Allen-Bradley 2099-BM08-S User manual

Type
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
User Manual
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/
) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Allen-Bradley, CompactLogix, ControlFlash, ControlLogix, DriveExplorer, Kinetix, RSLogix 5000, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 3
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.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Updated the Additional Resources with updated and new publications. 9
Updated the Typical System Diagrams to include updated catalog numbers for
Bulletin MPL motors, Bulletin MPM motors, and regenerative power supplies.
13
Added the Using Motion Analyzer to Determine Heat Dissipation information to the
Enclosure Selection section.
24
Added the mounting information from Chapter 3 - Mount the Kinetix 7000 Drive
System, to Chapter 2 - Install the Kinetix 7000 Drive System and removed Chapter 3.
39
Updated the Kinetix 7000 Front Panel Connectors and Displays, Kinetix 7000 Top
Panel Connectors and Switches, and Kinetix 7000 Bottom Panel Connectors
illustrations and tables for clarity.
42
Updated the IOD connector pinouts in the Hardware Enable, Home and Positive and
Negative Overtravel circuit diagrams.
55
Added information on Reading Analog Input Voltage Values. 61
Updated information on configuring the General Purpose I/O regenerative power
supply OK signal.
64
Added Figure 41 Safe-Off, Motion-allowed Jumper. 65
Updated the information in the Setting the Ground Jumper in Ungrounded Power
Configurations section.
78
Updated the Wire the Kinetix 7000 Drive Connectors section. 88
Added Flying-lead Feedback Cable Pinouts for the new 2090-XXNFMF-Sxx and 2090-
CFBMxDF-CDAFxx Feedback Cable.
95
Added illustrations to the Wire Feedback and I/O Connectors section. 95
Updated the information on External Shunt Module Connections to reflect
availability of certain shunt modules.
101
Updated the Node Addressing Examples to reflect current topologies. 108
Updated the steps and images in the Configure the Logix SERCOS interface Module
section to reflect the current software release.
110
Added the Configure Drive Parameters and System Variables section. 134
Added an explanation for the Drive Overtemperature Fault (E23) to the list of Error
Codes.
140
Updated the Specifications and Dimensions section to reflect current data and
specifications.
150
Added Korean Registration of Broadcasting and Communications Equipment
certification to the Certifications table.
154
Added the new External Shunt Modules section to Appendix A. 156
Updated the Interconnect Diagrams to reflect new cables and corrected connections
information.
161
4 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Summary of Changes
Notes:
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 5
Table of Contents
Preface
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Start
About the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Typical Drive System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CE Requirements - System without LIM . . . . . . . . . . . . . . . . . . . . . . . 19
CE Requirements - System with LIM . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CE Requirements - System with DC Common Bus through 8720MC-
RPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 2
Install the Kinetix 7000 Drive System
System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Establish Noise Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cable Categories for Kinetix 7000 Systems . . . . . . . . . . . . . . . . . . . . . 35
Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 36
Mount the Kinetix 7000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 3
Kinetix 7000 Connector Data
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
6 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Table of Contents
Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Digital Inputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Analog Inputs (IOD Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog Outputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General Purpose I/O (GPIO Connector). . . . . . . . . . . . . . . . . . . . . . . 63
General Purpose Relay (GPR Connector). . . . . . . . . . . . . . . . . . . . . . . 64
SERCOS Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safe-off (SO Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Control Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Motor (MF) and Auxiliary Feedback (AF) Connections . . . . . . . . . . . . . 66
Motor and Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . . . . 66
Chapter 4
Connect the Kinetix 7000 Drive
System
Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Building Your Own Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Shielded Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Required Cable Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
General Wire Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 75
Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Power Distribution Systems Without a Ground Reference . . . . . . . 77
Setting the Ground Jumper in Ungrounded Power Configurations . . . 78
Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and
2099-BM08-S Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Removing the Ground Wires on 2099-BM09-S and 2099-BM10-S
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Removing the Ground Wires on 2099-BM11-S and 2099-BM12-S
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Grounding the Kinetix 7000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 81
Grounding Your System to the Subpanel . . . . . . . . . . . . . . . . . . . . . . . 81
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Motor Power Cable Shield Termination. . . . . . . . . . . . . . . . . . . . . . . . 82
MP-Series (Bulletin MPL) Motor Connectors . . . . . . . . . . . . . . . . . . 83
Input Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Acceptable Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Shielded/Armored Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Wire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Power Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 7
Table of Contents
Wire the Kinetix 7000 Drive Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Wire the Control Power (CP) Connector . . . . . . . . . . . . . . . . . . . . . . 88
Wire AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Wire DC Input Power (Common Bus Configurations Only) . . . . 89
Wire the Safe-off (SO) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wire the General Purpose Relay (GPR) and General Purpose I/O
(GPIO) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Wire Motor Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Wire the Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Flying-lead Feedback Cable Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Wire Feedback and I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connect Premolded Motor Feedback Cables . . . . . . . . . . . . . . . . . . . 95
Wire Panel-mounted Breakout Board Kits. . . . . . . . . . . . . . . . . . . . . . 96
Wire Low-profile Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SERCOS Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 5
Configure and Startup the Kinetix
7000 Drive System
Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Node Addressing Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Configure the Logix SERCOS interface Module . . . . . . . . . . . . . . . . . . . 110
Configure the Logix Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Configure the SERCOS Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Configure the Kinetix 7000 Drive Modules. . . . . . . . . . . . . . . . . . . . 117
Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Apply Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Configure Drive Parameters and System Variables . . . . . . . . . . . . . . . . . 134
Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Chapter 6
Troubleshoot the Kinetix 7000 Drive
System
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Interpret Error Codes and Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 138
Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
General System Anomalies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Logix/Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Table of Contents
Appendix A
Specifications and Dimensions
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Power Dissipation Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Weight Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
AC Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
External Shunt Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Precharge Capacities of the Regenerative Power Supply . . . . . . . . . . . . . 157
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendix B
Interconnect Diagrams
Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Power Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Kinetix 7000 Drive/Rotary Motor Wiring Examples . . . . . . . . . . . 172
Kinetix Safe-off Feature Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Appendix C
Upgrade Firmware
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Upgrade Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Index
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 9
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
The following documents contain additional information concerning related
products from Rockwell Automation.
Resource Description
Kinetix 7000 DC-DC Converter and Control Board Kits, publication 2099-IN002 Provides information on removing and replacing the DC-DC converter, DC-DC
converter fuse, and the control board assembly in a Kinetix 7000 drive.
Kinetix 7000 Drive Installation Instructions, publication 2099-IN003
Provides information on installing a Kinetix 7000 drive.
Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010
Provides information on proper handling, installing, testing, and troubleshooting
fiber-optic cables.
ControlLogix SERCOS interface Module Installation Instructions, publication
1756-IN572
Provides details about installing a 3, 8 or 16-Axis ControlLogix SERCOS interface
module.
Logix5000 Controllers General Instructions Reference Manual, publication
1756-RM003
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.
ControlLogix System User Manual, publication 1756-UM001
Provides information about configuring and troubleshooting a ControlLogix
system.
CompactLogix SERCOS interface Module Installation Instructions, publication 1768-IN005 Provides information on installing and troubleshooting a CompactLogix SERCOS
interface motion module.
CompactLogix Controllers User Manual, publication 1768-UM001
Provides information on installing, configuring, programming, and operating a
CompactLogix system.
SoftLogix Motion Card Setup and Configuration Manual, publication 1784-UM003
Provides information on configuring and troubleshooting a SoftLogix PCI card.
SoftLogix 5800 User Manual, publication 1789-UM002
Provides information on configuring, programming, and operating a SoftLogix
system.
8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001 Provides a hardware description and start-up and programming procedures for
the 8720MC-RPS Regenerative Power Supply.
System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001
Provides information, examples, and techniques designed to minimize system
failures caused by electrical noise.
10 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Preface
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.
Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 Provides detailed installation instructions for wiring and troubleshooting a
Kinetix 7000 safe-off drive.
Kinetix Motion Control Selection Guide, publication GMC-SG001 Provides descriptions and specifications for the 2099 product family including
motors and accessories.
Kinetix 7000 Drive Systems Design Guide, publication GMC-RM007
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.
Kinetix Servo Drives Specifications Technical Data, publication GMC-TD003 Provides catalog numbers and product specifications, including performance,
environmental, certifications, load force, and dimension drawings for Allen-
Bradley® servo drives.
Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004 Provides catalog numbers, product specifications, and dimensions for Allen-
Bradley servo drive accessories.
Rockwell Automation Configuration and Selection Tools
website http://www.rockwellautomation.com/en/e-tools
Provides information and access to the Motion Analyzer application analysis
software for drive/motor sizing.
Provides online product selection and system configuration tools, including
AutoCAD (DXF) drawings.
Rockwell Automation Product Certification Website:
http://www.rockwellautomation.com/products/certification/
Provides online access to declarations of conformity (DoC) currently available
from Rockwell Automation.
Kinetix Accelerator Toolkit Quick Start, publication IASIMP-QS002 Provides examples of using a Logix controller to connect to multiple devices
(servo drives, motors, and HMI) over the EtherNet/IP network in a Kinetix
Integrated Motion application.
Kinetix Accelerator Toolkit Brochure, publication MOTION-BR004
Provides information about the Kinetix Accelerator Toolkit.
SERCOS and Analog Motion Configuration and Startup, publication
MOTION-UM001
Provides information to create a motion coordinate system with SERCOS or analog
motion modules.
Motion Coordinate System User Manual, publication MOTION-UM002 Provides, information on configuring and troubleshooting your ControlLogix,
CompactLogix, and SoftLogix SERCOS interface modules.
Logix5000 Controllers Motion Instructions Reference Manual, publication MOTION-RM002
Provides programmers with details about the motion instructions that are
available for a Logix5000 controller.
National Electrical Code, published by the National Fire Protection Association of Boston, MA Provides access to articles on wire sizes and types for grounding electrical
equipment.
Safety Products, publication S117-CA001 Provides information on principle standards and implementation of safety
products and catalogs available safety products.
Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls,
publication SGI-IN001
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.
Understanding the Machinery Directive, publication SHB-900
Provides information on the CE marking process, with references to key European
requirements and resources, and examples of safety component applications.
Allen-Bradley Industrial Automation Glossary, publication AG-7.1 A glossary of industrial automation terms and abbreviations.
Resource Description
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 11
Chapter 1
Start
Use this chapter to become familiar with the design and installation requirements
for Kinetix 7000 drive systems.
Topic Page
About the Drive System 12
Typical Drive System Diagrams 13
Catalog Number Explanation 18
Agency Compliance 18
12 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
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
Catalog Numbers Description
Servo Drive 2099-BMxx-S
(1)
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.
Regenerative Power
Supply
8720MC-RPS The 8720MC-RPS is a sinusoidal PWM converter that may serve as a regenerative power supply for one or more drives.
Logix Controller
Platform
1756-L60M03SE module
1756-MxxSE module
1768-M04SE module
1784-PM16SE PCI card
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 Software 9324-RLD300ENE RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of controllers.
Rotary Servo Motors MP-Series, HPK-Series, and
RDD-Series
Compatible rotary servo motors include MP-Series (Bulletin MPL and MPM) 400V class motors, HPK-Series motors, and
RDD-Series direct-drive motors.
Cables Motor Power, Feedback, and
Brake cables
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.
Large power motors may require user power wiring to handle larger current requirements.
Communication Bulletin 2090 SERCOS fiber-optic cables are available as enclosure only, PVC, nylon, and glass with connectors at both ends.
AC Line Filters 2090-XXLF-TCxxxx Bulletin 2090-XXLF-TCxxxx three-phase AC line filters are required to meet CE and available for use in all Kinetix 7000 drive
systems.
Line Interface Module 2094-BL50/75S, or 2094-
XL75S-Cx
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.
External Shunt
Modules
NA See External Shunt Modules
on page 156 for active shunt solutions from Rockwell Automation Encompass Partners and
intended for use with Kinetix 7000 drives.
(1) See the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002, for more information.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 13
Start Chapter 1
Typical Drive System
Diagrams
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
MAIN VACMAIN VAC
24V DC
Control Power
External Shunt Module (optional component). See
External Shunt Modules on page 156
for more
information.
2090-XXLF-TCxxxx
AC Line Filter
2094-BL75S
Line Interface Module
(optional component)
460V AC
Three-Phase
Input Power
RSLogix 5000 Software
Input
Logix 5000 Controller
Output
1756-MxxSE SERCOS
Interface Module
2090-SCxxx-x
SERCOS Fiber-Optic Ring
Commissioning
2099-BMxx-S Kinetix 7000 Drive
HPK-Series Motors, RDD-Series Direct Drive Motors, MPM-
B165xx and MPM-B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown) Servo Motors
ControlLogix Chassis
Motor Power Cable
Encoder
Feedback
Cable
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback
Safe-off,
General Purpose I/O,
General Purpose Relay
Connections
14 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Chapter 1 Start
Figure 2 - Kinetix 7000 System Configuration without Line Interface Module (LIM)
1606-XL
Power Supply
Input
Allen-Bradley
1606-XLxxx
24V DC
Control Power
2090-XXLF-TCxxxx
AC Line Filter
Input Fusing
Three-Phase
Input Power
Input
Logix 5000
Controller
Output
1756-MxxSE
SERCOS Interface Module
2090-SCxxx-x
SERCOS Fiber-Optic Ring
Commissioning
2099-BMxx-S Kinetix 7000 Drive
ControlLogix
Chassis
Motor Power Cable
Encoder
Feedback
Cable
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback.
Control Power Supply
Input
Input
Contactor
Safe-off,
General Purpose I/O,
General Purpose Relay
connections
External Shunt Module (optional component).
See External Shunt Modules on page 156
for more
information.
HPK-Series Motors, RDD-Series Direct Drive Motors, MPM-
B165xx and MPM-B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown) Servo Motors
RSLogix 5000 Software
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 15
Start Chapter 1
The Kinetix 7000 drive system shown in Figure 3 below illustrates a regenerative
power only configuration with a 8720MC regenerative power supply (RPS). The
harmonic filter and varistor are available separately, but are included with the
RPS unit when ordering the 8720MC-RPS065BM-HV2. In this configuration
the Kinetix 7000 drive provides motoring power and the 8720MC-RPS065
provides regenerative power.
Figure 3 - Kinetix 7000 System Configuration with AC Input and Regenerative Power Supply
1606-XL
Power Supply
Input
Allen-Bradley
R E G E NE R AT IV E P O WE R S U P P LY
REGENERA
TIVE POWER
SUPPLY
8720
8720
MC
MC
RST
PRG
ENT
READY
READY
FAULT
FAULT
PROGRAM
PROGRAM
kW
kW
V
A
Encoder
Feedback
Cable
2090-SCxxx-x
SERCOS Fiber-optic Ring
DC Bus
8720MC-RPS065BM-HV2
Regenerative Power Supply
8720MC-LRxx
Line Reactor
Three-phase
Input Power
8720MC-VA-B Varistor
Included with
8720MC-RPS065BM-HV2.
8720MC-HF-B2 Harmonic Filter
Included with
8720MC-RPS065BM-HV2.
Magnetic
Contactor
Motor
Power
Cable
1606-XLxxx
24V DC
Control Power
8720MC-RFI80
AC Line Filter
(required for CE)
Input
Fusing
Three-phase
Input Power
Magnetic
Contactor
Input
Fusing
1321-3R Type Line Reactor,
3% compatible with
Kinetix 7000 Drive
Regenerative
Power Only
2099-BMxx-S
Kinetix 7000 Drive
2090-K6CK-Dxxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
Control Power
Supply Input
Logix SERCOS
interface Module
ControlLogix Chassis
RSLogix 5000 Software
Logix Controller
Programming Network
Kinetix 7000 High Power
Servo Drive System
2090-XXLF-TCxxxx
AC Line Filter
(required for CE)
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165xx and MPM-
B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown)
Servo Motors
16 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Chapter 1 Start
The Kinetix 7000 drive system shown in Figure 4 below illustrates a DC
common bus configuration with two follower Kinetix 7000 (2099-BM11-S)
drives and an 8720MC regenerative power supply (RPS). In full-line regenerative
mode the 8720MC-RPS190 unit provides motoring and regenerative power.
Figure 4 - Kinetix 7000 System Configuration with AC Input and 8720MC-RPS190 with Full-line
Regeneration
1606-XL
Power Supply
Input
Allen-Bradley
R
EGE
NER
ATIVE PO
WER SUPPLY
REGENERATIVE PO
WER SUPPLY
87208720
MCMC
RST
PRG
ENT
READYREADY
FAULTFAULT
PROGRAMPROGRAM kWkW
V
A
1606-XL
Power Supply
Input
Allen-Bradley
R
EGENE
RA
TIVE
POW
ER
SU
PPLY
87208720
MCMC
RST
PRG
ENT
READYREADY
FAULFAULT
PR
OGRAMPROGRAM kWkW
V
A
2090-SCxxx-x
SERCOS Fiber-optic Ring
DC Bus
Kinetix 7000 Drive
2099-BM11-S
2090-K6CK-Dxxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
8720MC-RPS190BM
Regenerative Power Supply
Three-phase
Input Power
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.
Input
Fusing
Full Regenerative
2099-BM11-S
Kinetix 7000 Drive
2090-K6CK-Dxxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
1606-XLxxx
24V DC
Control Power
1606-XLxxx
24V DC
Control Power
Encoder
Feedback Cable
Motor
Power Cable
HPK-Series Motors
DC Bus
Fusing
DC Bus
Fusing
Control Power
Supply Input
Control Power
Supply Input
Logix SERCOS
interface Module
RSLogix 5000 Software
Logix Controller
Programming Network
8720MC-LR10-100B
Line Reactor
(two units in parallel)
Encoder
Feedback
Cable
Motor
Power Cable
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165xx and MPM-
B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown)
Servo Motors
Ground
Fault
Protection
Fusing
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 17
Start Chapter 1
The Kinetix 7000 drive system shown in Figure 5 below illustrates a DC
common bus configuration with two follower Kinetix 7000 drives and an
8720MC regenerative power supply (RPS). The harmonic filter and varistor are
available separately, but are included when ordering the 8720MC-RPS065BM-
HV2 RPS unit. In full-line regenerative mode the 8720MC-RPS065BM-HV2
unit provides motoring power and regenerative power. In common bus mode,
you must calculate the total bus capacitance of your DC common bus system.
This allows you to plan your panel layout and sufficiently size the 8720MC-RPS
to precharge the entire system.
Figure 5 - Kinetix 7000 System Configuration with DC Input from 8720MC-RPS065 Providing Full-
line Regeneration
1606-XLxxx
24V DC
Control Power
8720MC-RF180
AC Line Filter
Input
Fusing
Three-Phase
Input Power
RSLogix 5000 Software
Input
Logix 5000
Controller
Output
1756-MxxSE SERCOS
Interface Module
2090-SCxxx-x
SERCOS Fiber-Optic Ring
Commissioning
2099-BMxx-S
Kinetix 7000 Drive
ControlLogix
Chassis
Motor Power Cable
Encoder
Feedback
Cable
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback.
Control Power
Supply Input
(To retain logic control
when main DC power is
removed.)
Magnetic
Contactor
1606-XLxxx
24V DC
Control Power
HPK-Series Motors
Motor Power Cable Encoder Feedback Cable
DC Bus
Fusing
DC Bus
Fusing
Full Regenerative DC Bus
Control Power
Supply Input
(To retain logic
control when
main DC power
is removed.)
2099-BMxx-S
Kinetix 7000 Drive
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback
Ground
Fault
Protection
Fusing
8720MC-LRxx
Line Reactor
8720MC-RPS065BM-HV2
Regenerative Power Supply
Harmonic Filter
(included with
8720MC-RPS065BM-HV2
Regenerative Power Supply)
Varistor
(included with
8720MC-RPS065BM-HV2
Regenerative Power Supply)
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165xx and MPM-
B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xx
x, and MPL-B9xxx (shown)
Servo Motors
18 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Chapter 1 Start
Catalog Number Explanation
Kinetix 7000 drive catalog numbers and descriptions are listed in the table below.
Agency Compliance
If this product is installed within the European Union or EEC regions and has
the CE mark, the following regulations apply.
For more information on electrical noise reduction, see the System Design for
Control of Electrical Noise Reference Manual, publication GMC-RM001
.
Kinetix 7000 Drive Cat. No.
Kinetix 7000, 460V, 22 kW, 40 A continuous output 2099-BM06-S
Kinetix 7000, 460V, 30 kW, 52 A continuous output 2099-BM07-S
Kinetix 7000, 460V, 37 kW, 65 A continuous output 2099-BM08-S
Kinetix 7000, 460V, 56 kW, 96 A continuous output 2099-BM09-S
Kinetix 7000, 460V, 75 kW, 125 A continuous output 2099-BM10-S
Kinetix 7000, 460V, 112 kW, 180 A continuous output 2099-BM11-S
Kinetix 7000, 460V, 149 kW, 248 A continuous output 2099-BM12-S
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.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 19
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-TCxxxx) as close to the
Kinetix 7000 drive as possible.
• For MPx 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.
20 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
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-Cx or 2094-BL50/75S, and line filter
(2090-XXLF-TCxxx) as close to the Kinetix 7000 drive as possible.
CE Requirements - System with DC Common Bus through 8720MC-RPS
To meet CE requirements when your Kinetix 7000 system includes a common
DC bus with an 8720MC-RPS, follow all the requirements as stated in the CE
Requirements - System without LIM on page 19
, the recommended installation
and wiring in the 8720MC Regenerative Power Supply Reference Manual,
publication 8720MC-RM001
, and these additional requirements:
• Install a three-phase line filter on the AC input power line of the RPS as
indicated in Interconnect Diagrams beginning on page 161
.
• Install a single-phase line filter when attaching an AC line input to the
RPS MC1/2 circuit as indicated in the Interconnect Diagrams beginning
on page 161
.
IMPORTANT
The full rated current on the AC input line should not exceed that of the line
interface module.
Catalog numbers 2094-XL75S-Cx 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-BMxx-S
drive.
Never use a LIM in an ungrounded input, due to the potential for high line-
to-neutral voltages damaging components within the line filter.
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Allen-Bradley 2099-BM08-S User manual

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