Page 1 User Manual 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 Original Instructions...
Page 2 Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Allen-Bradley, CompactLogix, ControlFLASH, ControlLogix, GuardLogix, HPK-Series, Kinetix, Logix5000, MP-Series, PanelView, POINT I/O, RDD-Series, Rockwell Automation, Rockwell Software, RSLinx, Stratix 5700, Studio 5000 Logix Designer, Studio 5000, and TL-Series are trademarks of Rockwell Automation, Inc. CIP Sync and EtherNet/IP are trademarks of ODVA, Inc.
Page 3: Table Of Contents
Start About the Kinetix 5500 Servo Drive System......13 Drive Hardware and Input Power Configurations ....15 Standalone Configurations .
Page 4 Mount Your Kinetix 5500 Drive........56...
Page 5 Download the Program ......... . 137 Apply Power to the Kinetix 5500 Drive ......138 Applying Power after Changing Input Voltage Range.
Page 6 Table of Contents Kinetix 5500 Drive Status Indicators ......157 Kinetix 5500 Capacitor Module Status Indicators ....158 General Troubleshooting .
Page 7 Control Power Current Calculations ......230 Kinetix 5500 System Current Demand Example ....231 Energy Calculations .
Page 8 Table of Contents Basic Volts/Hertz for Fan/Pump Applications ....235 Sensorless Vector ..........236 Skip Speeds .
Page 9: Summary Of Changes
Updated fuse/CB tables by removing footnotes regarding UL approval. Added footnote to v21 Kinetix 5500 AOP with link to v26 Kinetix 5500 AOP. Added ControlLogix 5580 controller to Ethernet Cable Connections. Added link and installation information for the Kinetix 5500/5700 Add-on Profile available with drive firmware 4.001.
Page 10 Summary of Changes Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 11: Preface
EtherNet/IP™ communication module or controller. If you do not have a basic understanding of Kinetix 5500 servo drives, contact your local Rockwell Automation sales representative for information on available training courses.
Page 12 GMC-RM009 accessory, feedback connector kit, and motor cable catalog numbers for your Kinetix 5500 drive and Kinetix VP motor motion control system. Product specifications for Kinetix VP (Bulletin VPL, VPF, and VPS), MP-Series™ Kinetix Rotary Motion Specifications Technical Data, publication GMC-TD001 (Bulletin MPL, MPM, MPF, and MPS), Kinetix 6000M (Bulletin MDF), TL-Series™,...
Page 13: 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 14 Ethernet cables are available in standard lengths. Shielded cable is recommended. 2198-DB08-F AC Line Filters 2198-DB20-F Bulletin 2198 three-phase AC line filters are required to meet CE and available for use in all Kinetix 5500 drive systems. 2198-DB42-F 24V DC Power 1606-XLxxx Bulletin 1606 24V DC power supply for control circuitry, digital inputs, safety, and motor brake.
Page 15: 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 shared Power Configurations AC/DC hybrid configurations. Standalone Configurations In these examples, a single standalone drive is shown with and without the Bulletin 2198 capacitor module.
Page 16 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-DBxx-F Input...
Page 17: 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-DBxx-F Input 2198-CAPMOD-1300 Capacitor Module AC Line Filter...
Page 18: 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-DBxx-F Input AC Line Filter Fusing (required for CE) Shared DC (DC common bus)
Page 19: 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-DBxx-F Input AC Line Filter Fusing (required for CE) Shared AC (mains AC input)
Page 20: 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 21: 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. Devices without dual ports must include the 1783-ETAP module or be connected at the end of the line.
Page 22: Ring Topology
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 Logix Designer...
Page 23: Star Topology
In this example, the devices are connected by using star topology. Each device is connected directly to the switch. Kinetix 5500 drives have dual ports, so linear topology is maintained from drive- to-drive, but Kinetix 5500 drives and other devices operate independently. The loss of one device does not impact the operation of other devices.
Page 24: 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 25: 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 26 POINT Guard I/O EtherNet/IP Adapter 1783-BMS Safety Stratix 5700 Device Switch 1606-XLxxx 24V DC Control, Digital Inputs, Allen-Bradley 1585J-M8CBJM-x 1606-XL Powe r S u p p l y and Motor Brake Power Ethernet (shielded) Cable (customer-supplied) 2198-Hxxx-ERS2 Servo Drives Input...
Page 27: 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 28: Agency Compliance
2090-CSxM1DF-10Axxx (10 AWG) cables and any other 2090-CSxM1DF/DG cables with M40 or M58 connectors do not support this 50 m (164 ft) option. • Install the Kinetix 5500 system inside an approved enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure.
Page 29: 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 30: System Design Guidelines
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 EN 60529 (IEC 529) to IP54 such that they are not accessible to an operator or unskilled person.
Page 31: 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 GMC-TD003.
Page 32 Chapter 2 Plan the Kinetix 5500 Drive System Installation Standalone Drive Systems Kinetix 5500 Drives UL Applications IEC (non-UL) Applications Drive Voltage, Bussmann Fuses Molded Case CB Drive Cat. No. Phase Cat. No. Cat. No. 240V Single-phase KTK-R-2 140U-D6D2-B10 2198-H003-ERSx...
Page 33 Plan the Kinetix 5500 Drive System Installation Chapter 2 Shared AC Drive Systems Kinetix 5500 Drives UL Applications IEC (non-UL) Applications Bussmann Fuses Molded Case CB Drive Voltage, Cat. No. Cat. No. Drive Cat. No. (three-phase) 2 Axes 3 Axes...
Page 34: Enclosure Selection
Where d (depth), w (width), and h (height) are in meters. Where d (depth), w (width), and h (height) are in inches. 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 35: Minimum Clearance Requirements
Plan the Kinetix 5500 Drive System Installation Chapter 2 Table 7 - 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 36: 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 37 Plan the Kinetix 5500 Drive System Installation Chapter 2 These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets. Figure 15 - Recommended Bonding Practices for Painted Panels Stud-mounting the Subpanel Stud-mounting a Ground Bus...
Page 38: Bonding Multiple Subpanels
Chapter 2 Plan the Kinetix 5500 Drive System Installation Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together do not necessarily share a common low impedance path. This difference in impedance can affect networks and other devices that span multiple panels: •...
Page 39: Establishing Noise Zones
Plan the Kinetix 5500 Drive System Installation Chapter 2 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 40: Cable Categories For Kinetix 5500 Systems
Chapter 2 Plan the Kinetix 5500 Drive System Installation Cable Categories for Kinetix 5500 Systems These tables indicate the zoning requirements of cables connecting to the Kinetix 5500 drive components. Table 8 - Kinetix 5500 Drive Zone Method Wire/Cable Connector...
Page 41: Noise Reduction Guidelines For Drive Accessories
39 for an example): • Mount the AC line filter on the same panel as the Kinetix 5500 drive and as close to the drive as possible. • Good HF bonding to the panel is critical. For painted panels, refer to the...
Page 42 Chapter 2 Plan the Kinetix 5500 Drive System Installation 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 43 Plan the Kinetix 5500 Drive System Installation Chapter 2 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 44 Chapter 2 Plan the Kinetix 5500 Drive System Installation Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 45: Mount The Kinetix 5500 Drive System
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 46: 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 47: 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. When the shared-bus connection system is used, the zero-stack tab and IMPORTANT cutout must be engaged between adjacent drives.
Page 48: 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 22 on page •...
Page 49: 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-UM001F-EN-P - December 2015...
Page 50 Chapter 3 Mount the Kinetix 5500 Drive System These hole patterns apply to standalone drives. Figure 23 - 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 51 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 24 - Frame 1 and Frame 2 Hole Patterns...
Page 52 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 53 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 26 - Frame 3 Hole Pattern...
Page 54 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 55 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 56: 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 57 Chapter Connector Data and Feature Descriptions This chapter illustrates drive connectors and indicators, including connector pinouts, and provides descriptions for Kinetix 5500 drive features. Topic Page Kinetix 5500 Connector Data Understanding Control Signal Specifications Feedback Specifications Safe Torque-off Safety Features...
Page 58: Kinetix 5500 Connector Data
Kinetix 5500 Connector Data Use these illustrations to identify the connectors and indicators for the Kinetix 5500 servo drives. Figure 29 - Kinetix 5500 Drive Features and Indicators Kinetix 5500 Drive, Front View (2198-H003-ERSx drive is shown) Kinetix 5500, Top View...
Page 59: Safe Torque-Off Connector Pinout
Connector Data and Feature Descriptions Chapter 4 Safe Torque-off Connector Pinout For the hardwired safe torque-off (STO) connector pinouts, feature descriptions, and wiring information, refer to Chapter 9 beginning on page 169. Input Power Connector Pinouts Table 12 - Mains Input Power Connector IPD Pin Description Signal...
Page 60: Digital Inputs Connector Pinout
Connector Data and Feature Descriptions Digital Inputs Connector Pinout 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 61: Ethernet Communication Connector Pinout
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 Figure 49 page 84 for connector wiring examples.
Page 62: Motor Feedback Connector Pinout
CE requirements. Figure 32 - Pin Orientation for 2-pin Motor Feedback (MF) Connector Pin 1 Pin 2 This section provides a description of the Kinetix 5500 digital inputs, Ethernet Understanding Control communication, power and relay specifications, encoder feedback specifications, Signal Specifications and safe torque-off features.
Page 63 Propagation delay (registration functions) 0 (delay compensated) Registration repeatability 700 ns Windowed registration invalid-to-valid event delay 125 μs, min Figure 33 - Digital Input Circuitry IOD-1 or IOD-3 INPUT 24V DC IOD-2 Kinetix 5500 Drive Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 64: Ethernet Communication Specifications
INT PWR Control Board MBRK+ (BC-1) Inductive ISP772 Energy Kinetix 5500 Clamp Servo Drive MBRK– (BC-2) 24V COM IMPORTANT Motor parking-brake switching frequency must not exceed 10 cycles/min. Control of the solid-state relay to release the motor brake is configurable in the...
Page 65: Control Power
5. Use the motion instruction Motion Servo Off (MSF) to engage the brake and disable drive. Control Power The Kinetix 5500 drive requires 24V DC input power for control circuitry. SELV and PELV rated power supplies must be used to energize external safety IMPORTANT devices connected to the Kinetix 5500 safety inputs.
Page 66: Feedback Specifications
Auto-configuration in the Logix Designer application of intelligent absolute, high-resolution encoders is possible with only Allen-Bradley motors. The Kinetix 5500 drives support Kinetix VP motors with Stegmann Hiperface digital-servo-link (DSL) encoders by using the 2-pin (MF) feedback connector. Other Allen-Bradley motors and actuators with Stegmann Hiperface single-turn or multi-turn high-resolution absolute encoders are also accepted, but only when using drive firmware revision 2.002 or later, and the 2198-H2DCK Hiperface-...
Page 67: Safe Torque-Off Safety Features
Connector Data and Feature Descriptions Chapter 4 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 68 Chapter 4 Connector Data and Feature Descriptions Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 69 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 Remove the Grounding Screws in Select Power Configurations...
Page 70: 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 71: 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 both Configuration grounded and ungrounded environments.
Page 72 Chapter 5 Connect the Kinetix 5500 Drive System Figure 37 - Impedance-grounded Power Configuration (WYE Secondary) Kinetix 5500 Servo Drive (top view) Transformer (WYE) Secondary Transformer Three-phase AC Line Filter Three-phase Circuit Input VAC Protection Phase Ground Connect to Bonded Cabinet Ground...
Page 73: Ungrounded Power Configurations
Connect the Kinetix 5500 Drive System Chapter 5 Figure 39 - Grounded Power Configuration (single-phase input) Kinetix 5500 Servo Drive (top view) Transformer (WYE) Secondary Transformer Three-phase AC Line Filter Three-phase Circuit Input VAC Protection Phase Ground Connect to Bonded Cabinet Ground...
Page 74: Remove The Grounding Screws In Select Power Configurations
Chapter 5 Connect the Kinetix 5500 Drive System Figure 40 - Ungrounded Power Configuration Kinetix 5500 Servo Drive (top view) Transformer (Delta) Secondary Transformer Three-phase Input VAC Circuit Protection Chassis Ground Connect to Bonded Cabinet Ground Ground Stud Ground Grid or...
Page 75 Connect the Kinetix 5500 Drive System Chapter 5 ATTENTION: To avoid personal injury, the grounding screws access door must be kept closed when power is applied. If power was present and then removed, wait at least 5 minutes for the DC-bus voltage to dissipate and verify that no DC-bus voltage exists before accessing the grounding screws.
Page 76: Grounding 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 42 - Connecting the Ground Terminal...
Page 77: 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 43 - Subpanels Connected to a Single Ground Point Follow NEC and applicable local codes. Bonded Ground Bus...
Page 78: 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 79: 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. Use caution not to nick, cut, or otherwise damage strands as you IMPORTANT remove the insulation.
Page 80: Wiring The Power Connectors
Chapter 5 Connect the Kinetix 5500 Drive System Wiring 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 200 for an interconnect diagram.
Page 81: 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 82: Wiring The Digital Input Connectors
Chapter 5 Connect the Kinetix 5500 Drive System Figure 47 - IPD Connector Wiring - Shared Bus Mains AC Input Wiring Connector Kinetix 5500 Drives Top View Table 30 - Shared Bus IPD Connector Wiring Specifications Recommended Input Current, max...
Page 83: Wire The Digital Inputs Connector
Due to the unique characteristics of single cable technology, designed for IMPORTANT and tested with Kinetix 5500 drives and Kinetix VP motors, you cannot build your own cables or use third-party cables. Refer to the Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004, for cable specifications.
Page 84: Motor Power Connections
(included with Flying-lead feedback conductors. Leads are 2090-CSBM1DG-xxAAxx (standard) cables VPS-Bxxxxx each servo drive) longer to accommodate Kinetix 5500 or Kinetix 2090-CSWM1DG-xxAAxx (standard) cables 5700 drives. Extra service loops are required 2090-CSBM1DG-xxAFxx (continuous-flex) cables with Kinetix 5500 drives. Motor Power Connections...
Page 85: Motor Brake Connections
Connect the Kinetix 5500 Drive System Chapter 5 Motor Brake Connections Figure 50 - BC Connector Wiring Kinetix 5500 Servo Drive (front view) MBRK- Motor Brake (BC) Connector Plug MBRK+ Motor Cable Shield Clamp Table 34 - Motor Brake (BC) Connector Specifications...
Page 86: Motor Feedback Connections
Kinetix 5500 drives. When using the 2198-KITCON-DSL feedback connector kit, the ambient IMPORTANT temperature for the Kinetix 5500 drive enclosure is 0…50 °C (32…122 °F). Figure 51 - MF Connector Wiring Kinetix 5500 Servo Drive (front view)
Page 87: 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 88: Wiring Other Allen-Bradley Motors And Actuators
3 for each drive in multi-axis configurations. Wiring Other Allen-Bradley Kinetix 5500 drives are also compatible with other Allen-Bradley motors and actuators, however the 2198-H2DCK Hiperface-to-DSL (series B or later) Motors and Actuators feedback converter kit is required for converting the 15-pin Hiperface feedback signals to 2-pin DSL feedback signals.
Page 89: Install The Kinetix 5500 Add-On Profile
To configure these additional motors and actuators (see Table 37) with your IMPORTANT Kinetix 5500 servo drive, you must have drive firmware 2.002 or later. Refer Table 36 to determine if you need to install the Kinetix 5500 Add-on Profile.
Page 90: Motor Power And Brake Connections
600V 90 °C (194 °F) VFD XLPE TR To use your existing 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 91 635 (25) Power cable preparation on existing 16 and 14 AWG cables is sufficient to reuse on Kinetix 5500 frame 1 and 2 drives, except for the brake conductors, which are much longer than required. However, for frame 3 drives with 14 or 10 AWG cables, the overall length of the cable preparation area needs to be increased for the motor power conductors to reach the MP connector and also provide a proper service loop.
Page 92 Chapter 5 Connect the Kinetix 5500 Drive System 3. Cover 12.5 mm (0.5 in.) of the shield ends and an equal length of the conductors with 25 mm (1.0 in.) of electrical tape or heat shrink. Do the same on the other side of the cable shield. This keeps the shield ends from fraying and holds the conductors together.
Page 93 Connect the Kinetix 5500 Drive System Chapter 5 If the power/brake cable shield has a loose fit inside the shield clamp, insert IMPORTANT the clamp spacer between the shield clamp and the drive to reduce the clamp diameter. When the clamp screws are tight, 2.0 N•m (17.7 lb•in), the result must be a high-frequency bond between the cable shield and the drive chassis.
Page 94: Motor Feedback Connections
Table 40 Table 41, 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 95 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 96 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 97 Connect the Kinetix 5500 Drive System Chapter 5 Table 42 - 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 98: 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 relay output (MS) connections to the Logix5000 controller (optional). • Refer to Kinetix 5500 Capacitor Module wiring example on page 201.
Page 99: 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 42 for noise zone Resistor Connections considerations. • Refer to Shunt Resistor Wiring Example page 204.
Page 100: Ethernet Cable Connections
Refer to page 58 to locate the Ethernet connectors on your Kinetix 5500 drive. Refer to the figure below to locate the connectors on your Logix5000 controller. Shielded Ethernet cable is required and available in several standard lengths. Refer to the Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004, for more information.
Page 101: 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 Logix5000 controller. Topic Page Understanding the Kinetix 5500 Display Configure the Drive Studio 5000 Logix Designer Configure the Logix5000 Controller...
Page 102: Understanding The Kinetix 5500 Display
Chapter 6 Configure and Start the Kinetix 5500 Drive System Understanding the The Kinetix 5500 drive has two status indicators and an LCD status display. The indicators and display are used to monitor the system status, set network Kinetix 5500 Display parameters, and troubleshoot faults.
Page 103: Menu Screens
Configure and Start the Kinetix 5500 Drive System Chapter 6 Menu Screens The menu screens provide information about the drives, motors, diagnostics, and the fault log. Parameters cannot be updated in the menu screens. Press one of the menu buttons to access the menu.
Page 104: 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 105: Startup Sequence
Configure and Start the Kinetix 5500 Drive System Chapter 6 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 106: Configure The Drive
Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure the Drive You can include the drive in your Logix Designer application by adding it to a configured EtherNet/IP module or controller and adding it under the I/O configuration tree. After setting network parameters, you can view the drive status information in Studio 5000 software and use it in your Logix Designer application.
Page 107: Kinetix 5500/5700 Add-On Profile
The Logix Designer application, version 28.00 and later, makes possible the configuration of additional drive features not available in previous versions. To configure these additional drive features with your Kinetix 5500 servo IMPORTANT drive, you must have drive firmware 4.001 or later. Refer to Table 49 determine if you need to install the Kinetix 5500/5700 Add-on Profile.
Page 108: Configure The Logix5000 Controller
Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure the Logix5000 These procedures assume that you have wired your Kinetix 5500 drive system. In this example, the GuardLogix 5570 safety controller, ControlLogix 1756-EN2T Controller communication module, and CompactLogix 5370 controller dialog boxes are shown.
Page 109 Configure and Start the Kinetix 5500 Drive System Chapter 6 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 Logix5000 controller. 1. Expand the Logix5000 controller family and select your controller.
Page 110 6. Right-click I/O Configuration in the Controller Organizer and choose New Module. The Select Module Type dialog box appears. 7. By using the filters, check Communication and Allen-Bradley, and select 1756-EN2T, 1756-EN2TR, or 1756-EN3TR as appropriate for your actual hardware configuration.
Page 111 Configure and Start the Kinetix 5500 Drive System Chapter 6 d. Select an Ethernet Address option. In this example, the Private Network address is selected. e. Enter the address of your EtherNet/IP module. In this example, the last octet of the address is 1.
Page 112 Chapter 6 Configure and Start the Kinetix 5500 Drive System 14. Click the Date/Time tab. 15. Check Enable Time Synchronization. The motion modules set their clocks to the module you assign as the Grandmaster. Check Enable Time Synchronization for all controllers that participate IMPORTANT in CIP Sync™.
Page 113: 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 114 Chapter 6 Configure and Start the Kinetix 5500 Drive System 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 115 Configure and Start the Kinetix 5500 Drive System Chapter 6 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 116 Chapter 6 Configure and Start the Kinetix 5500 Drive System 4. Configure the new drive. a. Type the drive Name. b. Select an Ethernet Address option. In this example, the Private Network address is selected. c. Enter the address of your 2198-Hxxx-ERS2 servo drive.
Page 117 Configure and Start the Kinetix 5500 Drive System Chapter 6 Your 2198-Hxxx-ERS2 servo drive appears in the Controller Organizer under the Ethernet controller in the I/O Configuration folder. 7. Right-click the drive you just created in the Controller Organizer and choose Properties.
Page 118 Chapter 6 Configure and Start the Kinetix 5500 Drive System The connection between the owner and the 2198-Hxxx-ERS2 servo drive is based on the following: • Servo drive catalog number must be 2198-Hxxx-ERS2 (integrated) • Servo drive safety network number •...
Page 119 Configure and Start the Kinetix 5500 Drive System Chapter 6 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 120 Chapter 6 Configure and Start the Kinetix 5500 Drive System The axis (Axis_1 in this example) appears in the Controller Organizer under Motion Groups> Ungrouped Axes and is assigned as Axis 1. You can configure an axis as Feedback Only. Refer to...
Page 121 Configure and Start the Kinetix 5500 Drive System Chapter 6 11. Click the Power tab. Single-phase operation is possible only when Module Properties>Power IMPORTANT tab>Bus Configuration is configured as Standalone. The Logix Designer application enforces shared-bus configuration rules for IMPORTANT Kinetix 5500 drives, except for shared AC configurations.
Page 122 Chapter 6 Configure and Start the Kinetix 5500 Drive System 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 123: Configure The Motion Group
Configure and Start the Kinetix 5500 Drive System Chapter 6 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 124: Configure Feedback-Only Axis Properties
Chapter 6 Configure and Start the Kinetix 5500 Drive System Configure Feedback-only Follow these steps to configure feedback-only axis properties. Axis Properties 1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the General category. The General dialog box appears.
Page 125: Configure Induction-Motor Frequency-Control Axis Properties
Configure and Start the Kinetix 5500 Drive System Chapter 6 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 126 Chapter 6 Configure and Start the Kinetix 5500 Drive System 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 127: Basic Volts/Hertz Method
Configure and Start the Kinetix 5500 Drive System Chapter 6 Basic Volts/Hertz Method 1. Configure the General tab and Motor tab as shown in General and Motor Categories page 125. 2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Basic Volts/ Hertz.
Page 128 Chapter 6 Configure and Start the Kinetix 5500 Drive System The Motion Axis Parameters dialog box appears. 7. From the Parameter Group pull-down menu, choose Frequency Control. 8. Set the FluxUp, SkipSpeed, and VelocityDroop attributes appropriate for your application. See the corresponding section in Appendix D, beginning on...
Page 129: Sensorless Vector Method
Configure and Start the Kinetix 5500 Drive System Chapter 6 Sensorless Vector Method 1. Configure the General tab and Motor tab as shown in General and Motor Categories page 125. 2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Sensorless Vector.
Page 130 Chapter 6 Configure and Start the Kinetix 5500 Drive System 7. The Motion Axis Parameters dialog box appears. 8. From the Parameter Group pull-down menu, choose Frequency Control. 9. Set the FluxUp, SkipSpeed, VelocityDroop, MaximumFrequency, and MaximumVoltage attributes appropriate for your application.
Page 131 Configure and Start the Kinetix 5500 Drive System Chapter 6 12. The Analyze Motor to Determine Motor Model dialog box opens. 13. Click one of the motor test tabs. In this example, Calculate Model is chosen. See Motor Tests and Autotune...
Page 132: 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 125. 2. Select the Frequency Control category. 3. From the Frequency Control Method pull-down menu, select Fan/Pump 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, RunBoost, MaximumFrequency, and MaximumVoltage attributes appropriate for your application.
Page 134: Configure Pm Motor Closed-Loop Control Axis Properties
Table 51 - 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 135 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 136 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 137: Download The Program
Configure and Start the Kinetix 5500 Drive System Chapter 6 From this dialog box, you can program actions and change the action for exceptions (faults). Refer to Logix5000 Controller and Drive Behavior page 160 for more information. 17. Select the Parameter List category.
Page 138: Apply Power To The Kinetix 5500 Drive
Chapter 6 Configure and Start the Kinetix 5500 Drive System Apply Power to the This procedure assumes that you have wired and configured your Kinetix 5500 system and your Logix5000 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 139: Understanding Bus Sharing Group Configuration
Configure and Start the Kinetix 5500 Drive System Chapter 6 Understanding 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 bus- Group Configuration sharing (power) groups.
Page 140: Bus Sharing Group Example
Chapter 6 Configure and Start the Kinetix 5500 Drive System 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 141: Configure Bus-Sharing Groups
Configure and Start the Kinetix 5500 Drive System Chapter 6 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 142 Chapter 6 Configure and Start the Kinetix 5500 Drive System 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 66 - Group 2 Leader Drive Configuration...
Page 143: Test And Tune The Axes
Chapter 6 Test and Tune the Axes This procedure assumes that you have configured your Kinetix 5500 drive, your Logix5000 controller, and applied power to the system. Before proceeding with testing and tuning your axes, verify that the MOD and...
Page 144 Chapter 6 Configure and Start the Kinetix 5500 Drive System Test Description Verifies marker detection capability as you manually rotate the motor shaft. The test completes when the drive either detects the marker or when the motor moves the distance specified in the Test Distance field. If the marker remains undetected, the test...
Page 145: Tune The Axes
Configure and Start the Kinetix 5500 Drive System Chapter 6 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 146 Chapter 6 Configure and Start the Kinetix 5500 Drive System b. Set the Load Ratio = 0. 4. Click the Observer tab in the Axis Properties dialog box. a. From the Configuration pull-down menu, choose Load Observer with Velocity Estimate.
Page 147 Configure and Start the Kinetix 5500 Drive System Chapter 6 Tune Induction Motors The Automatic FluxUpControl setting is recommended for best Autotune IMPORTANT results. Follow these steps to tune the induction motor axes. 1. Verify the load is removed from the axis being tuned.
Page 148 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 149: Troubleshoot The Kinetix 5500 Drive System
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 Logix5000 Controller and Drive Behavior Safety Precautions Observe the following safety precautions when troubleshooting your Kinetix 5500 servo drive.
Page 150: 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 151 Troubleshoot the Kinetix 5500 Drive System Chapter 7 Table 52 - Fault Code Summary (1) (2) Fault Code Type Description FLT Sxx Standard runtime axis exceptions. FLT Mxx Manufacturer-specific runtime axis exception. INIT FLT Sxx Exceptions that prevent normal operation and occur during the initialization process.
Page 152 Chapter 7 Troubleshoot the Kinetix 5500 Drive System Table 53 - FLT Sxx Fault Codes (continued) Exception Code on Display Exception Text Problem Possible Solutions • Modify the command profile to reduce speed or increase time Inverter Overtemperature The measured inverter temperature has exceeded the FLT S11 –...
Page 153 Troubleshoot the Kinetix 5500 Drive System Chapter 7 Table 53 - FLT Sxx Fault Codes (continued) Exception Code on Display Exception Text Problem Possible Solutions The feedback device has detected an internal error. The nn sub-code is defined as follows:...
Page 154 Chapter 7 Troubleshoot the Kinetix 5500 Drive System Table 54 - FLT Mxx Fault Codes Exception Code on Display Exception Text Problem Possible Solutions The configured voltage of the drive is greater than the Set the drive voltage to a lower value or replace motor with voltage FLT M02 –...
Page 155 Troubleshoot the Kinetix 5500 Drive System Chapter 7 Table 56 - INHIBIT Fault Codes Exception Code on Display Exception Text Problem Possible Solutions INHIBIT S02 – MTR NOT CONFIG Motor Not Configured The motor has not been properly configured for use.
Page 156: Safe Flt Fault Codes
Chapter 7 Troubleshoot the Kinetix 5500 Drive System Table 58 - NODE ALARM Fault Codes Exception Code on Display Exception Text Problem Possible Solutions • Remove unnecessary network devices from the motion network • Change network topology so that fewer devices share common...
Page 157: Kinetix 5500 Drive Status Indicators
Troubleshoot the Kinetix 5500 Drive System Chapter 7 Kinetix 5500 Drive Status Indicators The module status and network status indicators are just above the LCD status display. Status indicators are not reliable for safety functions. Use them only for general IMPORTANT diagnostics during commissioning or troubleshooting.
Page 158: Kinetix 5500 Capacitor Module Status Indicators
Chapter 7 Troubleshoot the Kinetix 5500 Drive System 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 Logix5000 controller.
Page 159 Troubleshoot the Kinetix 5500 Drive System Chapter 7 Table 64 - General Troubleshooting (continued) 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.
Page 160: Logix5000 Controller And Drive Behavior
Chapter 7 Troubleshoot the Kinetix 5500 Drive System Logix5000 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 The INIT FLT xxx faults are always generated after powerup, but before the drive is enabled, so the stopping behavior does not apply.
Page 161 Troubleshoot the Kinetix 5500 Drive System Chapter 7 For Kinetix 5500 drives, only selected exceptions are configurable. In the drive behavior tables, the controlling attribute is given for programmable fault actions. Table 67 - Configurable Stopping Actions Stopping Action Description...
Page 162 Chapter 7 Troubleshoot the Kinetix 5500 Drive System Table 68 - 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 S10 – INV OVERCURRENT...
Page 163 Troubleshoot the Kinetix 5500 Drive System Chapter 7 Table 69 - Drive Behavior, FLT Mxx Fault Codes Fault Action Best Available Permanent Exception Fault Code Exception Text Induction Motor Stopping Action Magnet Motor (applies to major faults) FLT M02 – MOTOR VOLTAGE...
Page 164 Chapter 7 Troubleshoot the Kinetix 5500 Drive System Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 165: Before You Begin
Chapter Remove and Replace Servo Drives 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.
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. Frame 1 and 2 drives have one top and bottom screw. Frame 3 drives have two top and bottom screws.
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 138 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
Safe Torque-off Specifications A ControlLogix 5570, ControlLogix 5580, or CompactLogix 5370 controller is required for hardwired safety control of the Kinetix 5500 safe torque-off function. The 2198-Hxxx-ERS servo drives use the STO connector for wiring external safety devices and cascading hardwired safety connections from one drive to another.
Page 170: Category 3 Requirements According To En Iso 13849-1
Chapter 9 Kinetix 5500 Safe Torque-off - Hardwired Safety Category 3 Requirements According to EN ISO 13849-1 Safety-related parts are designed with these attributes: • A single fault in any of these parts does not lead to the loss of the safety function.
Page 171: Troubleshoot The Safe Torque-Off Function
Kinetix 5500 Safe Torque-off - Hardwired Safety Chapter 9 ATTENTION: If any of the safety enable inputs de-energize, the Start Inhibit field indicates SafeTorqueOffInhibit and GuardStopRequestStatus bit of AxisGuardStatus tag set to 1. Both inputs must be de-energized within 1 second and re-energized within 1 second to avoid GuardStopInputFault conditions.
Page 172 Chapter 9 Kinetix 5500 Safe Torque-off - Hardwired Safety Figure 71 demonstrates when the safe torque-off mismatch is detected and a GuardStopInputFault is posted. Figure 71 - System Operation in the Event that the Safety Enable Inputs Mismatch 24V DC...
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 system Failure Per Hour 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 The National Electrical Code and local electrical codes take precedence over the IMPORTANT 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 EN ISO 13849-1 (PLd), Category 3 or according to IEC EN 61508, EN 61800-5-2, and EN 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
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 conditions of the Specifications 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 EN ISO 13849-1 and SIL 3 per IEC EN 61508, EN 61800-5-2 and EN 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 EN ISO 13849-1 performance level or EN 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 EN 60204 or safe torque-off as defined by EN 61800-5-2 is achieved with immediate removal of motion producing power to the actuator.
Page 180: Troubleshoot The Safe Torque-Off Function
Refer to Table 76 for integrated safety troubleshooting. Refer to Figure 77 for an understanding of the 2198-Hxxx-ERS2 STO-state manual restart functionality. Figure 77 - Kinetix 5500 STO Timing Diagram - Manual Restart Drv:SO.SafeTorqueOff Drv:SO.Reset Drv:SI.ResetRequired Drv:SI.TorqueDisabled Axis.SafeTorqueOffActiveInhibit Axis.SafeTorqueOffActiveStatus Axis.SafeTorqueDisabledStatus...
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 system Failure Per Hour 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: Understanding 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: Replacing An Integrated Safety Drive In A Guardlogix System
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety the correct safety devices. The SNN is also used to provide integrity on the initial download to the 2198-Hxxx-ERS2 servo drive. When the Logix Designer application is online, the Safety tab of the Module Properties dialog box displays the current configuration ownership.
Page 185: Signature Exists Enabled
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Replacement with Configure Only When No Safety Signature Exists Enabled When a 2198-Hxxx-ERS2 servo drive is replaced and the DeviceID of the new drive matches the original, you can download the configuration from the safety controller.
Page 186 Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety The Safety Network Number dialog box appears. 4. Click Set. 5. Verify that the Network Status (NET) status indicator is alternating red/ green on the correct drive. 6. Click Yes to set the SNN and accept the replacement drive.
Page 187 Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Scenario 2- Replacement Integrated Safety Drive SNN Is Different from Original and Safety Signature Exists 1. Remove and replace the existing integrated safety drive. 2. Right-click the replacement drive and choose Properties.
Page 188 Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety The Safety Network Number dialog box appears. 8. Click Set. 9. Verify that the Network Status (NET) status indicator is alternating red/ green on the correct drive. Follow your company-prescribed procedures to functionally test the IMPORTANT replacement drive and system and to authorize the system for use.
Page 189: Replacement With Configure Always Enabled
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Scenario 3- Replacement Integrated Safety Drive SNN Is Different from Original and No Safety Signature Exists 1. Remove and replace the existing integrated safety drive. 2. Right-click the replacement drive and choose Properties.
Page 190 Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety If the project is configured for Configure Always, follow the appropriate steps to replace a 2198-Hxxx-ERS2 servo drive. Follow these steps when the Configure Always feature is enabled. 1. Remove and replace the existing integrated safety drive.
Page 191: Motion Direct Commands In Motion Control Systems
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 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 is Motion Control Systems executed in Run mode.
Page 192: Logix Designer Application Warning Messages
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety 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 193 Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 When you issue a motion direct command to an axis to produce torque in Program mode, for example MSO or MDS, with the safety connection present to the drive, a warning message is presented before the motion direct command is...
Page 194: Torque Permitted In A Multi-Workstation Environment
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety The persistent warning message text Safe Torque Off bypassed appears IMPORTANT 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 195 Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Figure 85 - Axis and Safe State Indications on Motion Direct Commands Dialog Box Figure 86 - Axis and Safe State Indications on the Motion Console Dialog Box Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 196: Functional Safety Considerations
Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety 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 197: Safe Torque-Off Specifications
Kinetix 5500 Safe Torque-off - Integrated Safety Chapter 10 Safe Torque-off To maintain safety rating, Kinetix 5500 drives must be installed inside protected control panels or cabinets appropriate for the environmental conditions of the Specifications industrial location. The protection class of the panel or cabinet must be IP54 or higher.
Page 198 Chapter 10 Kinetix 5500 Safe Torque-off - Integrated Safety Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 199: Interconnect Diagram Notes
Kinetix 5500 Drive and Motor/Actuator Wiring Examples 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. Note...
Page 200: Power Wiring Examples
You must supply input power components. The single-phase and three-phase line filters are wired downstream of the circuit protection. Single-axis Drive Wiring Examples Figure 87 - Kinetix 5500 Drives Power Wiring (three-phase operation) 2198-Hxxx-ERSx Kinetix 5500 Drives Refer to table on page 199 for note information.
Page 201 Interconnect Diagrams Appendix A Figure 88 - Kinetix 5500 Drives Power Wiring (single-phase operation) 2198-H003-ERSx, 2198-H008-ERSx, or 2198-H015-ERSx Refer to table on page 199 for note information. Kinetix 5500 Drives Bonded Cabinet Ground Bus * PE Ground Note 6 Chassis...
Page 202: 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 90 - Kinetix 5500 Drives with Shared AC Bus 2198-Hxxx-ERSx 2198-Hxxx-ERSx 2198-Hxxx-ERSx Kinetix 5500 Drive Kinetix 5500 Drive...
Page 203 Interconnect Diagrams Appendix A Figure 92 - 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 199 for note information. PE Ground Note 6...
Page 204: Shunt Resistor Wiring Example
Shunt Resistor Wiring Refer to the External Passive-shunt Resistor Connections page 99 for the Bulletin 2097 external shunt resistor catalog numbers available for Kinetix 5500 Example servo drives. Before wiring the Bulletin 2097 external shunt to the RC connector, remove the IMPORTANT wires from the servo drive internal shunt.
Page 205: Kinetix 5500 Drive And Motor/Actuator Wiring Examples
The Kinetix VP motors use single cable technology. The motor power, brake, and feedback wires are all packaged in a single cable. Motor/Actuator Wiring Examples Figure 95 - Kinetix 5500 Drives with Kinetix VP Motors (Bulletin VPL, VPF, and VPS) 2198-Hxxx-ERSx VPL-A/Bxxxx-C/P Motors Kinetix 5500 Servo Drives...
Page 206 Compatible Allen-Bradley rotary motors (Bulletin MPL, MPM, MPF, and MPS) and linear actuators (Bulletin MPAS, MPAR, MPAI, and LDAT-Series) have separate connectors and cables for power/brake and feedback connections. Figure 97 - Kinetix 5500 with MP-Series Rotary Motors MPL-A15xx…MPL-A5xx, Refer to table on page 199 for note information.
Page 207 Interconnect Diagrams Appendix A Figure 98 - 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 199 for note information. High Resolution Feedback 2198-H2DCK Feedback Cable Shield Converter Kit...
Page 208 Appendix A Interconnect Diagrams Figure 99 - 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 199 for note information. High Resolution Feedback 2198-H2DCK Feedback Cable Shield Converter Kit...
Page 209 Interconnect Diagrams Appendix A Figure 100 - Kinetix 5500 with MP-Series Electric Cylinders MPAR-A/Bxxxxx and 2198-Hxxx-ERSx Refer to table on page 199 for note information. MPAI-A/Bxxxxx Kinetix 5500 Servo Drives Electric Cylinders with 2198-H2DCK Feedback High Resolution Feedback Cable Shield...
Page 210: System Block Diagrams
Appendix A Interconnect Diagrams System Block Diagrams This section provides block diagrams of the Kinetix 5500 drive modules. Figure 101 - Kinetix 5500 Drive Block Diagram Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 211 Interconnect Diagrams Appendix A Figure 102 - 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 212 Appendix A Interconnect Diagrams Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 213 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 Logix5000 controller communication, selecting the drive to upgrade, and upgrading the firmware.
Page 214: Before You Begin
ControlFLASH software kit 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 215: Configure Logix5000 Controller Communication
Upgrade the Drive Firmware Appendix B Configure Logix5000 Controller Communication This procedure assumes that your communication method to the Logix5000 controller is the Ethernet network. It also assumes that your Logix5000 Ethernet module or controller has already been configured. For more controller information, refer to Additional Resources page Follow these steps to configure Logix5000 controller communication.
Page 216: 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 217: 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. You can also open ControlFLASH software by choosing Start>Programs>FLASH Programming Tools>ControlFLASH. The Welcome to ControlFLASH dialog box appears.
Page 218 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 219 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 220 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 221: Verify The Firmware Upgrade
Upgrade the Drive Firmware Appendix B Verify the Firmware Upgrade Follow these steps to verify your firmware upgrade was successful. 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 222 Appendix B Upgrade the Drive Firmware Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 223: 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 224: Shared Ac Configurations
Shared AC, max 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx Figure 103 - 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 225 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 104 - Typical DC Common Bus Configuration Bonded Cabinet Ground Three-phase DC Bus Connections...
Page 226: 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 105 - Typical Shared AC/DC Configuration Bonded Cabinet Ground Three-phase DC Bus Connections...
Page 227: Shared Ac/Dc Hybrid Configurations
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 Typical Shared AC/DC Bus Hybrid Installations...
Page 228: 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 229: 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 230: 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 the combined Calculations current demand from your 24V DC power supply includes the following: •...
Page 231: 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 110 - Shared AC/DC Hybrid Configuration...
Page 232: Energy Calculations
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 233: Frequency Control Methods
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 Skip Speeds Flux Up Current Regulator Loop Settings Motor Category...
Page 234: Basic Volts/Hertz
Pole pairs, max 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. Basic Volts/Hertz Volts/hertz operation creates a fixed relationship between output voltage and output frequency.
Page 235: Basic Volts/Hertz For Fan/Pump Applications
Motor Control Feature Support Appendix D 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 112 - Output Voltage Equation Where: = Output voltage –...
Page 236: Sensorless Vector
Appendix D Motor Control Feature Support 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 114 - Sensorless Vector Method Motor Pole Pairs Velocity Trim...
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 117 - 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 develope. 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 121 - 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 93 - Current Regulator Loop Settings Default Torque/Current Loop Bandwidth Motor Type Rotary permanent magnet 1000 Rotary induction Linear permanent magnet 1000 The Logix Designer application does not perform calculations when the...
Page 243 Motor Control Feature Support Appendix D Figure 123 - 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 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 The Static and Dynamic tests require that you enter initial estimates for the IMPORTANT Rated Flux Current, Stator Resistance (Rs), Stator Leakage Reactance (X1), and Rotor Leakage Reactance (X2) into the Motor Model fields. This can be done by running and accepting the results of a Calculate test, or by entering the values directly into the Logix Designer application.
Page 247: Selection Of Motor Thermal Models
Motor Control Feature Support Appendix D 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 248: Thermally Characterized Motors
Appendix D Motor Control Feature Support 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 249: Speed Limited Adjustable Torque (Slat)
Motor Control Feature Support Appendix D 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 250: Slat Min Speed/Torque
Appendix D Motor Control Feature Support SLAT Min Speed/Torque SLAT Min Speed/Torque is a special mode of operation primarily used in web handling applications. The drive typically operates as a torque regulator, provided that the TorqueTrim attribute is less than the torque output due to the velocity regulator's control effort.
Page 251: Slat Max Speed/Torque
Motor Control Feature Support Appendix D 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 252: Configure The Axis For Slat
Appendix D Motor Control Feature Support 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 253 Motor Control Feature Support Appendix D 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. SLAT Disable, when viewed in the Logix Designer application, version IMPORTANT 28.00 (and earlier) reads Torque Only.
Page 254 Motor Control Feature Support The Drive Parameters to Controller Mapping dialog box appears. When using SLAT with the Kinetix 5500, the velocity command is sent to the drive via an MAJ instruction. The torque command is sent via the cyclic write TorqueTrim attribute.
Page 255: Motor Overload Retention
Motor Control Feature Support Appendix D 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 256: Torque Proving
Appendix D Motor Control Feature Support Torque Proving The torque proving 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 257: Torque Proving Configuration
Motor Control Feature Support Appendix D Torque Proving Configuration Follow these steps to configure the torque proving 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 258: Torque Proving Current Example
Appendix D Motor Control Feature Support Torque Proving 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 torque-proving equation and table to calculate the minimum torque-proving current as a percentage of motor rated current.
Page 259: Velocity Droop
Motor Control Feature Support Appendix D 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 260: Velocity Droop Configuration
Appendix D Motor Control Feature Support 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 261: Ec Certifications
Appendix EC Certifications This appendix provides Kinetix 5500 servo drive certification information. Topic Page EC Type - Examination Certificate EU Declaration of Conformity European Union Directives EC Type - Examination For product certifications currently available from Rockwell Automation, go to http://www.rockwellautomation.com/products/certification.
Page 262: Eu Declaration Of Conformity
Appendix E EC Certifications EU Declaration of Conformity For all declarations of conformity (DoC) currently available from Rockwell Automation, go to http://www.rockwellautomation.com/ rockwellautomation/certification/overview.page. Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 263 EC Certifications Appendix E Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 264 Appendix E EC Certifications Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 265 EC Certifications Appendix E Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 266 Appendix E EC Certifications Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 267: European Union Directives
EC Certifications Appendix E European Union Directives If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply. CE Conformity Conformity with the Low Voltage Directive and Electromagnetic Compatibility (EMC) Directive is demonstrated by using harmonized European Norm (EN) standards published in the Official Journal of the European Communities.
Page 268 Appendix E EC Certifications Notes: Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 269: Index
Index Numerics 2090-CSBM1DF 14 cables 2090-CSBM1DG 14 catalog numbers 84 categories 40 2198-CAPMOD-1300 27 Ethernet cable length 100 2198-H2DCK 13 induction motors 90 2198-KITCON-DSL 13 routing 30 24V input power connector shield clamp 87 pinouts 59 calculate test 245 wiring 80 capacitor module 211 catalog number 27 description 13...
Page 270 103 motor feedback 95 module properties 114 motor power/brake 91 inhibit module 216 description 13 motion group 123 Kinetix 5500 AOP 89 motor CP connector test 143 motor category 126 pinouts 59 motor feedback 134 wiring 80 motor>analyzer category 131...
Page 271 Index encoder support DSL 66 energy calculations 232 digital inputs specifications 62 erratic operation 159 ignore 160 Ethernet connector induction motor control 90 pinouts 61 calculate, static, dynamic tests 245 EtherNet/IP configure flux up 241 connecting cables 100 control methods connections 64 basic volts/hertz 234 module properties 110...
Page 272 170 model category 243 stop category definitions 170 motor and inertia tests 244 overload retention 255 thermal models 247 motors Kinetix 5500 13 accel/decel problems 158 brake connector pinouts 61 wiring 85 cable catalog numbers 84 Lapp 90 cable length 28...
Page 273 Index navigation buttons 102 SAB 90 network safe torque-off 174 parameters 106 bypass wiring 175 status indicator 157 cascaded wiring 176 new tag configurations hardwired 24 data type 119 integrated 25 noise operation 170 abnormal 159 PFH 173 feedback 159 pinouts 173 reduction 41 specifications 67...
Page 274 Index SLAT 249 troubleshooting attributes 251 alarm 160 configuring 252 capacitor module status 158 soft menu ControlFLASH 220 controller/drive fault behavior 160 home screen 102 fault software code summary 151 Logix Designer application 108 codes 150 specifications status only 160 brake relay 64 general system problems 158 control power input 65...
Page 275 Index wiring BC connector 85 capacitor module 98 converter kit shield clamp 96 CP connector 80 earth ground 76 Ethernet cables 100 external shunt resistor 99 grounded power configuration 71 grounding screws 74 guidelines 79 input power type 71 IOD connector 83 IPD connector 81 MF connector 86 motor cable shield clamp 87...
Page 276 Index Rockwell Automation Publication 2198-UM001F-EN-P - December 2015...
Page 278 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

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Allen-Bradley Kinetix 5500 User Manual

Summary of Changes

Preface

Chapter 1

Start

Plan the Kinetix 5500 Drive System Installation

Chapter 2 System Design Guidelines

Mount the Kinetix 5500 Drive System

Chapter 3 Determine Mounting Order

Chapter 4

Chapter 5 Routing the Power and Signal Cables

Configure and Start the Kinetix 5500 Drive System

Chapter 6 Understanding the Kinetix 5500 Display

Chapter 7

Troubleshoot the Kinetix 5500 Drive System

Chapter 8 Remove and Replace Kinetix 5500 Servo Drives

Chapter 9

Chapter 10 Certification

Appendix A

Appendix B

Appendix C

Appendix D

Appendix E

EC Certifications

Index

Quick Links

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Summary of Contents for Allen-Bradley Kinetix 5500