Installation Instructions
Continuous Flexible Power Cables
with
DIN SpeedTec Connector
Catalog Numbers 2090-CPBM7DF-xxAFxx,
2090-CPWM7DF-xxAFxx
Topic Page
About Flexible Power Cables 1
Important User Information 2
Before You Begin 3
Install Cables 4
Schematics and Connector Pinouts for Cables 6
Specifications 7
Additional Resources 8
About Flexible Power Cables
Continuous flexible motor power cables, with or without brake connections, can be
repeatedly flexed within a specified bend radius when properly installed. The
cables have circular SpeedTec connectors at the motor end, and flying leads at the
drive end.
2 Continuous Flexible Power Cables Installation Instructions
WARNING
IMPORTANT
ATTENTION
SHOCK HAZARD
BURN HAZARD
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls, publication
SGI-1.1
, available from your local Rockwell Automation sales office or online at
http://literature.rockwellautomation.com
equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot
assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,
equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell
Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Identifies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
damage, or economic loss.
, describes some important differences between solid state
Publication 2090-IN025A-EN-P — October 2009
Identifies information that is critical for successful application and understanding of
the product.
Identifies information about practices or circumstances that can lead to personal injury
or death, property damage, or economic loss. Attentions help you identify a hazard,
avoid a hazard and recognize the consequences.
Labels may be on or inside the equipment, for example, a drive or motor, to alert
people that dangerous voltage may be present.
Labels may be on or inside the equipment, for example, a drive or motor, to alert
people that surfaces may reach dangerous temperatures.
Continuous Flexible Power Cables Installation Instructions 3
WARNING
ATTENTION
WARNING
ATTENTION
Before You Begin
Remove all packing material from within and around the item. After unpacking,
verify the catalog number against the purchase order., and visually inspect the cable
and each connector for damage. If necessary, notify the carrier of any shipping
damage immediately.
Cables are stored and shipped in a coil, and will retain this shape unless you allow
the cable to straighten itself. To straighten a cable, hang a short cable from its
mid-point or lay a long cable on the floor in a straight line. Any coiling that persists
in the cable should relax within the next twenty-four hours. Doing this results in a
cable that is easier to install.
Observe the following precautions when installing the cables in a servo system.
Failure to observe these safety notices could result in personal injury or damage to
the motor and equipment.
Arcing or unexpected motion can occur if the power, brake, or feedback cables are
connected or disconnected while power is applied to the drive.
Always remove power to the servo drive before connecting or disconnecting cables at
the drive or at the motor.
The maximum length of cabling between the drive and the motor must not exceed 90 m
(295.5 ft). Also, a maximum of two (2) extension cables may be connected from a motor to
a drive.
To avoid the hazard of electrical shock, ensure shielded power cables are grounded at a
minimum of one point. To prevent the build-up of electrical energy, factory supplied
power cables use one of these grounding techniques:
• The overall shield is bonded to the connector housing.
• A section of the overall shield is exposed for connection to ground.
• The overall shield is connected to a ground wire.
If the exposed cable braid or a ground wire is present, connect it to the power cable
clamp, housing, or another suitable chassis ground on the drive.
Do not tightly gather or coil the excess length of a power cable. Heat is generated
within a cable whenever power is applied. Always position a power cable so it may
freely dissipate any heat.
A power cable should not be coiled, except for temporary use when building or
testing a machine. If you temporarily coil a power cable, you must also derate the
cable to meet local code or follow a authoritative directive, such as Engineering
Section 310.15(C) of the NEC Handbook.
Publication 2090-IN025A-EN-P — October 2009
4 Continuous Flexible Power Cables Installation Instructions
ATTENTION
IMPORTANT
U
Y
W
PE
WHITE
BLACK
MBRK+
MBRK-
Feature Offset
Minimum of 1x Cable Diameter
Flex Zone
2090-CPBM7DF-xxAFxx shown
Installation Area
300 mm (12 in.)
approx.
Installation Area
300 mm (12 in.)
approx.
Exposed
Shields
The examples in this publication show all the available connections, some of which
may not be appropriate for your specific installation. Refer to your drive installation or
user manual for recommended wire trim lengths, and wiring examples appropriate to
your drive and motor application.
Do not connect unused wires. Unused wires may be trimmed and finished as necessary
to prevent accidental contact with other wires or wire shields, or with a ground
connection.
Continuos flexible cables with SpeedTec connectors are incompatible with some
MP-Series motors.
Only install cables with a threaded connector on these motors: MPL-A15x0, MPL-A2x0,
MPL-B15x0, MPL-B2x0, MPS-A330, MPS-A4540, MPS-B330, MPS-B4540, and
MPS-B560.
Install Cables
Follow these steps when installing a cable.
1. Identify the recommended installation areas and the correct offset from
features before beginning any cable bend. Features include these areas on
the cable:
• Connectors
• Transitions from exposed wire to insulation (for example, flying leads)
• Exposed cable ground shields
The offset from these features should be greater than or equal to (>
cable diameter.
2. Keep cable bends within the specified bend radius. Continuous flexible
cables have an operational bend radius of twelve times (12x) the cable
diameter.
Publication 2090-IN025A-EN-P — October 2009
1x) the
Continuous Flexible Power Cables Installation Instructions 5
IMPORTANT
SpeedTec Plug
Threaded Plug
Remove O-ring when mating with a
SpeedTec plug.
Install O-ring when mating with a
threaded plug.
O-ring in groove.
If an O-ring is installed, a SpeedTec plug will not engage with the receptacle.
Never bend a cable tighter than the specified bend radius. Refer to
Specifications for value.
3. When installing a continuous flexible cable observe these restrictions on the
flex zone and installation area:
• The flex zone is the area in which the cable can repeatedly flex up to its
specified bend radius.
• The installation areas require rigid mounting to prevent the cable from
flexing where it connects to other components.
4. Identify each connection on a cable by attaching a label around the outer
insulation of each wire adjacent to the drive connection.
5. Remove the O-ring on the motor connector when using a power cable with
a SpeedTec power plug.
The type of plug on the cable determines whether an O-ring is required on
the receptacle.
The O-ring dampens the effects of vibration at the cable-to-motor connection. This
creates a more secure connection for a cable with a threaded plug.
Publication 2090-IN025A-EN-P — October 2009
6 Continuous Flexible Power Cables Installation Instructions
Twisted Wire Pair
360° shield-to-ground
connections required.
To
Motor
Connector Backshell
Shielded 360°
Shield
Wire Connection
To
Drive
1
1
1
1
Brown
Black
Blue
Green/Yellow
Shield
A
B
C
D
U
V
W
GND
CC
B
A
E
F
G
H
L
360°
shield-to-ground
connection required.
To
Motor
Shield
Wire Connection
To
Drive
Connector
Backshell
Shielded 360°
Schematics and Connector Pinouts for Cables
Schematics show wire colors and connector pinouts necessary to connect the cable
to a servo system.
2090-CPBM7DF-xxAFxx
This cable is available in several wire gauges and lengths. Refer to the Kinetix
Motion Control Selection Guide, publication GMC-SG001, for this information and
additional specifications.
1
A
CC
B
G
A
F
E
L
H
B
C
D
F
G
Brown
1
Black
1
Blue
1
Green/Yellow
18 AWG White
18 AWG Black
Shield
U
V
W
GND
MBRK+
MBRK-
1 Wire gauge and connector keying varies based on motor and power requirements. Refer to Kinetix Motion Control Selection
Guide, publication GMC-SG001
, for additional information.
2090-CPWM7DF-xxAFxx
This cable is available in several wire gauges and lengths. Refer to the Kinetix
Motion Control Selection Guide, publication GMC-SG001
additional specifications.
1 Wire gauge and connector keying varies based on motor and power requirements. Refer to Kinetix Motion Control Selection
Guide, publication GMC-SG001
Publication 2090-IN025A-EN-P — October 2009
, for additional information.
, for this information and
Continuous Flexible Power Cables Installation Instructions 7
Specifications
These specifications provide information that is useful when installing a cable.
Additional specifications for each cable are available in the Kinetix Motion Control
Selection Guide, publication GMC-SG001
2090-CPBM7DF-xxAFxx Specifications
Attribute Value
Wire Size 16 AWG 14 AWG
Diameter 12.5 mm (0.5 in.) 13.7 mm (0.5 in.)
1
Bend Radius
Flex Area 150 mm (6.0 in.) 165 mm (6.5 in.)
Installation Areas
1
Apply the multiplier for operational (12 x dia.) and static (10 x dia.) bend radius to cables with a different diameter. Refer to
the diagram to locate the areas for flex (operational), and static (installation) bend areas.
2
The installation areas are approximately 300 mm (12 in.) in length at both ends of the cable. Secure this area with a rigid
mount that prevents the cable from flexing where it connects to other components.
2
125 mm (5.0 in.) 137 mm (5.5 in.)
.
2090-CPWM7DF-xxAFxx Specifications
Attribute Value
Wire Size 16 AWG 14 AWG
Diameter 9.7 mm (0.4 in.) 10.4 mm (0.4 in.)
1
Bend Radius
Flex Area 120 mm (5.0 in.) 125 mm (5.0 in.)
Installation Areas
1
Apply the multiplier for operational (12 x dia.) and static (10 x dia.) bend radius to cables with a different diameter. Refer to
the diagram to locate the areas for flex (operational), and static (installation) bend areas.
2
The installation areas are approximately 300 mm (12 in.) in length at both ends of the cable. Secure this area with a rigid
mount that prevents the cable from flexing where it connects to other components.
2
100 mm (4.0 in.) 105 mm (4.0 in.)
Publication 2090-IN025A-EN-P — October 2009
Additional Resources
These documents contain additional information concerning related Rockwell
Automation products.
Resource Description
Kinetix 2000 Multi-axis Servo Drive User
Manual, publication 2093-UM001
Kinetix 6000 Multi-axis Servo Drives User
Manual, publication 2094-UM001
Kinetix 7000 High Power Servo Drive User
Manual, publication 2099-UM001
Ultra1500 Digital Servo Amplifiers User Manual,
publication 2092-UM001
Ultra3000 Digital Servo Drive Installation
Manual, publication 2098-IN003
Manual, publication 2098-IN005
Ultra5000 Intelligent Positioning Drives
Installation Manual, publication 2098-IN00
Allen-Bradley Industrial Automation Glossary,
publication AG-7.1
System Design for Control of Electrical Noise
Reference Manual, publication GMC-RM001
Kinetix Motion Control Selection Guide,
publication GMC-SG001
or Integration
Provides mounting, wiring, and application-based
information for a Kinetix multi-axis or an Ultra single-axis
servo drive system and its components.
1
A glossary of industrial automation terms and
abbreviations.
Information, examples, and techniques designed to
minimize system failures caused by electrical noise.
Specifications, motor/servo-drive system combinations,
and accessories for Kinetix motion control products.
You can view or download publications at
http://literature.rockwellautomation.com. To order paper copies of technical
documentation, contact your local Rockwell Automation distributor or sales
representative.
Allen-Bradley, Kinetix, Rockwell Automation, Rockwell Software, Ultra1500, Ultra3000, and Ultra5000 are trademarks of
Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 2090-IN025A-EN-P — October 2009 PN-48090
Supersedes Publication 2090-IN025A-EN-P — October 2009 Copyright © 2009 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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