a Kinetix 7000 servo drive using ControlFLASH involves entering the name of the target device, locating the SERCOS interface module and Kinetix 7000 servo drive to be flashed, finding the existing new firmware levels, and flashing the drive firmware.
Before you begin this procedure, make sure you have the following.
Description
RSLogix 5000
Software
RSLinx Software
ControlFLASH Kit
(1)
Firmware for Logix SERCOS interface module or
PCI card
Catalog Numbers
9324-RLD300NE
0355-RSLETENE
N/A
Firmware upgrade file for Kinetix 7000
1756-M
xx
SE
1756-L60M03SE
1768-M04SE
1784-PM16SE
(2),(3)
Version
15.0 or later
2.50.00 or later
4.00.09 or later
15.32 or later
15.4 or later
15.35 or later
15.33 or later
(1) For ControlFLASH information not specific to the Kinetix 7000 drive family, refer to the ControlFLASH Firmware Upgrade Kit Quick
Start, publication 1756-QS105 .
(2) Contact Rockwell Automation Technical Support at (440) 646-5800 for firmware upgrade files and assistance.
(3) Go to http://support.rockwellautomation.com/firmware.asp
for firmware upgrades.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
181
Appendix C
Upgrade Firmware
Upgrade Firmware
This procedure requires you to use ControlFLASH software to upgrade the firmware in a Kinetix 7000 drive.
1.
Verify 24V DC control power is supplied to the Kinetix 7000 drive requiring firmware upgrade.
IMPORTANT
The seven segment LED on the Kinetix 7000 must display a 2, 3, or 4 before beginning this procedure. Only these displays indicates the drive has been recognized by the SERCOS interface.
ATTENTION:
To avoid injury or damage to equipment due to unpredictable motor activity, do not apply main input power to the drive, or source drive power from a DC common bus.
2.
Open your ControlFLASH software or select ControlFLASH from the
Tools menu of RSLogix 5000 software.
The Welcome to ControlFLASH dialog opens.
182
3.
Click Next.
The Catalog Number dialog opens.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Upgrade Firmware
Appendix C
4.
Select the catalog number of the Kinetix 7000 (2099-BM
xx-
S) drive to upgrade.
5.
Click Next.
6.
Select the SERCOS interface module and Kinetix 7000 drive to flash in the RSLinx Gateway dialog.
7.
Click OK.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
183
Appendix C
Upgrade Firmware
8.
Select the firmware revision to use in this update.
Select the new firmware from the list, or browse for it using the Current
Folder option.
9.
Click Next.
10.
Confirm the catalog number and serial number of the drive, and its current revision and new revision of firmware.
11.
Click Finish.
184
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
12.
Click Yes to confirm updating of the target device.
Upgrade Firmware
Appendix C
13.
Click OK to acknowledge the Motion Stop notice.
A dialog will display the progress of the flash update.
While this display is active, the Status display on the drive will display an F.
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
185
Appendix C
Upgrade Firmware
The Update Status dialog indicates success or failure as described below.
Flashing If
Succeeded 5. Update complete appears in a GREEN status dialog.
Failed 1. Update failure appears in a RED status dialog.
2. Contact Technical Support.
14.
Click OK.
The ControlFLASH software returns to the Welcome screen where you can flash another drive or select Cancel to exit the program.
186
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Index
Numerics
1756 module properties
1756-MxxSE interface module
2090-K6CK-D15F
2090-K6CK-D15M
2090-K6CK-D26M
2090-K7CK-KENDAT
A
AC line filters
noise reduction
accessories
applying power
auxiliary feedback
pin-outs
specifications
axis unstable
circuit breakers
sizing
configuring
base node address
baud rate, IAM
delay times
IAM
optical power level
SERCOS module
connecting
external shunt resistor
feedback
I/O
input power
motor brake
motor power
premolded feedback cables
SERCOS cables
connecting your Kinetix 7000
contactor specifications
Kinetix 7000
controller properties
conventions used in this manual
B
bandwidth
base node address
example with two ControlLogix chassis
,
baud rate,communication rate
block diagrams
safe-off feature
bonding build
EMI (ElectroMagnetic Interference)
high frequency energy
mounting
subpanels
motor cables
bus regulator
bus status LED
D
data rate
date and time tab
DC common bus
total bus capacitance
typical installation
delay times
digital inputs
dip switches
disable drive
download program
drive status indicators
drive status LED
drive tab
C
cables
build motor cables
categories
fiber optic
maximum fdbk cable length
maximum length of fiber-optic
catalog number
integrated axis module
CB1, CB2, CB3
CE
meeting requirements
certifications
Rockwell Automation Product Certification
changing parameters
HIM
circuit breaker specifications
Kinetix 7000
E
EMC
motor ground termination
EMI (ElectroMagnetic Interference)
bonding
enable time synchronization
enclosure
requirements
enclosure sizing
Kinetix 7000
environmental specifications
Kinetix 7000
erratic operation
error codes
establishing communication
external shunt resistor
wiring
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
187
Index
188
F
fault action
fault action, programmable
fault actions tab
feedback power supply
fiber optic cables
maximum length
receive and transmit connectors
fiber optic signals
full-line regen
typical installation
fuse sizing
fuse specifications
Kinetix 7000
G
grounding
high impedance ground
H
high frequency energy
hookup tab
I
I/O
connections
specifications
indicator
drive status
indicators
status
input power wiring
determining input power
three-phase delta 76 without LIM
installation
fiber optic cable
installing your Kinetix 7000
integrated axis module
catalog number
configuring
K
Kinetix 7000
accessories
motors
specifications circuit breaker/fuse
contactor ratings
enclosure sizing
environmental
maximum fdbk cable length
power dissipation
power section
weight
typical configuration
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
DC common bus
full-line regen
regen braking
typical installation, with LIM
typical installation, without LIM
L
LED
bus status
drive status
SERCOS interface module
status
logic power status indicator
low profile connector kits
wiring
M
maintenance
maximum fdbk cable length
Kinetix 7000
module properties
1756 SERCOS interface
Motion
motor accel/decel problems
motor overheating
motor velocity
motors
feedback pin-outs
feedback specifications
ground termination
power wiring
testing
tuning
motors brake wiring
mounting
external shunt resistor
guidelines to reduce noise
N
no communication
no rotation
node address
noise
abnormal
feedback
noise zones
O
optical power level
P
panel
cable categories
noise zones
Index
ControlLogix
,
requirements
pin-outs
auxiliary feedback connector
motor feedback connector
,
power dissipation specifications
Kinetix 7000
power supply, feedback
power up
premolded feedback cables
R
reference documents
Allen-Bradley automation glossary
CompactLogix controllers user manual
CompactLogix Sercos interface installation instructions
control of electrical noise
ControlLogix motion module configuration
ControlLogix SERCOS interface installation
fiber optic cable installation and handling
Kinetix 7000 installation instructions
Kinetix motion control selection guide
motion coordinate system configuration
national electrical code
safety guidelines for solid state controls
SoftLogix 5800 user manual
SoftLogix motion card configuration
understanding the machinery directive
routing power and signal wiring
RSLogix 5000 software
S
safe-off
block diagram
SERCOS
connecting cables
connections
seven segment status indicator
shutdown
software
RSLogix 5000
specifications
feedback motor and auxiliary
power supply
I/O digital inputs
Kinetix 7000 circuit breaker/fuse
contactor ratings
environmental
maximum fdbk cable length
power dissipation
power section
weight
SERCOS connections
status indicator
logic power
status LEDs
status only
stop motion
surge suppression
switches
base node address
baud rate
optical power level
system block diagrams
safe-off feature
system mounting requirements
circuit breakers
fuse sizing
transformer sizing
T
testing axes
hookup tab
total bus capacitance
training
transformer sizing
transmit power level
troubleshooting
bus status LED
disable drive
drive status LED
error codes
fault action
general system problems
abnormal noise
axis unstable
erratic operation
feedback noise
motor accel/decel problems
motor overheating
motor velocity
no rotation
Logix/drive fault behavior
programmable fault action
shutdown
status only
stop motion
tuning axes
bandwidth
tune tab
typical configuration
Kinetix 7000
DC common bus
full-line regen
regen braking
typical installation
Kinetix 7000, with LIM
Kinetix 7000, without LIM
W
weight specifications
Kinetix 7000
who should use this manual
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
189
Index wiring
build motor cables
common dc bus power
external shunt resistor
ground reference 77 grounding
I/O connections
impedance grounded power system
input power determining type
without LIM
low profile connectors
motor brake
motor power
requirements
routing power and signal wiring
SERCOS fiber optic cables
unbalanced power system
ungrounded power system
190
Rockwell Automation Publication 2099-UM001E-EN-P - July 2015
Rockwell Automation Support
Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.
In addition, we offer multiple support programs for installation, configuration, and troubleshooting. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/services/online-phone .
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada 1.440.646.3434
Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page
, or contact your local
Rockwell Automation representative.
New Product Satisfaction Return
Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.
United States
Outside United States
Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.
Please contact your local Rockwell Automation representative for the return procedure.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002 , available at http://www.rockwellautomation.com/literature/ .
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.
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Publication 2099-UM001E-EN-P - July 2015
Supersedes Publication 2099-UM001D-EN-P - December 2012 Copyright © 2015 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Key features
- High output power
- Safe-off feature
- 460V AC input power
- Shared DC bus capability
- Kinetix Integrated Motion solution
- SERCOS communication protocol