Page 1 User Manual Original Instructions Kinetix 5500 Servo Drives Catalog Numbers 2198-H003-ERS, 2198-H008-ERS, 2198-H015-ERS, 2198-H025-ERS, 2198-H040-ERS, 2198-H070-ERS 2198-H003-ERS2, 2198-H008-ERS2, 2198-H015-ERS2, 2198-H025-ERS2, 2198-H040-ERS2, 2198-H070-ERS2, 2198-CAPMOD-1300...
Page 2 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.
Page 3: Table Of Contents
Start About the Kinetix 5500 Servo Drive System ..... 15 Drive Hardware and Input Power Configurations ....17 Standalone Configurations .
Page 4 Connector Data and Feature Kinetix 5500 Connector Data ........62 Module Status Connector Pinout .
Page 5 Download the Program ........142 Apply Power to the Kinetix 5500 Drive ......143 Applying Power after Changing Input Voltage Range.
Page 6 Fault Codes ..........157 Kinetix 5500 Drive Status Indicators ..... . . 158 Kinetix 5500 Capacitor Module Status Indicators .
Page 7 Kinetix 5500 Servo Drive and Rotary Motor Wiring Examples . . . 199 Kinetix 5500 Drive and Linear Actuator Wiring Examples..201 System Block Diagrams ........205...
Page 8 Control Power Current Calculations ......224 Kinetix 5500 System Current Demand Example ... . 225 Energy Calculations .
Page 9 Table of Contents Commutation Test......... . . 262 Adaptive Tuning .
Page 10 Table of Contents Notes: Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 11: Preface
Topic Page Added Access the Attachments that explains how the fault code tables (FLT Sxx, FLT Mxx, and INIT FLT for example), previously in Troubleshoot the Kinetix 5500 Drive System (chapter 7), moved to the attached spreadsheet. Added Kinetix VP (Bulletin VPH) hygienic stainless-steel servo motors as another rotary motor compatible with Kinetix 5500 servo drives.
Page 12: Conventions Used In This Manual
Kinetix Motion Accessories Specifications Technical Data, publication KNX-TD004 connector kits, drive power components, and other servo drive accessory items. Provides information on how to install AC line filters designed for Kinetix 5500 and AC Line Filter Installation Instructions, publication 2198-IN003 Kinetix 5700 servo drive systems.
Page 13 Kinetix 5500 Drive Systems Design Guide, publication KNX-RM009 accessory, feedback connector kit, and motor cable catalog numbers for your Kinetix 5500 drive and Kinetix VP motor motion control system. Rockwell Automation Product Selection Online product selection and system configuration tools, including AutoCAD (DXF) website http://www.rockwellautomation.com/global/support/selection.page...
Page 14 Preface Notes: Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 15: Start
Catalog Number Explanation Agency Compliance About the Kinetix 5500 The Kinetix 5500 servo drives are designed to provide a Kinetix Integrated Motion solution for your drive and motor/actuator application. Servo Drive System Table 2 - Kinetix 5500 Drive System Overview Drive System Cat.
Page 16 Ethernet cables are available in standard lengths. Shielded cable is recommended. 2198-DB08-F Bulletin 2198 three-phase AC line filters are required to meet CE and available for use in all Kinetix 5500 drive systems. Use 2198-DB20-F 2198-DBxx-F filters as field replacements in existing installations. Select 2198-DBRxx-F filters for all new systems and do not 2198-DB42-F remove the servo drive ground screws.
Page 17: Drive Hardware And Input Power Configurations
Start Chapter 1 Drive Hardware and Input Typical Kinetix 5500 systems include single-phase and three-phase standalone configurations, three-phase shared AC, shared AC/DC, shared DC, and Power Configurations shared AC/DC hybrid configurations. Standalone Configurations In these examples, a single standalone drive is shown with and without the Bulletin 2198 capacitor module.
Page 18 All drives must have the same power rating (catalog number). Figure 2 - Typical Shared AC Installations Three-phase Input Power Line Bonded Cabinet Kinetix 5500 Servo Drives (top view) Disconnect Ground Bus (2198-H008-ERS drives shown) Device 2198-DBRxx-F Input...
Page 19: Shared Ac/Dc Configurations
All drives must be the same power rating (catalog number). Figure 3 - Typical Shared AC/DC Installations Three-phase Input Power Line Bonded Cabinet Disconnect Kinetix 5500 Servo Drives (top view) Ground Bus Device (2198-H015-ERS drives shown) 2198-DBRxx-F Input 2198-CAPMOD-1300 Capacitor Module AC Line Filter...
Page 20: Shared Dc Common-Bus Configurations
Figure 4 - Typical Shared DC Common-bus Installations Three-phase Input Power Line Bonded Cabinet Disconnect Ground Bus Kinetix 5500 Servo Drive System (top view) Device 2198-DBRxx-F Input AC Line Filter Fusing (can be required for CE) Shared DC (DC common bus)
Page 21: Shared Ac/Dc Hybrid Configuration
Figure 5 - Typical Shared AC/DC Bus Hybrid Installations Three-phase Input Power Line Bonded Cabinet Disconnect Ground Bus Kinetix 5500 Servo Drive System (top view) Device 2198-DBRxx-F Input AC Line Filter Fusing (can be required for CE) Shared AC (mains AC input)
Page 22: Motor Feedback And Feedback-Only Configurations
Chapter 1 Start Motor Feedback and Feedback connections are made at the 2-pin motor feedback (MF) connector. These examples illustrate how you can use the Bulletin 2198 connector kits for Feedback-only making these connections. To see motor power and brake connections, refer to Configurations Chapter 5 page...
Page 23: Typical Communication Configurations
1769-TD005, for more information on CompactLogix 5370 L1, L2, and L3 controllers. Linear Topology In this example, all devices are connected in linear topology. The Kinetix 5500 drives include dual-port connectivity, however, if any device becomes disconnected, all devices downstream of that device lose communication.
Page 24: Ring Topology
Embedded Switch Technology Application Guide, publication ENET-AP005. Devices without dual ports, for example the display terminal, require a 1783-ETAP module to complete the network ring. Figure 8 - Kinetix 5500 Ring Communication Installation CompactLogix Controller Programming Network CompactLogix 5370 Controller...
Page 25: Star Topology
In this example, the devices are connected by using star topology. Each device is connected directly to the switch. Kinetix 5500 drives have dual ports, so linear topology is maintained from drive-to-drive, but Kinetix 5500 drives and other devices operate independently.
Page 26: Safe Torque-Off Configurations
Chapter 1 Start Safe Torque-off Kinetix 5500 servo drives are available with safe torque-off via hardwired connections or integrated over the EtherNet/IP network. These examples Configurations illustrate the safe torque-off configuration options. Hardwired Safety Configuration The 2198-Hxxx-ERS drives use the safe torque-off (STO) connector for wiring external safety devices and cascading hardwired safety connections from one drive to another.
Page 27: Integrated Safety Configurations
Safety Device 1783-BMS Stratix 5700 Switch 2198-Hxxx-ERS2 Servo Drives 1606-XLxxx (front view) Allen-Bradley 24V DC Control, Digital Inputs, 1606-XL Powe r S u p p l y and Motor Brake Power (customer-supplied) Input AC Input Power Motion and Safety Connections to the Drive...
Page 28 (top view) POINT Guard I/O EtherNet/IP Adapter 1783-BMS Safety Stratix 5700 Device Switch 1606-XLxxx Allen-Bradley 24V DC Control, Digital Inputs, 1585J-M8CBJM-x 1606-XL Powe r S u p p l y and Motor Brake Power 2198-Hxxx-ERS2 Servo Drives Ethernet (shielded) Cable (customer-supplied)
Page 29: Catalog Number Explanation
Start Chapter 1 Catalog Number Explanation Kinetix 5500 drive catalog numbers and performance descriptions. Table 3 - Kinetix 5500 Servo Drive Catalog Numbers Continuous Output Continuous Output Drive Cat. No. Drive Cat. No. Power Current Frame Size Input Voltage (hardwired STO)
Page 30: Agency Compliance
2090-CSxM1Dx-10Axxx (10 AWG/M40 connector) single cables are not compatible with 2090-CPBM7DF-10Axxx (10 AWG/M40 connector) power/brake cables. • Install the Kinetix 5500 system inside an approved enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure.
Page 31: Plan The Kinetix 5500 Drive System Installation
Chapter Plan the Kinetix 5500 Drive System Installation This chapter describes system installation guidelines used in preparation for mounting your Kinetix® 5500 drive components. Topic Page System Design Guidelines Electrical Noise Reduction 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.
Page 32: System Design Guidelines
AutoCAD (DXF) drawings of the product, refer to https://www.rockwellautomation.com/global/support/selection.page. System Mounting Requirements • To comply with UL and CE requirements, the Kinetix 5500 drive systems must be enclosed in a grounded conductive enclosure offering protection as defined in standard IEC 60529 to IP20 such that they are not accessible to an operator or unskilled person.
Page 33: Ac Line Filter Selection
Plan the Kinetix 5500 Drive System Installation Chapter 2 AC Line Filter Selection An AC line filter is required to meet CE requirements. Install an AC line filter for input power as close to the 2198-Hxxx-ERSx drive as possible. IMPORTANT AC line filters are only recommended with grounded WYE power configurations.
Page 34: Transformer Selection
However, a transformer can be required to match the voltage requirements of the drive to the available service. To size a transformer for the main AC power inputs, refer to the Kinetix 5500 power specifications in the Kinetix Servo Drives Technical Data, publication KNX-TD003.
Page 35 Plan the Kinetix 5500 Drive System Installation Chapter 2 Standalone Drive Systems Kinetix 5500 Drives UL Applications IEC (non-UL) Applications Bussmann Fuses Molded Case CB DIN gG Fuses Molded Case CB Drive Cat. No. Drive Voltage, nom Phase Cat. No.
Page 36 Chapter 2 Plan the Kinetix 5500 Drive System Installation Table 10 - Input Power IEC (non-UL) Circuit-protection Specifications DIN gG Fuses Molded Case CB Drive Voltage, Kinetix 5500 Drives Amps (max) Cat. No. (three-phase) Cat. No. 2 Axes 3 Axes...
Page 37: 24V Control Power Evaluation
Chapter 2 24V Control Power Evaluation The Kinetix 5500 drive system requires 24V DC input for its control circuitry. Due to the 24V shared-bus connection system and the 24V current requirements of the Kinetix 5500 drives, a thorough evaluation of control power is required prior to implementation.
Page 38: Passive Shunt Considerations
Plan the Kinetix 5500 Drive System Installation Passive Shunt Considerations The Kinetix 5500 drives all include an internal shunt that is wired to the shunt resistor (RC) connector at the factory. Bulletin 2097-Rx external passive shunts are available to provide additional shunt capacity for applications where the internal shunt capacity is exceeded.
Page 39: Enclosure Selection
A = (2dw + 2dh + 2wh) /144 Where d (depth), w (width), and h (height) are in meters. If the maximum ambient rating of the Kinetix 5500 drive system is 50 °C (122 °F) and if the maximum environmental temperature is 20 °C (68 °F), then T=30.
Page 40: Minimum Clearance Requirements
Chapter 2 Plan the Kinetix 5500 Drive System Installation Table 14 - Power Dissipation Specifications Usage as % of Rated Power Output Kinetix 5500 Drive Frame (watts) Cat. No. Size 100% 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx Minimum Clearance Requirements...
Page 41: Electrical Noise Reduction
Electrical Noise Reduction This section outlines best practices that minimize the possibility of noise- related failures as they apply specifically to Kinetix 5500 system installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001.
Page 42 Chapter 2 Plan the Kinetix 5500 Drive System Installation These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets. Figure 16 - Recommended Bonding Practices for Painted Panels Stud-mounting the Subpanel Stud-mounting a Ground Bus...
Page 43: Bonding Multiple Subpanels
Plan the Kinetix 5500 Drive System Installation Chapter 2 Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together do not necessarily share a common low impedance path. This...
Page 44: Establishing Noise Zones
Plan the Kinetix 5500 Drive System Installation Establishing Noise Zones Observe these guidelines when routing cables used in the Kinetix 5500 system: • The clean zone (C) is right of the drive system and includes the digital inputs wiring and Ethernet cable (gray wireway).
Page 45: Cable Categories For Kinetix 5500 Systems
Plan the Kinetix 5500 Drive System Installation Chapter 2 Cable Categories for Kinetix 5500 Systems These tables indicate the zoning requirements of cables connecting to the Kinetix 5500 drive components. Table 15 - Kinetix 5500 Drive Zone Method Wire/Cable Connector...
Page 46: Noise Reduction Guidelines For Drive Accessories
44 for an example): • Mount the AC line filter on the same panel as the Kinetix 5500 drive and as close to the drive as possible. • Good HF bonding to the panel is critical. For painted panels, refer to...
Page 47 Plan the Kinetix 5500 Drive System Installation Chapter 2 External Passive Shunt Resistor Observe these guidelines when mounting your Bulletin 2097 external passive-shunt resistor outside of the enclosure: • Mount shunt resistor and wiring in the very dirty zone or in an external shielded enclosure.
Page 48 Chapter 2 Plan the Kinetix 5500 Drive System Installation When mounting your Bulletin 2097 passive-shunt resistor inside the enclosure, follow these additional guidelines: • Mount metal-clad modules anywhere in the dirty zone, but as close to the Kinetix 5500 drive as possible.
Page 49 SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Kinetix 5500 drives prior to applying power. Once power is applied, connector terminals can have voltage present even when not in use. ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure.
Page 50: Determine Mounting Order
Chapter 3 Mount the Kinetix 5500 Drive System Determine Mounting Order Mount drives in order (left to right) according to power rating (highest to lowest) starting with the highest power rating. If power rating is unknown, position drives (highest to lowest) from left to right based on amp rating.
Page 51: Shared-Bus Connection System
Mount the Kinetix 5500 Drive System Chapter 3 Shared-bus Connection System The shared-bus connection system is used to extend the mains AC input, 24V control input, and the DC bus power from drive-to-drive in shared-bus multi- axis configurations. IMPORTANT When the shared-bus connection system is used, the zero-stack tab and cutout must be engaged between adjacent drives.
Page 52: Single-Axis Configurations
Chapter 3 Mount the Kinetix 5500 Drive System Single-axis Configurations The following restrictions exist for standalone (single-axis) configurations: • Standalone (single-axis) drives can be mounted to the panel individually or by using the zero-stack tab and cutout (refer to Figure 23 on page •...
Page 53: Drill-Hole Patterns
Hybrid Number of capacitor modules connected, max 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx (1) Catalog number 2198-H003-ERS and any drive in standalone single-phase operation is not compatible with the Kinetix 5500 capacitor module. Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 54 Chapter 3 Mount the Kinetix 5500 Drive System These hole patterns apply to standalone drives. Figure 24 - Frame 1, Frame 2, and Frame 3 Standalone Hole Patterns Frame 3 Frame 1 Frame 2 Standalone Drive Standalone Drive Standalone Drive ØM4 (#8-32)
Page 55 Mount the Kinetix 5500 Drive System Chapter 3 These hole patterns apply when all drives in the system are frame 1 or frame 2. There is 50 mm (2.0 in.) between mounting holes (A-to-A and B-to-B). Figure 25 - Frame 1 and Frame 2 Hole Patterns...
Page 56 Chapter 3 Mount the Kinetix 5500 Drive System This hole pattern applies when transitioning from frame 2 drives to frame 1 drives. To mount additional frame 1 drives to the right of Axis 2 in this figure, refer to the frame 1 hole pattern in...
Page 57 Mount the Kinetix 5500 Drive System Chapter 3 This hole pattern applies when all drives in the system are frame 3 drives. There is 85.20 mm (3.4 in.) between mounting holes, as shown. Figure 27 - Frame 3 Hole Pattern...
Page 58 Chapter 3 Mount the Kinetix 5500 Drive System This hole pattern applies when transitioning from frame 3 drives to frame 1 drives. To mount additional frame 1 drives to the right of Axis 2 in this figure, refer to the frame 1 hole pattern in...
Page 59 Mount the Kinetix 5500 Drive System Chapter 3 This hole pattern applies when transitioning from frame 3 drives to frame 2 drives. To mount additional frame 2 drives to the right of Axis 2 in this figure, refer to the frame 2 hole pattern in...
Page 60: Mount Your Kinetix 5500 Drive
Follow these steps to mount your Kinetix 5500 drives to the panel. 1. Lay out the hole pattern for each Kinetix 5500 drive in the enclosure. Refer to Establishing Noise Zones...
Page 61 This chapter illustrates drive connectors and indicators, including connector pinouts, and provides descriptions for Kinetix® 5500 drive features. Topic Page Kinetix 5500 Connector Data Understand Control Signal Specifications Feedback Specifications Safe Torque-off Safety Features Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 62: Kinetix 5500 Connector Data
Kinetix 5500 Connector Data Use these illustrations to identify the connectors and indicators for the Kinetix 5500 drive modules. Figure 30 - Kinetix 5500 Drive Features and Indicators Kinetix 5500 Drive, Front View (2198-H003-ERSx drive is shown) Kinetix 5500, Top View...
Page 63: Module Status Connector Pinout
Connector Data and Feature Descriptions Chapter 4 Figure 31 - Capacitor Module Features and Indicators Kinetix 5500 Capacitor Module Top View Kinetix 5500 Capacitor Module Front View Item Description Ground screw (green) Module status (MS) connector (relay output) Module status indicator...
Page 64: Input Power Connector Pinouts
Chapter 4 Connector Data and Feature Descriptions Input Power Connector Pinouts Table 19 - Mains Input Power Connector IPD Pin Description Signal Chassis ground Three-phase input power Table 20 - 24V Input Power Connector CP Pin Description Signal 24V power supply, customer supplied 24V+ 24V common 24V-...
Page 65: Digital Inputs Connector Pinouts
Connector Data and Feature Descriptions Chapter 4 Digital Inputs Connector Pinouts The Kinetix 5500 drive has two configurable digital inputs and 5 configurable functions to choose from in the Logix Designer application. Digital input 1 can be configured as a dual-function (home/registration) input.
Page 66: Motor Power, Brake, And Feedback Connector Pinouts
Three-phase motor power Black Blue Chassis ground Green ATTENTION: To avoid damage to the Kinetix 5500 DC-bus power supply and inverter, make sure the motor power signals are wired correctly. Refer to Connector Wiring page 88 for motor power connector wiring examples.
Page 67: Understand Control Signal Specifications
Connector Data and Feature Descriptions Chapter 4 Understand Control Signal This section provides a description of the Kinetix 5500 digital inputs, Ethernet communication, power and relay specifications, encoder feedback Specifications specifications, and safe torque-off features. Digital Inputs Two digital inputs are available for the machine interface on the IOD connector.
Page 68: Ethernet Communication Specifications
Connector Data and Feature Descriptions Figure 34 - Digital Input Circuitry IOD-1 or IOD-3 INPUT 24V DC IOD-2 Kinetix 5500 Drive Ethernet Communication Specifications The PORT1 and PORT2 (RJ45) Ethernet connectors are provided for communication with the Logix 5000™ controller. Attribute Value The drive auto-negotiates speed and duplex modes.
Page 69 Turn-on and turn-off delays are specified by the MechanicalBrakeEngageDelay and MechanicalBrakeReleaseDelay settings. IMPORTANT Holding brakes that are available on Allen-Bradley® rotary motors are designed to hold a motor shaft at 0 rpm for up to the rated brake- holding torque, not to stop the rotation of the motor shaft, or be used as a safety device.
Page 70: Control Power
Connector Data and Feature Descriptions Control Power The Kinetix 5500 drive requires 24V DC input power for control circuitry. IMPORTANT SELV and PELV rated power supplies must be used to energize external safety devices connected to the Kinetix 5500 safety inputs.
Page 71: Absolute Position Feature
Connector Data and Feature Descriptions Chapter 4 Absolute Position Feature The absolute position feature of the drive tracks the position of the motor, within the multi-turn retention limits, while the drive is powered off. The absolute position feature is available with only multi-turn encoders. Table 31 - Absolute Position Retention Limits Retention Limits Cat.
Page 72: Safe Torque-Off Safety Features
Chapter 4 Connector Data and Feature Descriptions Safe Torque-off Safety Kinetix 5500 servo drives have safe torque-off (STO) capability and can safely turn off the inverter power transistors in response to a monitored digital input, Features according to Category 0 Stop behavior.
Page 73 Chapter Connect the Kinetix 5500 Drive System This chapter provides procedures for wiring your Kinetix® 5500 system components and making cable connections. Topic Page Basic Wiring Requirements Determine the Input Power Configuration Ground Screw Settings Remove the Ground Screws in Select Power Configurations...
Page 74: Basic Wiring Requirements
Connect the Kinetix 5500 Drive System Basic Wiring Requirements This section contains basic wiring information for the Kinetix 5500 drives. ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure.
Page 75: Determine The Input Power Configuration
Connect the Kinetix 5500 Drive System Chapter 5 Determine the Input Power Before wiring input power to your Kinetix 5500 system, you must determine the type of input power within your facility. The drive is designed to operate in Configuration both grounded and ungrounded environments.
Page 76 Chapter 5 Connect the Kinetix 5500 Drive System Figure 38 - Impedance-grounded Power Configuration (WYE Secondary) Kinetix 5500 Servo Drive (top view) Transformer (WYE) Secondary AC Screw DC Screw Transformer Three-phase Circuit Input VAC Protection Phase Ground Connect to Bonded Cabinet Ground...
Page 77: Ungrounded Power Configurations
Connect the Kinetix 5500 Drive System Chapter 5 Figure 40 - Grounded Power Configuration (single-phase input) Kinetix 5500 Servo Drive (top view) Transformer (WYE) Secondary Transformer Three-phase AC Line Filter (can be required for CE) Three-phase Circuit Input VAC Protection...
Page 78: Ground Screw Settings
Power Wiring Examples beginning on page 194 for input power interconnect diagrams. Ground Screw Settings Determine the ground screw setting for your Kinetix 5500 servo drives. Table 32 - Ground Screw Settings Ground Configuration Example Diagram Ground Screw Setting Grounded (wye)
Page 79: Remove The Ground Screws In Select Power Configurations
Connect the Kinetix 5500 Drive System Chapter 5 Remove the Ground Screws Removing the ground screws involves gaining access, opening the sliding door, and removing the screws. in Select Power Configurations IMPORTANT If you have grounded-wye power distribution, you do not need to remove the ground screws.
Page 80: Ground The Drive System
Agency Compliance page Ground the System Subpanel Ground Kinetix 5500 drives and 2198-CAPMOD-1300 capacitor modules to a bonded cabinet ground bus with a braided ground strap. Keep the braided ground strap as short as possible for optimum bonding. Figure 43 - Connecting the Ground Terminal...
Page 81: Ground Multiple Subpanels
Connect the Kinetix 5500 Drive System Chapter 5 Ground Multiple Subpanels In this figure, the chassis ground is extended to multiple subpanels. Figure 44 - Subpanels Connected to a Single Ground Point Follow NEC and applicable local codes. Bonded Ground Bus...
Page 82: Wiring Requirements
Chapter 5 Connect the Kinetix 5500 Drive System Wiring Requirements Wires must be copper with 75 °C (167 °F) minimum rating. Phasing of main AC power is arbitrary and earth ground connection is required for safe and proper operation. Refer to...
Page 83: Wiring Guidelines
Establishing Noise Zones page Follow these steps when wiring the connectors for your Kinetix 5500 drive. 1. Prepare the wires for attachment to each connector plug by removing insulation equal to the recommended strip length. IMPORTANT Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.
Page 84: Wire The Power Connectors
Chapter 5 Connect the Kinetix 5500 Drive System Wire the Power Connectors This section provides examples and guidelines to assist you in making connections to the input power connectors. Refer to Power Wiring Examples page 194 for an interconnect diagram.
Page 85: Wire The Input Power Connector
Connect the Kinetix 5500 Drive System Chapter 5 Wire the Input Power Connector The input power (IPD) connector requires 195…528V AC (single-phase or three-phase) for mains input power. The single-axis connector plug is included with the drive, shared-bus connector kits are purchased separately.
Page 86: Wire The Digital Input Connectors
Chapter 5 Connect the Kinetix 5500 Drive System Figure 48 - IPD Connector Wiring - Shared Bus Mains AC Input Wiring Connector Kinetix 5500 Drives Top View Table 37 - Shared Bus IPD Connector Wiring Specifications Recommended Input Current, max...
Page 87: Wire The Digital Inputs Connector
IMPORTANT Due to the unique characteristics of single cable technology, designed for and tested with Kinetix 5500 drives and Kinetix VP motors, you cannot build your own cables or use third-party cables.
Page 88: Maximum Cable Lengths
Agency Compliance page 30 for additional cable length details. Motor Power Connections Refer to Kinetix 5500 Servo Drive and Rotary Motor Wiring Examples page 199 for an interconnect diagram. Figure 50 - MP Connector Wiring Kinetix 5500 Servo Drive (front view)
Page 89: Motor Brake Connections
Connect the Kinetix 5500 Drive System Chapter 5 Table 40 - Motor Power (MP) Connector Specifications Recommended Wire Size Strip Length Torque Value Drive Cat. No. Signal/Wire Color (AWG) mm (in.) N•m (lb•in) 2198-H003-ERSx Motor power cable depends on 2198-H008-ERSx motor/drive combination.
Page 90: Motor Feedback Connections
Kinetix 5500 drives. IMPORTANT When using the 2198-KITCON-DSL feedback connector kit, the ambient temperature for the Kinetix 5500 drive enclosure is 0…50 °C (32…122 °F). Figure 52 - MF Connector Wiring Kinetix 5500 Servo Drive...
Page 91: Apply The Single Motor-Cable Shield Clamp
Connect the Kinetix 5500 Drive System Chapter 5 Apply the Single Motor-cable Shield Clamp Factory-supplied 2090-Series single motor cables are shielded, and the braided cable shield must terminate at the drive during installation. A small portion of the cable jacket has been removed to expose the shield braid. The exposed area must be clamped (with the clamp provided) at the bottom front of the drive.
Page 92: Wire Other Allen-Bradley Motors And Actuators
1 through step 3 for each drive in multi-axis configurations. Kinetix 5500 drives are also compatible with many other Allen-Bradley® Wire Other Allen-Bradley motors and actuators, however the 2198-H2DCK Hiperface-to-DSL feedback Motors and Actuators converter kit is required for converting the 15-pin Hiperface feedback signals to 2-pin DSL feedback signals.
Page 93: Install The Kinetix 5500 Add-On Profile
Chapter 5 IMPORTANT To configure these additional motors and actuators (see Table 44) with your Kinetix 5500 servo drive, you must have drive firmware 2.002 or later. Refer to Table 43 to determine if you need to install the Kinetix 5500 Add-on Profile.
Page 94: Motor Power And Brake Connections
Chapter 5 Connect the Kinetix 5500 Drive System Motor Power and Brake Connections The motors and actuators in Table 44 have separate power/brake and feedback cables. The motor power/brake cable attaches to the cable clamp on the drive and the power/brake conductors attach to the MP and BC connectors, respectively.
Page 95: Motor Power/Brake Cable Series Change
Conductors Brake Shield (remove) 635 (25) To reuse your existing (series A) Bulletin 2090 cables with Kinetix 5500 drives, some preparation is necessary so that the cable shield, conductor, and strip lengths are correct. Follow these cable preparation guidelines: • Trim the shield flush so that no strands can short to adjacent terminals.
Page 96: Maximum Cable Lengths
Cable Preparation for Frame 3 Drives 2090-CPBM7DF (series B) 12 and 10 AWG cables are designed for use with Kinetix 5500 drives and do not require any modifications. For frame 3 drives, 2090-CPBM7DF (14 AWG) cables, and 12 and 10 AWG...
Page 97 Connect the Kinetix 5500 Drive System Chapter 5 Follow these steps to prepare your existing 14 AWG cables, and 12 and 10 AWG (series A) cables. 1. Remove a total of 325 mm (12.8 in.) of cable jacket from your existing cable.
Page 98: Apply The Motor Power/Brake Shield Clamp
Chapter 5 Connect the Kinetix 5500 Drive System Apply the Motor Power/brake Shield Clamp The power/brake cable shield attaches to the drive cable clamp. A clamp spacer is included with the 2198-H2DCK feedback converter kit for cable diameters that are too small for a tight fit within the drive clamp alone.
Page 99 Connect the Kinetix 5500 Drive System Chapter 5 Figure 56 - Cable Clamp Attachment Service Loops Frame 1 Frame 2 Frame 3 Clamp Compressed Servo Drive Servo Drive Servo Drive Around Shield Clamp features apply to all (no spacer required) frame sizes.
Page 100: Motor Feedback Connections
Table 47 Table 48, the ambient temperature for the Kinetix 5500 drive enclosure is derated to 0…40 °C (32…104 °F). All of the current and legacy feedback cables listed below are compatible with the 2198-H2DCK (series B or later) converter kit.
Page 101: Motor Feedback Cable Preparation
Connect the Kinetix 5500 Drive System Chapter 5 Figure 57 - 2198-H2DCK Converter Kit Pinout Strip Length Torque Value Terminal Signal Wire Color mm (in.) N•m (lb•in) SIN+ Black SIN– White/Black 10-pin Connector COS+ COS– White/Red DATA+ Green 0.22…0.25 5.0 (0.2) (1.9…2.2)
Page 102 Chapter 5 Connect the Kinetix 5500 Drive System Apply the Converter Kit Shield Clamp Follow these steps to apply the converter kit shield clamp. 1. Apply the shield clamp to the 12 mm (0.5 in.) of exposed cable shield to achieve a high-frequency bond between the shield braid and clamp.
Page 103 Connect the Kinetix 5500 Drive System Chapter 5 Table 49 - 2090-CFBM7DF-CEAxxx Feedback Cables MPL-B15xxx…MPL-B2xxx-V/Ex4/7xAA MPL-A15xxx…MPL-A2xxx-V/Ex4/7xAA MPL-B3xxx…MPL-B6xxx-M/Sx7xAA MPL-A3xxx-M/Sx7xAA MPL-A5xxx-M/Sx7xAA MPL-A4xxx-M/Sx7xAA MPL-A45xxx-M/Sx7xAA MPM-A165xxx…MPM-A215xxx Rotary Motors MPM-A115xxx…MPM-A130xxx-M/S MPM-Bxxxxx-M/S MPF/MPS-A3xx-M/S MPF-Bxxx-M/S 2198-H2DCK MPF/MPS-A4xx-M/S MPF-A5xxx-M/S Converter Kit Pin MPF/MPS-A45xx-M/S MPS-Bxxx-M/S MPS-A5xxx-M/S MPAS-Bxxxxx-VxxSxA MPAR-Bxxxx, MPAS-Axxxxx-VxxSxA...
Page 104: Capacitor Module Connections
Chapter 5 Connect the Kinetix 5500 Drive System Capacitor Module Follow these guidelines when wiring the 2198-CAPMOD-1300 capacitor module: Connections • Wire output (MS) connections to the Logix 5000™ controller (optional). • Refer to Kinetix 5500 Capacitor Module wiring example on page 195.
Page 105: External Passive-Shunt Resistor Connections
Connect the Kinetix 5500 Drive System Chapter 5 External Passive-shunt Follow these guidelines when wiring your 2097-Rx shunt resistor: • Refer to External Passive Shunt Resistor page 47 for noise zone Resistor Connections considerations. • Refer to Shunt Resistor Wiring Example page 198.
Page 106: Ethernet Cable Connections
Connect the Kinetix 5500 Drive System Ethernet Cable Connections This procedure assumes you have your Logix 5000 controller and Kinetix 5500 drive modules mounted and are ready to connect the network cables. The EtherNet/IP™ network is connected by using the PORT 1 and PORT 2 connectors.
Page 107: Configure And Start The Kinetix 5500 Drive System
Chapter Configure and Start the Kinetix 5500 Drive System This chapter provides procedures for configuring your Kinetix® 5500 drive system with a Logix 5000™ controller. Topic Page Understand the Kinetix 5500 Display Configure the Drive Studio 5000 Logix Designer Configure the Logix 5000 Controller...
Page 108: Understand The Kinetix 5500 Display
MOTOR INFO Press to return to the Home screen. Press to display the fault help (possible solutions in troubleshooting tables). (1) Refer to the Kinetix 5500 Fault Codes.xlsx file to review the troubleshooting tables. See Access the Attachments page 13 information on accessing the Kinetix 5500 Fault Codes.xlsx file.
Page 109: Menu Screens
110%. Fault help • Reduce the number of drives in the same bus group The Possible Solution as reported in the Kinetix 5500 Fault Codes.xlsx file. • Reduce duty-cycle of commanded motion (1) See Access the Attachments page 13 for information on accessing the Kinetix 5500 Fault Codes.xlsx file.
Page 110: Setup Screens
Chapter 6 Configure and Start the Kinetix 5500 Drive System Setup Screens The setup screens provide the means of changing drive settings, for example, the IP address. Press one of the setup buttons to access the setup screens. You can use the soft menu items and navigation buttons to SETTINGS view the information and make changes.
Page 111 Configure and Start the Kinetix 5500 Drive System Chapter 6 Table 52 - Navigating the Settings Menu Settings Menu Selections Sub Menu Selections Attributes Default Description ENABLED When Enabled (default), identity object or safety resets are Reset ENABLED DISABLED not possible when a controller connection is open.
Page 112: Startup Sequence
Chapter 6 Configure and Start the Kinetix 5500 Drive System Startup Sequence On initial powerup, the drive performs a self test. Upon successful completion, the drive firmware revision is displayed. until Kinetix 5500 is spelled out… Kinetix 55 Kinetix 5500 then…...
Page 113: Configure The Drive
Each release of the Studio 5000 Logix Designer application makes possible the configuration of additional Allen-Bradley® motors, actuators, and drive features not available in previous versions. IMPORTANT To configure these additional drive features with your Kinetix 5500 servo drive, you must have drive firmware 4.001 or later. Refer to Table 54 determine if you need to install the Kinetix 5500/5700 Add-on Profile.
Page 114: Install The Kinetix 5500 Add-On Profile
Download Add-On profiles (AOP) from the Product Compatibility Download Center (PCDC) website: http://compatibility.rockwellautomation.com/Pages/home.aspx. Follow these steps to download the Kinetix 5500 Add-On profile. 1. Go to the Product Compatibility Download Center. The Compatibility & Downloads webpage appears. 2. Click Download.
Page 115: Configure The Logix 5000 Controller
Configure and Start the Kinetix 5500 Drive System Chapter 6 Configure the Logix 5000 These procedures assume that you have wired your Kinetix 5500 drive system. In this example, the GuardLogix® 5570 safety controller, ControlLogix 1756- Controller EN2T communication module, and CompactLogix 5370 controller dialog boxes are shown.
Page 116 Chapter 6 Configure and Start the Kinetix 5500 Drive System In this example, the typical dialog boxes for 1756-ENxT EtherNet/IP modules and CompactLogix 5370 controllers with embedded Ethernet are shown. Follow these steps to configure your Logix 5000 controller. 1. Expand the Logix 5000 controller family and select your controller.
Page 117 Configure and Start the Kinetix 5500 Drive System Chapter 6 7. From the Edit menu, choose Controller Properties. The Controller Properties dialog box appears. 8. Click the Date/Time tab. 9. Check Enable Time Synchronization. The motion modules set their clocks to the module you assign as the Grandmaster.
Page 118: Configure The Kinetix 5500 Drive
2198-Hxxx-ERS2 Configure Drive with Integrated Safety Connections Configure Drive with Hardwired Safety Connections Follow these steps to configure Kinetix 5500 drives with hardwired safety. 1. Below the controller you just created, right-click Ethernet and choose New Module. The Select Module Type dialog box appears.
Page 119 Configure and Start the Kinetix 5500 Drive System Chapter 6 The New Module dialog box appears. 4. Configure the new drive. a. Type the drive Name. b. Select an Ethernet Address option. In this example, the Private Network address is selected.
Page 120 Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure Drive with Integrated Safety Connections Follow these steps to configure Kinetix 5500 drives with integrated safety. 1. Below the controller you just created, right-click Ethernet and choose New Module.
Page 121 Configure and Start the Kinetix 5500 Drive System Chapter 6 In this example, the Private Network address is selected. c. Enter the address of your 2198-Hxxx-ERS2 servo drive. In this example, the last octet of the address is 2. d. Under Module Definition click Change.
Page 122 Chapter 6 Configure and Start the Kinetix 5500 Drive System The Module Properties dialog box appears. 8. Click the Drive Safety tab. 9. From the Restart Type pull-down menu, choose Manual or Automatic depending on your specific application. • Manual restart indicates a transition from 0 to 1 on the SO.Reset tag is required to allow torque after the SO.SafeTorqueOff tag has...
Page 123 Configure and Start the Kinetix 5500 Drive System Chapter 6 If any differences are detected, the connection between the GuardLogix controller and the 2198-Hxxx-ERS2 drive is lost, and the yellow yield icon appears in the controller project tree after you download the program.
Page 124 Chapter 6 Configure and Start the Kinetix 5500 Drive System Continue Drive Configuration After you’ve established your Kinetix 5500 drive in the Logix Designer application, the remaining configuration steps are the same regardless of the drive catalog number. 1. Right-click the 2198-Hxxx-ERSx servo drive you just created and choose Properties.
Page 125 Configure and Start the Kinetix 5500 Drive System Chapter 6 The axis (Axis_1 in this example) appears in the Controller Organizer under Motion Groups> Ungrouped Axes and is assigned as Axis 1. TIP You can configure an axis as Feedback Only. Refer to...
Page 126 IMPORTANT Single-phase operation is possible only when Module Properties>Power tab>Bus Configuration is configured as Standalone. IMPORTANT The Logix Designer application enforces shared-bus configuration rules for Kinetix 5500 drives, except for shared AC configurations. Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 127 Configure and Start the Kinetix 5500 Drive System Chapter 6 12. From the pull-down menus, choose the power options appropriate for your actual hardware configuration. ATTENTION: To avoid damage to equipment, make sure the AC input voltage configured in the Logix Designer application matches the actual hardware being configured.
Page 128: Configure The Motion Group
Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure the Motion Group Follow these steps to configure the motion group. 1. In the Controller Organizer, right-click Motion Groups and choose New Motion Group. The New Tag dialog box appears.
Page 129: Configure Feedback-Only Axis Properties
Configure and Start the Kinetix 5500 Drive System Chapter 6 Configure Feedback-only Axis Follow these steps to configure feedback-only axis properties. Properties 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category. The General dialog box appears.
Page 130: Configure Induction-Motor Frequency-Control Axis Properties
Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure Induction-motor Follow these steps to configure induction-motor axis properties for various frequency control methods. Frequency-control Axis Properties General and Motor Categories 1. In the Controller Organizer, right-click an axis and choose Properties.
Page 131 Configure and Start the Kinetix 5500 Drive System Chapter 6 7. Select the Motor category. 8. From the Data Source pull-down menu, choose Nameplate Datasheet. This is the default setting. 9. From the Motor Type pull-down menu, choose Rotary Induction.
Page 132: Basic Volts/Hertz Method
Chapter 6 Configure and Start the Kinetix 5500 Drive System Basic Volts/Hertz Method 1. Configure the General tab and Motor tab as shown in General and Motor Categories page 130. 2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Basic Volts/Hertz.
Page 133 Configure and Start the Kinetix 5500 Drive System Chapter 6 The Motion Axis Parameters dialog box appears. 7. From the Parameter Group pull-down menu, choose Frequency Control. 8. Set the FluxUp, SkipSpeed, VelocityDroop, and CurrentVectorLimit attributes appropriate for your application.
Page 134: Sensorless Vector Method
Chapter 6 Configure and Start the Kinetix 5500 Drive System Sensorless Vector Method 1. Configure the General tab and Motor tab as shown in General and Motor Categories page 130. 2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Sensorless Vector.
Page 135 Configure and Start the Kinetix 5500 Drive System Chapter 6 9. Set the FluxUp, SkipSpeed, VelocityDroop, MaximumFrequency, MaximumVoltage, and CurrentVectorLimit attributes appropriate for your application. See the corresponding section in Appendix D, beginning on page 227, for information and configuration examples regarding all of these topics.
Page 136: Fan/Pump Volts/Hertz Method
Chapter 6 Configure and Start the Kinetix 5500 Drive System Fan/Pump Volts/Hertz Method 1. Configure the General tab and Motor tab as shown in General and Motor Categories page 130. 2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Fan/ Pump Volts/Hertz.
Page 137 Configure and Start the Kinetix 5500 Drive System Chapter 6 The Motion Axis Parameters dialog box appears. 7. From the Parameter Group pull-down menu, choose Frequency Control. 8. Set the FluxUp, SkipSpeed, VelocityDroop, RunBoost, MaximumFrequency, MaximumVoltage and CurrentVectorLimit attributes appropriate for your application.
Page 138: Configure Spm Motor Closed-Loop Control Axis Properties
Table 55 - Motor Feedback Compatibility Feedback Feedback Type Description Connector Applies to Allen-Bradley Bulletin MPL, MPM, MPF, MPS (-M/S or -V/E) rotary Hiperface motors and Bulletin MPAS (ballscrew), MPAR, MPAI linear actuators, and High-resolution 2-pin motor LDAT-Series (-xDx) linear thrusters, wired to the 2198-H2DCK converter kit.
Page 139 Configure and Start the Kinetix 5500 Drive System Chapter 6 4. From the Associated Module>Module pull-down menu, choose your Kinetix 5500 drive. The drive catalog number populates the Module Type and Power Structure fields. 5. Click Apply. 6. Select the Motor category.
Page 140 Chapter 6 Configure and Start the Kinetix 5500 Drive System 12. Select the Scaling category and edit the default values as appropriate for your application. 13. Click Apply, if you make changes. 14. Select the Load category and edit the default values as appropriate for your application.
Page 141 Configure and Start the Kinetix 5500 Drive System Chapter 6 The Actions to Take Upon Conditions dialog box appears. From this dialog box you can program actions for the drive module to take. Refer to Logix 5000 Controller and Drive Behavior page 161 for more information.
Page 142: Download The Program
Chapter 6 Configure and Start the Kinetix 5500 Drive System 18. Select the Parameter List category. The Motion Axis Parameters dialog box appears. From this dialog box you can set brake engage and release delay times for servo motors. For recommended motor brake delay times, refer to the Kinetix Rotary Motion Specifications Technical Data, publication KNX-TD001.
Page 143: Apply Power To The Kinetix 5500 Drive
Configure and Start the Kinetix 5500 Drive System Chapter 6 Apply Power to the This procedure assumes that you have wired and configured your Kinetix 5500 system and your Logix 5000 controller. Kinetix 5500 Drive SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2198 servo drives prior to applying power.
Page 144: Understand Bus-Sharing Group Configuration
Chapter 6 Configure and Start the Kinetix 5500 Drive System Understand Bus-sharing When configuring Module Properties>Power tab for each Kinetix 5500 servo drive, you can breakout drives from one or more servo systems into multiple Group Configuration bus-sharing (power) groups.
Page 145: Bus-Sharing Group Example
Configure and Start the Kinetix 5500 Drive System Chapter 6 Bus-sharing Group Example In this example, twelve axes are needed to support the motion application. All twelve axes are configured in the same Motion group in the Logix Designer application.
Page 146: Configure Bus-Sharing Groups
Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure Bus-sharing Groups Group 1 is a shared AC/DC hybrid configuration. The Bus Configuration for the first two converter drives is Shared AC/DC. The Bus Configuration for the inverter drives is Shared DC.
Page 147 Configure and Start the Kinetix 5500 Drive System Chapter 6 Group 2 is a shared DC (common-bus) configuration. The Bus Configuration for the leader drive is Shared AC/DC. The Bus Configuration for the follower drives is Shared DC. Figure 68 - Group 2 Leader Drive Configuration...
Page 148: Test And Tune The Axes
Configure and Start the Kinetix 5500 Drive System Test and Tune the Axes This procedure assumes that you have configured your Kinetix 5500 drive, your Logix 5000 controller, and applied power to the system. IMPORTANT Before proceeding with testing and tuning your axes, verify that the MOD...
Page 149 If the marker remains undetected and the test fails, the motor did not move the full test distance. Run this test after running the Motor Feedback and Motor and Feedback tests. Verifies the commutation offset and commutation polarity of the motor. For Kinetix 5500 drives, this Commutation test applies to only third-party motors.
Page 150: Tune The Axes
Chapter 6 Configure and Start the Kinetix 5500 Drive System Tune the Axes Choose the tuning procedure best suited for your motor type. Motor Type Go directly to Permanent magnet (PM) Tune Permanent Magnet Motors Induction Tune Induction Motors on...
Page 151 Configure and Start the Kinetix 5500 Drive System Chapter 6 3. Click the Load category in the Axis Properties dialog box. a. Check Use Load Ratio. b. Set the Load Ratio = 0. 4. Click the Observer category in the Axis Properties dialog box.
Page 152 Chapter 6 Configure and Start the Kinetix 5500 Drive System 5. Click the Compliance category in the Axis Properties dialog box. a. From the Adaptive Tuning Configuration pull-down menu, choose Tracking Notch. b. Click Apply. 6. Enable the drive for a few seconds with an MSO instruction or motion direct command, followed by an MSF instruction or motion direct command, to make sure that no audible squealing noise is present.
Page 153 Configure and Start the Kinetix 5500 Drive System Chapter 6 Tune Induction Motors IMPORTANT The Automatic FluxUpControl setting is recommended for best Autotune results. Follow these steps to tune the induction motor axes. 1. Verify the load is removed from the axis being tuned.
Page 154 Chapter 6 Configure and Start the Kinetix 5500 Drive System The Logix Designer - Autotune dialog box appears. When the test completes, the Test State changes from Executing to Success. Tuned values populate the Loop and Load parameter tables. Actual bandwidth values (Hz) depend on your application and can require adjustment once motor and load are connected.
Page 155: Safety Precautions
Chapter Troubleshoot the Kinetix 5500 Drive System This chapter provides troubleshooting tables and related information for your Kinetix® 5500 servo drives. Topic Page Safety Precautions Interpret Status Indicators General Troubleshooting Logix 5000 Controller and Drive Behavior Safety Precautions Observe the following safety precautions when troubleshooting your Kinetix 5500 servo drive.
Page 156: Interpret Status Indicators
Chapter 7 Troubleshoot the Kinetix 5500 Drive System Interpret Status Indicators Refer to these troubleshooting tables to identify faults, potential causes, and the appropriate actions to resolve the fault. If the fault persists after attempting to troubleshoot the system, contact your Rockwell Automation sales representative for further assistance.
Page 157: Fault Codes
For example, FLT S08 – MTR OVERLOAD UL. Fault Codes For fault code descriptions and possible solutions, see the Kinetix 5500 Fault Codes.xlsx file attached to this publication. For more information about the file, see...
Page 158: Kinetix 5500 Drive Status Indicators
Chapter 7 Troubleshoot the Kinetix 5500 Drive System Kinetix 5500 Drive Status Indicators The module status and network status indicators are just above the LCD status display. IMPORTANT Status indicators are not reliable for safety functions. Use them only for general diagnostics during commissioning or troubleshooting.
Page 159: Kinetix 5500 Capacitor Module Status Indicators
Troubleshoot the Kinetix 5500 Drive System Chapter 7 Kinetix 5500 Capacitor Module Status Indicators The capacitor module status indicator and module status (MS) connector are on the front of the module. The module status connector is a relay output suitable for wiring to the Logix 5000 controller.
Page 160 Chapter 7 Troubleshoot the Kinetix 5500 Drive System Condition Potential Cause Possible Resolution The axis cannot be enabled until stopping time has expired. Disable the axis, wait for 1.5 seconds, and enable the axis. The motor wiring is open. Check the wiring.
Page 161: Logix 5000 Controller And Drive Behavior
Logix 5000 Controller and By using the Logix Designer application, you can configure how the Kinetix 5500 drives respond when a drive fault/exception occurs. Drive Behavior TIP The INIT FLT xxx faults are always generated after powerup, but before the drive is enabled, so the stopping behavior does not apply.
Page 162 Chapter 7 Troubleshoot the Kinetix 5500 Drive System For Kinetix 5500 drives, only selected exceptions are configurable. In the drive behavior tables, the controlling attribute is given for programmable fault actions. Table 64 - Configurable Stopping Actions Stopping Action Description...
Page 163 Troubleshoot the Kinetix 5500 Drive System Chapter 7 This dialog box applies to Kinetix 5500 (EtherNet/IP network) servo drives. Table 65 - Drive Behavior, FLT Sxx Fault Codes Fault Action Best Available Permanent Exception Fault Code Exception Text Induction Motor...
Page 164 Chapter 7 Troubleshoot the Kinetix 5500 Drive System Table 65 - Drive Behavior, FLT Sxx Fault Codes (continued) Fault Action Best Available Permanent Exception Fault Code Exception Text Induction Motor Stopping Action Magnet Motor (applies to major faults) FLT S51 – NEG HW OTRAVEL...
Page 165: Before You Begin
This chapter provides remove and replace procedures for Kinetix® 5500 drives. Topic Page Before You Begin Remove and Replace Kinetix 5500 Servo Drives Start and Configure the Drive ATTENTION: This drive contains electrostatic discharge (ESD) sensitive parts and assemblies. You are required to follow static-control precautions when you install, test, service, or repair this assembly.
Page 166: Remove And Replace Kinetix 5500 Servo Drives
Remove and Replace Servo Drives Remove and Replace Follow these steps to remove and replace servo drives from the panel. Kinetix 5500 Servo Drives Remove Power and All Connections 1. Verify that all control and input power has been removed from the system.
Page 167: Remove The Servo Drive
IMPORTANT This procedure applies to any 2198-Hxxx-ERSx drive in any configuration. Follow these steps to remove Kinetix 5500 servo drives from the panel. 1. Loosen the top and bottom screws of the drive to remove.
Page 168: Start And Configure The Drive
Out-of-Box State page 182. 1. Reapply power to the drive/system. Refer to Apply Power to the Kinetix 5500 Drive page 143 for the procedure. 2. Configure the network settings for the drive. a. If your old drive was configured as Static IP, you need to set the IP address, gateway, and subnet mask in the new drive identical to the old drive.
Page 169: Certification
Chapter Kinetix 5500 Safe Torque-off - Hardwired Safety The 2198-Hxxx-ERS servo drives are equipped for hardwired safe torque-off (STO). The hardwired STO function meets the requirements of Performance Level d (PLd) and safety category 3 (CAT 3) per ISO 13849-1 and SIL 2 per IEC 61508, IEC 61800-5-2 and IEC 62061.
Page 170: Important Safety Considerations
Chapter 9 Kinetix 5500 Safe Torque-off - Hardwired Safety Important Safety Considerations The system user is responsible for the following: • Validation of any sensors or actuators connected to the system • Completing a machine-level risk assessment • Certification of the machine to the desired ISO 13849-1 performance level or IEC 62061 SIL level •...
Page 171: Description Of Operation
Kinetix 5500 Safe Torque-off - Hardwired Safety Chapter 9 Description of Operation The safe torque-off feature provides a method, with sufficiently low probability of failure, to force the power-transistor control signals to a disabled state. When disabled, or any time power is removed from the safety enable inputs, all of the drive output-power transistors are released from the ON-state.
Page 172: Fault Codes
Chapter 9 Kinetix 5500 Safe Torque-off - Hardwired Safety Fault Codes For fault code descriptions and possible solutions, see the Kinetix 5500 Fault Codes.xlsx file attached to this publication. For more information about the file, see Access the Attachments page...
Page 173: Probability Of Dangerous Failure Per Hour
Kinetix 5500 Safe Torque-off - Hardwired Safety Chapter 9 Probability of Dangerous Safety-related systems are classified as operating in a High-demand/continuous mode. The SIL value for a High-demand/continuous mode safety-related Failure Per Hour system is directly related to the probability of a dangerous failure occurring per hour (PFH).
Page 174: Wire The Safe Torque-Off Circuit
Chapter 9 Kinetix 5500 Safe Torque-off - Hardwired Safety Wire the Safe Torque-off This section provides guidelines for wiring your Kinetix 5500 safe torque-off drive connections. Circuit IMPORTANT The National Electrical Code and local electrical codes take precedence over the values and methods provided.
Page 175: Safe Torque-Off Feature
Kinetix 5500 Safe Torque-off - Hardwired Safety Chapter 9 Safe Torque-off Feature The safe torque-off circuit, when used with suitable safety components, provides protection according to ISO 13849-1 (PLd), Category 3 or according to IEC 61508, IEC 61800-5-2, and IEC 62061 (SIL CL2). All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding.
Page 176: Cascade The Safe Torque-Off Signal
Pin 1 Safety Device 24V DC Safe Torque-off To maintain safety rating, Kinetix 5500 drives must be installed inside protected control panels or cabinets appropriate for the environmental Specifications conditions of the industrial location. The protection class of the panel or cabinet must be IP54 or higher.
Page 177: Certification
Chapter Kinetix 5500 Safe Torque-off - Integrated Safety The 2198-Hxxx-ERS2 servo drives are equipped for integrated safe torque-off (STO). The integrated STO function meets the requirements of Performance Level e (PLe) and safety category 3 (CAT 3) per ISO 13849-1 and SIL 3 per IEC 61508, IEC 61800-5-2 and IEC 62061.
Page 178: Important Safety Considerations
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety Important Safety Considerations The system user is responsible for the following: • Validation of any sensors or actuators connected to the system • Completing a machine-level risk assessment • Certification of the machine to the desired ISO 13849-1 performance level or IEC 62061 SIL level •...
Page 179: Stop Category Definition
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Stop Category Definition Stop Category 0 as defined in IEC 60204 or safe torque-off as defined by IEC 61800-5-2 is achieved with immediate removal of motion producing power to the actuator.
Page 180: Fault Codes
IMPORTANT 2198-Hxxx-ERS2 servo drives enter the STO state if any STO function fault is detected. Refer to Figure 79 for an understanding of the 2198-Hxxx-ERS2 STO-state manual restart functionality. Figure 79 - Kinetix 5500 STO Timing Diagram - Manual Restart Drv:SO.SafeTorqueOff Drv:SO.Reset Drv:SI.ResetRequired Drv:SI.TorqueDisabled Axis.SafeTorqueOffActiveInhibit Axis.SafeTorqueOffActiveStatus...
Page 181: Probability Of Dangerous Failure Per Hour
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Probability of Dangerous Safety-related systems are classified as operating in a High-demand/continuous mode. The SIL value for a High-demand/continuous mode safety-related Failure Per Hour system is directly related to the probability of a dangerous failure occurring per hour (PFH).
Page 182: Out-Of-Box State
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety Out-of-Box State The 2198-Hxxx-ERS2 servo drives ship in the out-of-box state. ATTENTION: In the out-of-box state, motion producing power is allowed by the safe torque-off (STO) function unless an integrated safety connection configuration has been applied to the drive at least once.
Page 183: Understand Integrated Safety Drive Replacement
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 The Safety tab appears. 5. In the Configuration Ownership field, click Reset Ownership. IMPORTANT Only authorized personnel should attempt Reset Ownership. If any active connection is detected, the reset is rejected.
Page 184: Replace An Integrated Safety Drive In A Guardlogix System
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety The device number and SNN make up the safety device’s DeviceID. Safety devices require this more complex identifier to make sure that duplicate device numbers do not compromise communication between the correct safety devices.
Page 185: Configure Only When No Safety Signature Exists
ATTENTION: Enable the Configure Always feature only if the entire integrated safety control system is not being relied on to maintain SIL 3 behavior during the replacement and functional testing of a Kinetix 5500 drive. Do not place drives that are in Hardwired STO mode on an integrated safety network when the Configure Always feature is enabled.
Page 186: Motion Direct Commands In Motion Control Systems
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety Motion Direct Commands in You can use the Motion Direct Command (MDC) feature to initiate motion while the controller is in Program mode, independent of application code that Motion Control Systems is executed in Run mode.
Page 187: Logix Designer Application Warning Messages
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Logix Designer Application Warning Messages When the controller is in Run mode, executing safety functions, the 2198-Hxxx-ERS2 drive follows the commands that it receives from the safety controller. Safety state = Running, Axis state = Stopped/Running, as shown in...
Page 188 Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety When you issue a motion direct command to an axis to produce torque in Program mode, for example MSO or MDS, with the safety connection present to the drive, a warning message is presented before the motion direct command...
Page 189: Torque Permitted In A Multi-Workstation Environment
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 IMPORTANT The persistent warning message text Safe Torque Off bypassed appears when a motion direct command is executed. Warning message persists even after the dialog is closed and reopened as long as the integrated safety drive is in STO Bypass mode.
Page 190 Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety Figure 87 - Axis and Safe State Indications on Motion Direct Commands Dialog Box Figure 88 - Axis and Safe State Indications on the Motion Console Dialog Box Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 191: Functional Safety Considerations
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Functional Safety Considerations ATTENTION: Before maintenance work can be performed in Program mode, the developer of the application must consider the implications of allowing motion through motion direct commands and should consider developing logic for run-time maintenance operations to meet the requirements of machine safety operating procedures.
Page 192: Safe Torque-Off Specifications
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety Safe Torque-off To maintain safety rating, Kinetix 5500 drives must be installed inside protected control panels or cabinets appropriate for the environmental Specifications conditions of the industrial location. The protection class of the panel or cabinet must be IP54 or higher.
Page 193: Interconnect Diagrams
System Block Diagrams Interconnect Diagram Notes This appendix provides wiring examples to assist you in wiring the Kinetix 5500 drive system. These notes apply to the wiring examples on the pages that follow. Table 75 - Interconnect Diagram Notes Note...
Page 194: Power Wiring Examples
You must supply input power components. The single-phase and three-phase Power Wiring Examples line filters are wired downstream of the circuit protection. Single-axis Drive Wiring Examples Figure 89 - Kinetix 5500 Drives Power Wiring (three-phase operation) 2198-Hxxx-ERSx Kinetix 5500 Drives Refer to table on page 193 for note information.
Page 195 Interconnect Diagrams Appendix A Figure 90 - Kinetix 5500 Drives Power Wiring (single-phase operation) 2198-H003-ERSx, 2198-H008-ERSx, or 2198-H015-ERSx Refer to table on page 193 for note information. Kinetix 5500 Drives Bonded Cabinet Ground Bus * PE Ground Note 6 Chassis...
Page 196: Bus-Sharing Wiring Examples
Appendix A Interconnect Diagrams Bus-sharing Wiring Examples For bus-sharing configurations, use the 2198-H0x0-xx-x shared-bus connection system to extend power from drive to drive. Figure 92 - Kinetix 5500 Drives with Shared AC Bus 2198-Hxxx-ERSx 2198-Hxxx-ERSx 2198-Hxxx-ERSx Kinetix 5500 Drive Kinetix 5500 Drive...
Page 197 Interconnect Diagrams Appendix A Figure 94 - Kinetix 5500 Drives with Shared DC (common bus) 2198-Hxxx-ERSx 2198-Hxxx-ERSx 2198-Hxxx-ERSx Kinetix 5500 Drive Kinetix 5500 Drive Kinetix 5500 Drive Refer to table on page 193 for note information. PE Ground Note 6...
Page 198: Shunt Resistor Wiring Example
Bulletin 2097 external shunt resistor catalog numbers available for Example Kinetix 5500 servo drives. IMPORTANT Before wiring the Bulletin 2097 external shunt to the RC connector, remove the wires from the servo drive internal shunt. Do not connect internal and external shunt resistors to the drive.
Page 199: Kinetix 5500 Servo Drive And Rotary Motor Wiring Examples
These compatible Kinetix VP rotary motors use single cable technology. The motor power, brake, and feedback wires are all packaged in a single cable. Rotary Motor Wiring Examples Figure 97 - Kinetix 5500 Drives with Kinetix VP Motors (Bulletin VPL, VPF, VPH, and VPS) 2198-Hxxx-ERSx VPL-A/Bxxxx-C/P/Q/W, Kinetix 5500 Servo Drives...
Page 200 Appendix A Interconnect Diagrams These compatible MP-Series™ rotary motors have separate connectors and cables for power/brake and feedback connections. Figure 99 - Kinetix 5500 with MP-Series Rotary Motors MPL-A15xx…MPL-A5xx, Refer to table on page 193 for note information. MPL-B15xx…MPL-B6xx, 2198-Hxxx-ERSx...
Page 201: Kinetix 5500 Drive And Linear Actuator Wiring Examples
Power, Brake, and Feedback Connector 2090-CSxM1DF single cables have flying-lead conductors designed specifically for Kinetix 5500 servo drives. 2090-CSxM1DG cables have flying- leads that are longer than 2090-CSxM1DF cables to accommodate Kinetix 5500 or Kinetix 5700 servo drives. See the cable-shield grounding technique for single cables on page 199.
Page 202 Appendix A Interconnect Diagrams These compatible linear actuators have separate connectors and cables for power/brake and feedback connections. Figure 101 - Kinetix 5500 with LDAT-Series Linear Thrusters LDAT-Sxxxxxx-xDx 2198-Hxxx-ERSx Linear Thrusters with Kinetix 5500 Servo Drives Refer to table on page 193 for note information.
Page 203 Interconnect Diagrams Appendix A Figure 102 - Kinetix 5500 with MP-Series Linear Stages MPAS-A/Bxxxxx-VxxSxA 2198-Hxxx-ERSx Ballscrew Linear Stages with Kinetix 5500 Servo Drives Refer to table on page 193 for note information. High Resolution Feedback 2198-H2DCK Feedback Cable Shield Converter Kit...
Page 204 Appendix A Interconnect Diagrams Figure 103 - Kinetix 5500 with MP-Series Electric Cylinders MPAR-A/Bxxxxx and 2198-Hxxx-ERSx Refer to table on page 193 for note information. MPAI-A/Bxxxxx Kinetix 5500 Servo Drives Electric Cylinders with 2198-H2DCK Feedback High Resolution Feedback Cable Shield...
Page 205: System Block Diagrams
Interconnect Diagrams Appendix A System Block Diagrams This section provides block diagrams of the Kinetix 5500 drive modules. Figure 104 - Kinetix 5500 Drive Block Diagram Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 206 Appendix A Interconnect Diagrams Figure 105 - Kinetix 5500 Capacitor Module Block Diagram Precharge Protection Relay K2 Fuse F2 Relay K1 Capacitor Bank DC Bus Connector 1360 μF 24V+ 24V Control Power SMPS 24V- Module Status RELAY+ Connector (NO relay output)
Page 207 Appendix Upgrade the Drive Firmware This appendix provides procedures for upgrading firmware by using ControlFLASH™ software. Topic Page Before You Begin Upgrade Firmware Verify the Firmware Upgrade Upgrading drive firmware by using ControlFLASH software involves configuring your Logix 5000™ controller communication, selecting the drive to upgrade, and upgrading the firmware.
Page 208: Upgrade The Drive Firmware
11.00 or later Catalog numbers of the targeted Kinetix® 5500 drive module you want to upgrade. Network path to the targeted Kinetix 5500 drive module you want to upgrade. (1) Download the ControlFLASH kit from http://support.rockwellautomation.com/controlflash. Contact Rockwell Automation Technical Support at (440) 646-5800 for assistance.
Page 209: Configure Logix 5000 Controller Communication
Upgrade the Drive Firmware Appendix B Configure Logix 5000 Controller Communication This procedure assumes that your communication method to the Logix 5000 controller is the Ethernet network. It also assumes that your Logix 5000 Ethernet module or controller has already been configured. For more controller information, refer to Additional Resources page...
Page 210: Inhibit Feedback Only Axis
Appendix B Upgrade the Drive Firmware 7. Type the IP address of your Kinetix 5500 servo drive. 8. Click OK. The new Ethernet driver appears under Configured Drivers. 9. Click Close. 10. Minimize the RSLinx application dialog box. Inhibit Feedback Only Axis If an axis is configured as Feedback Only, you must inhibit the axis prior to performing the firmware upgrade.
Page 211: Upgrade Firmware
Upgrade the Drive Firmware Appendix B Upgrade Firmware Follow these steps to select the drive module to upgrade. 1. In the Logix Designer application, from the Tools menu, choose ControlFLASH. TIP You can also open ControlFLASH software by choosing Start>Programs>FLASH Programming Tools>ControlFLASH. The Welcome to ControlFLASH dialog box appears.
Page 212 Appendix B Upgrade the Drive Firmware 3. Select your drive module. In this example, the 2198-H003-ERS servo drive is selected. 4. Click Next. The Select Device to Update dialog box appears. 5. Expand your Ethernet node, Logix backplane, and EtherNet/IP™ network module.
Page 213 Upgrade the Drive Firmware Appendix B The Summary dialog box appears. 10. Confirm the drive catalog number and firmware revision. 11. Click Finish. This ControlFLASH warning dialog box appears. 12. Click Yes (only if you are ready). This ControlFLASH warning dialog box appears. 13.
Page 214 Appendix B Upgrade the Drive Firmware The Progress dialog box appears and updating begins. The axis state on the LCD display changes from CONFIGURING, STOPPED, or PRECHARGE to FIRMWARE UPDATE, which indicates that the upgrade is in progress. After the upgrade information is sent to the drive, the drive resets and performs diagnostic checking.
Page 215: Verify The Firmware Upgrade
Upgrade the Drive Firmware Appendix B Verify the Firmware Upgrade Follow these steps to verify your firmware upgrade was successful. TIP Verifying the firmware upgrade is optional. 1. Open your RSLinx software. 2. From the Communications menu, choose RSWho. 3. Expand your Ethernet node, Logix backplane, and EtherNet/IP network module.
Page 216 Appendix B Upgrade the Drive Firmware Notes: Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 217: Size Multi-Axis Shared-Bus Configurations
Appendix Size Multi-axis Shared-bus Configurations This appendix provides information and examples for sizing your Kinetix® 5500 drive shared-bus configurations. Topic Page Shared-bus Configurations Power-sharing Sizing Examples Control Power Current Calculations Energy Calculations Shared-bus configurations include the following types: • Shared AC •...
Page 218: Shared Ac Configurations
Number of Drives Configured as Shared AC, max 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx Figure 106 - Typical Shared AC Configuration Bonded Cabinet Kinetix 5500 Servo Drives Ground (top view) Do not remove the protective Three-phase knock-out DC connector cover. Input Power 24V Input Control Power...
Page 219 2198-H070-ERSx 3 and 2 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx (1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004. Figure 107 - Typical DC Common Bus Configuration Bonded Cabinet Ground Three-phase DC Bus Connections...
Page 220: Shared Ac/Dc Configurations
Modules, max 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx (1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004. Figure 108 - Typical Shared AC/DC Configuration Bonded Cabinet Ground Three-phase DC Bus Connections...
Page 221: Shared Ac/Dc Hybrid Configurations
2198-H008-ERSx Leader Drives Common-bus (inverter) Follower Drives (1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004. For an example shared AC/DC hybrid installation with additional details, refer to Typical Shared AC/DC Bus Hybrid Installations...
Page 222: Power-Sharing Sizing Examples
Appendix C Size Multi-axis Shared-bus Configurations Power-sharing Sizing For best results, size motors based on load torque requirements by using Motion Analyzer software. Select drives based on continuous or peak torque Examples requirements. Based on the load profile, use Motion Analyzer software to estimate the net converter and inverter power and bus regulator capacity.
Page 223: Shared Ac/Dc Hybrid Example
Size Multi-axis Shared-bus Configurations Appendix C Shared AC/DC Hybrid Example If the required motoring power exceeds the available converter power sourced by the shared DC configuration, then connect a second converter drive to make a shared AC/DC hybrid configuration. This increases the available converter power.
Page 224: Shared Ac/Dc Example
180% over the same drives in shared DC configuration. Control Power Current Kinetix 5500 servo drives and the Bulletin 2198 capacitor module have different 24V DC power consumption. Factors to consider when calculating Calculations the combined current demand from your 24V DC power supply includes the following: •...
Page 225: Kinetix 5500 System Current Demand Example
(1) Inrush current duration is less than 30 ms. Kinetix 5500 System Current Demand Example In this example, the Kinetix 5500 drive system includes two 2198-H040-ERS drives, four 2198-H008-ERS drives, and one capacitor module. Figure 113 - Shared AC/DC Hybrid Configuration...
Page 226: Energy Calculations
Appendix C Size Multi-axis Shared-bus Configurations Energy Calculations The Kinetix 5500 servo drives have internal shunt resistors for dissipating excessive energy. In addition, Bulletin 2097 external shunt resistors and Bulletin 2198 capacitor modules are available to increase the shared DC bus capacitance.
Page 227: Motor Control Feature Support
Appendix Motor Control Feature Support This appendix provides feature descriptions for the induction motors and permanent-magnet motors that are supported by Kinetix® 5500 servo drives. Topic Page Frequency Control Methods Current Limiting for Frequency Control Stability Control for Frequency Control Skip Speeds Flux Up Current Regulator Loop Settings...
Page 228: Frequency Control Methods
Motor cable length, max 50 m (164 ft) (1) Applies to all Kinetix 5500 (frame 2 and 3) drives. For Kinetix 5500 (frame 1) drives in continuous-flex applications, 30 m (98 ft) is the maximum cable length. Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 229: Basic Volts/Hertz
Motor Control Feature Support Appendix D Basic Volts/Hertz Volts/hertz operation creates a fixed relationship between output voltage and output frequency. Voltage is applied to the motor, which is based on the operating frequency command at a fixed volts/hertz ratio. The ratio is calculated from the motor nameplate data and entered into the Logix Designer application>Axis Properties>Frequency Control category.
Page 230: Basic Volts/Hertz For Fan/Pump Applications
Appendix D Motor Control Feature Support Basic Volts/Hertz for Fan/Pump Applications The Basic Volts/Hertz Fan/Pump (fan/pump) method is based on the Basic Volts/Hertz (V/Hz) method, but is specifically tailored for fan/pump applications. Figure 115 - Output Voltage Equation Where: = Output voltage –...
Page 231: Sensorless Vector
Motor Control Feature Support Appendix D Sensorless Vector The Sensorless Vector method uses a volts/hertz core enhanced by a current resolver, slip estimator, and a voltage-boost compensator based on the operating conditions of the motor. Figure 117 - Sensorless Vector Method Motor Pole Pairs Velocity Trim...
Page 232: Current Limiting For Frequency Control
Appendix D Motor Control Feature Support Current Limiting for The current limiting module prevents the OutputCurrent value from exceeding the OperativeCurrentLimit value when the drive is configured in Frequency Control Frequency Control mode. Figure 119 - Current Limiting Module Fine Velocity Velocity from Planner Command...
Page 233 Motor Control Feature Support Appendix D Figure 121 - Effects of Current Limiting on an Impact Load Impact Load, No Current Limiting Impact Load, Current Limiting Active 4000 4200 5600 4000 4200 5600 4400 4600 4800 5000 5200 5400 5800 4400 4600 4800...
Page 234: Enable The Current Limiting Feature
Appendix D Motor Control Feature Support Enable the Current Limiting Feature In this example, a Message Configuration (MSG) instruction is configured to enable the CurrentLimitingEnable attribute for axis 1. The Instance field is used to direct the message to the proper axis. Set the CurrentVectorLimit Attribute Value For current limiting, the CurrentVectorLimit attribute is used to help determine the OperativeCurrentLimit of the drive.
Page 235: Stability Control For Frequency Control
Motor Control Feature Support Appendix D Stability Control for Stability control is available for induction motors configured for frequency control. This feature can be used to help remove resonances that are sometimes Frequency Control seen on larger motors. The stability control feature adjusts the OutputFrequency and OutputVoltage commands to stabilize the OutputCurrent.
Page 236: Enable The Stability Control Feature
Appendix D Motor Control Feature Support Enable the Stability Control Feature In this example, a Message Configuration (MSG) instruction is configured to enable the StabilityControl attribute for axis 1. The Instance field is used to direct the message to the proper axis. Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 237: Skip Speeds
Motor Control Feature Support Appendix D Skip Speeds Some machines have a resonant operating frequency (vibration speed) that is undesirable or could cause equipment damage. To guard against continuous operation at one or more resonant points, you can configure the skip-speed attributes in the Logix Designer application>Axis Properties>Parameter List category.
Page 238: Multiple Skip Speeds
Appendix D Motor Control Feature Support Multiple Skip Speeds The Kinetix 5500 drives feature two independent skip-speed attributes (SkipSpeed1 and SkipSpeed2) that use the same SkipSpeedBand. Figure 124 - Multiple Skip Speed Example SkipSpeed2 SkipSpeedBand SkipSpeedBand SkipSpeed1 Time When skip-speed band boundaries of SkipSpeed1 and SkipSpeed2 overlap, the skip-speed hysteresis is calculated using the effective skip band.
Page 239: Flux Up
Motor Control Feature Support Appendix D Flux Up AC induction motors require that flux builds in the motor stator before controlled torque can develop. To build flux, voltage is applied. There are two methods to flux the motor and three configurable FluxUpControl settings. With the No Delay setting (normal start), flux is established when the output voltage and frequency are applied to the motor.
Page 240: Flux Up Attributes
Appendix D Motor Control Feature Support Once rated flux is reached in the motor, normal operation can begin and the desired acceleration profile achieved. Figure 128 - Rated Flux Reached IR Voltage - SVC Greater of IR Voltage or Voltage Boost - V/Hz Flux Up Stator Voltage Voltage...
Page 241: Configure The Flux Up Attributes
Motor Control Feature Support Appendix D Configure the Flux Up Attributes Follow these steps to configure the flux-up attributes. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to FluxUpControl. 3.
Page 242: Current Regulator Loop Settings
Appendix D Motor Control Feature Support Current Regulator Loop Current loop bandwidth is set differently based on the selected motor type. Settings Table 90 - Current Regulator Loop Settings Default Torque/Current Loop Bandwidth Motor Type Rotary permanent magnet Rotary interior permanent magnet 1000 Linear permanent magnet IMPORTANT The Logix Designer application does not perform calculations when the...
Page 243 Motor Control Feature Support Appendix D Figure 130 - Motor Manufacturer Performance Data Sheet C E R T I FI C A T I ON DA T A SHE E T T Y PI C A L M OT OR PE R FOR M A NC E DA T A SY NC .
Page 244: Motor Tests And Autotune Procedure
Appendix D Motor Control Feature Support Motor>Analyzer Category From the Motor>Analyzer category you can perform three types of tests to identify motor parameters. In this example, the Calculate Model test was run. If the Motor>Analyzer test executes successfully, and you accept the test values, they populate the Model Parameter attributes.
Page 245: Motor Analyzer Category Troubleshooting
Motor Control Feature Support Appendix D The Motor>Analyzer category offers three choices for calculating or measuring electrical motor data. Follow these steps to run motor tests and identify motor parameters. 1. In the Controller Organizer, right-click an axis and choose Properties. 2.
Page 246 Appendix D Motor Control Feature Support motor movement. The drive also calculates the rated slip speed based on rated speed and rated frequency. The Static test requires that you enter initial estimates for Rated Flux Current, Rated Slip Speed, Stator Resistance (Rs), Stator Leakage Reactance (X1), and Rotor Leakage Reactance (X2) into the Motor Model fields.
Page 247 Motor Control Feature Support Appendix D that the dynamic test will not return expected results if the torque limit is set below 30.0. Table 92 - Slip Test via Messaging Attribute Conditional Type Attribute Name Description Offset Implementation Sets positive and negative torque limits for the slip test within the Dynamic motor test 3095 REAL IM Slip Test Torque Limit...
Page 248: Selection Of Motor Thermal Models
Appendix D Motor Control Feature Support Selection of Motor Thermal The Kinetix 5500 drives contain two motor thermal-overload protection algorithms that you can use to prevent the motor from overheating. Models Generic Motors The default thermal model is a generic I T Class 10 overload protection algorithm.
Page 249: Thermally Characterized Motors
Motor Control Feature Support Appendix D Thermally Characterized Motors If the MotorWindingToAmbientResistance and MotorWindingToAmbientCapacitance attribute values are both non-zero, the motor is considered thermally characterized and an alternate motor thermal model is run. The purpose of this algorithm is to limit the time a motor is operating with excessive levels of current.
Page 250: Speed Limited Adjustable Torque (Slat)
Appendix D Motor Control Feature Support Speed Limited Adjustable Speed limited adjustable torque (SLAT) is a special mode of operation used primarily in web handling applications. While configured for SLAT, the drive Torque (SLAT) typically operates as a torque regulator. The drive can automatically enter velocity regulation based on conditions within the velocity regulator and the magnitude of the velocity regulator's output, relative to the applied TorqueTrim attribute.
Page 251: Slat Min Speed/Torque
Motor Control Feature Support Appendix D Table 94 - SLAT Operation When Motion Polarity Is Inverted Velocity Command Motion Polarity SLAT Configuration Normal Positive (clockwise) Inverted Normal Negative (CCW) Inverted SLAT Min Speed/Torque SLAT Min Speed/Torque is a special mode of operation primarily used in web handling applications.
Page 252: Slat Max Speed/Torque
Appendix D Motor Control Feature Support SLAT Max Speed/Torque SLAT Max Speed/Torque is a special mode of operation primarily used in web handling applications. The drive typically operates as a torque regulator, provided that the TorqueTrim attribute is greater than the torque output due to the velocity regulator's control effort.
Page 253: Configure The Axis For Slat
Motor Control Feature Support Appendix D Configure the Axis for SLAT Follow these steps to configure the SLAT attributes. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category. The General dialog box appears. 3.
Page 254 Appendix D Motor Control Feature Support 5. Click Apply. 6. Select the Parameters List category. The Motion Axis Parameters dialog box appears. 7. From the SLATConfiguration pull-down menu, choose the SLAT configuration appropriate for your application. IMPORTANT SLAT parameters are configurable only when Velocity Loop is chosen from the General category, Axis Configuration pull-down menu.
Page 255 Appendix D The Drive Parameters to Controller Mapping dialog box appears. When using SLAT with Kinetix 5500 drives, the velocity command is sent to the drive via an MAJ instruction. The torque command is sent via the cyclic write TorqueTrim attribute. See the Integrated Motion on the EtherNet/IP Network Reference Manual, publication MOTION-RM003, for more information on cyclic read and cyclic write.
Page 256: Motor Overload Retention
Appendix D Motor Control Feature Support Motor Overload Retention The motor overload retention feature protects the motor in the event of a drive power-cycle, in which the motor thermal state is lost. With motor overload retention, upon drive power-up the MotorCapacity attribute initially reads: •...
Page 257: Phase Loss Detection
Motor Control Feature Support Appendix D Phase Loss Detection The phase-loss detection feature is designed to determine if motor power wiring is electrically connected to a motor and that reasonable current control exists. This attribute enables the operation of the drive's torque proving functions that work in conjunction with mechanical brake control.
Page 258: Phase-Loss Detection Configuration
Appendix D Motor Control Feature Support Phase-loss Detection Configuration Follow these steps to configure the phase-loss detection attributes. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to ProvingConfiguration. 3. From the ProvingConfiguration pull-down menu, choose Enabled to enable the torque proving feature.
Page 259: Phase Loss Detection Current Example
Motor Control Feature Support Appendix D Phase Loss Detection Current Example In this example, a 2198-H025-ERSx servo drive is paired with a VPL-B1003T-C motor with 6.77 A rms rated current. Use the phase-loss detection equation and table to calculate the initial minimum torque-proving current as a percentage of motor rated current.
Page 260: Velocity Droop
Appendix D Motor Control Feature Support Velocity Droop The velocity droop function can be useful when some level of compliance is required due to rigid mechanical coupling between two motors. The feature is supported when the axis is configured for Frequency Control, Velocity Control, or Position Control.
Page 261: Velocity Droop Configuration
Motor Control Feature Support Appendix D Velocity Droop Configuration Follow these steps to configure the velocity droop attribute. 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to VelocityDroop. 3. Enter a value in the Velocity Droop attribute appropriate for your application.
Page 262 You can also use the commutation test to verify a known commutation offset and the polarity start-up commutation wiring. IMPORTANT For Kinetix 5500 drives, this test applies to only third-party motors. IMPORTANT When motors have an unknown commutation offset and are not listed in the Motion Database by catalog number, you cannot enable the axis.
Page 263 Index Numerics bus-sharing group 127 2090-CSBM1DF 16 group example 145 2090-CSBM1DG 16 groups 144 2198-CAPMOD-1300 29 2198-DBRxx-F 16 2198-DBxx-F 16 cables 2198-H2DCK 15 catalog numbers 88 2198-KITCON-DSL 15 categories 45 24V input power connector Ethernet cable length 106 evaluation 37 induction motors 94 pinouts 64 shield clamp 91...
Page 264 119 motor feedback 101 inhibit module 210 motor power/brake 96 motion group 128 description 15 motor Kinetix 5500 AOP 93 category 242 CP connector test 148 motor category 131 pinouts 64 motor feedback 138 wiring 84 motor>analyzer category 135...
Page 265 Index erratic operation 160 IEC 62061 170 Ethernet connector ignore 161 pinouts 65 induction motor control 94 EtherNet/IP configure flux up 241 connecting cables 106 control methods connections 68 basic volts/hertz 229 PORT1 and PORT2 connectors 106 fan/pump 230 external shunt resistor 47 sensorless vector 231 flux up 239 pinouts 64...
Page 266 135 stop category definitions 170 category 131 data sheet 243 feedback compatibility 138 model category 243 Kinetix 5500 15 motor and inertia tests 244 Kinetix VP electric cylinders 22 overload retention 256 thermal models 248 motors accel/decel problems 159...
Page 267 Index MS connector remove grounding screws 79 pinouts 63 remove/replace drive multiple skip speed 238 remove drive 167 remove power 166 replace drive 167 startup and configure 168 routing power and signal wiring 74 navigation buttons 108 network parameters 113 status indicator 158 SAB 94 new tag...
Page 268 Index shared DC 222 shared-bus configurations 217 testing axes shared AC 218 hookup test 148 shared AC/DC 220 time synchronization 117 shared AC/DC hybrid 221 shared DC 218 torque proving 256 shared-bus guidelines 217 attributes 256 skip speed 237 configuring 258 SLAT 250 training 11 attributes 252...
Page 269 Index velocity droop 260 attribute 260 configure 261 verify upgrade 215 voltage drop 24V input power 37 website certifications 13 Motion Analyzer 13 product selection 13 wiring BC connector 89 capacitor module 104 converter kit shield clamp 102 CP connector 84 earth ground 80 Ethernet cables 106 external shunt resistor 105...
Page 270 Index Notes: Rockwell Automation Publication 2198-UM001I-EN-P - May 2019...
Page 272 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, CompactLogix, ControlFLASH, ControlLogix, GuardLogix, HPK-Series, Kinetix, Logix 5000, MP-Series, PanelView Plus, POINT Guard I/O, POINT I/O, Rockwell Automation, Rockwell Software, RSLinx, Stratix, Studio 5000, Studio 5000 Logix Designer, and TL-Series, are trademarks of Rockwell Automation, Inc.

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Allen-Bradley Kinetix 5500 User Manual

Preface

Chapter 1 About the Kinetix 5500 Servo Drive System

Start

Plan the Kinetix 5500 Drive System Installation

Chapter 2 System Design Guidelines

Chapter 3

Chapter 4

Chapter 5 Routing the Power and Signal Cables

Configure and Start the Kinetix 5500 Drive System

Chapter 6 Understand the Kinetix 5500 Display

Chapter 7 Interpret Status Indicators

Before You Begin

Chapter 8 Remove and Replace Kinetix 5500 Servo Drives

Chapter 9

Chapter 10

Appendix A Interconnect Diagram Notes

Interconnect Diagrams

Appendix B before You Begin

Upgrade the Drive Firmware

Appendix C Shared-Bus Configurations

Size Multi-Axis Shared-Bus Configurations

Motor Control Feature Support

Appendix D Frequency Control Methods

Quick Links

Troubleshooting

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Summary of Contents for Allen-Bradley Kinetix 5500