Rockwell Automation 2099-BMxx User Manual
User Manual
Kinetix 7000 High Power Servo Drive
Catalog Numbers 2099-BM06-S, 2099-BM07-S, 2099-BM08-S, 2099-BM09-S, 2099-BM10-S, 2099-BM11-S, 2099-BM12-S
Important User Information
IMPORTANT
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
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
available from
) describes some
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, CompactLogix, ControlFlash, ControlLogix, DriveExplorer, Kinetix, RSLogix 5000, Rockwell Sof tware, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belong ing to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
New and Updated Information
This table contains the changes made to this revision.
Topic Page
Updated the Additional Resources with updated and new publications. 9
Updated the Typical System Diagrams to include updated catalog numbers for
Bulletin MPL motors, Bulletin MPM motors, and regenerative power supplies.
Added the Using Motion Analyzer to Determine Heat Dissipation information to the
Enclosure Selection section.
Added the mounting information from Chapter 3 - Mount the Kinetix 7000 Drive
System, to Chapter 2 - Install the Kinetix 7000 Drive System and removed Chapter 3.
Updated the Kinetix 7000 Front Panel Connectors and Displays, Kinetix 7000 Top
Panel Connectors and Switches, and Kinetix 7000 Bottom Panel Connectors
illustrations and tables for clarity.
Updated the IOD connector pinouts in the Hardware Enable, Home and Positive and
Negative Overtravel circuit diagrams.
Added information on Reading Analog Input Voltage Values. 61
Updated information on configuring the General Purpose I/O regenerative power
supply OK signal.
Added Figure 41 Safe-Off, Motion-allowed Jumper. 65
Updated the information in the Setting the Ground Jumper in Ungrounded Power
Configurations section.
Updated the Wire the Kinetix 7000 Drive Connectors section. 88
Added Flying-lead Feedback Cable Pinouts for the new 2090-XXNFMF-Sxx and 2090-
CFBMxDF-CDAFxx Feedback Cable.
Added illustrations to the Wire Feedback and I/O Connectors section. 95
Updated the information on External Shunt Module Connections to reflect
availability of certain shunt modules.
Updated the Node Addressing Examples to reflect current topologies. 108
Updated the steps and images in the Configure the Logix SERCOS interface Module
section to reflect the current software release.
Added the Configure Drive Parameters and System Variables section. 134
Added an explanation for the Drive Overtemperature Fault (E23) to the list of Error
Codes.
Updated the Specifications and Dimensions section to reflect current data and
specifications.
Added Korean Registration of Broadcasting and Communications Equipment
certification to the Certifications table.
Added the new External Shunt Modules section to Appendix A. 156
Updated the Interconnect Diagrams to reflect new cables and corrected connections
information.
13
24
39
42
55
64
78
95
101
110
140
150
154
161
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 3
Summary of Changes
Notes:
4 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Table of Contents
Preface
Start
Install the Kinetix 7000 Drive System
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
About the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Typical Drive System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CE Requirements - System without LIM . . . . . . . . . . . . . . . . . . . . . . . 19
CE Requirements - System with LIM . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CE Requirements - System with DC Common Bus through 8720MC-
RPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 2
System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Minimizing Electrical Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Establish Noise Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cable Categories for Kinetix 7000 Systems . . . . . . . . . . . . . . . . . . . . . 35
Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 36
Mount the Kinetix 7000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Kinetix 7000 Connector Data
Chapter 3
Locate and Identify Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . 42
Digital and Analog Input/Output (IOD) Connector Pinout. . . . . 45
General Purpose I/O (GPIO) Terminal Block Connections . . . . . 46
General Purpose Relay (GPR) Terminal Block Connections . . . . . 46
Motor Feedback (MF) Connector Pinouts . . . . . . . . . . . . . . . . . . . . . 47
Auxiliary Feedback (AF) Connector Pinouts . . . . . . . . . . . . . . . . . . . 49
Safe-off (SO) Terminal Block Connections. . . . . . . . . . . . . . . . . . . . . 50
Control Power (CP) Terminal Block Connections. . . . . . . . . . . . . . 51
Power Terminal Block (PTB) Connections. . . . . . . . . . . . . . . . . . . . . 51
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 5
Table of Contents
Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Digital Inputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Analog Inputs (IOD Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analog Outputs (IOD Connector). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
General Purpose I/O (GPIO Connector). . . . . . . . . . . . . . . . . . . . . . . 63
General Purpose Relay (GPR Connector). . . . . . . . . . . . . . . . . . . . . . . 64
SERCOS Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safe-off (SO Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Control Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Motor (MF) and Auxiliary Feedback (AF) Connections . . . . . . . . . . . . . 66
Motor and Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . . . . 66
Chapter 4
Connect the Kinetix 7000 Drive
System
Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Building Your Own Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Shielded Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Required Cable Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
General Wire Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 75
Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Power Distribution Systems Without a Ground Reference . . . . . . . 77
Setting the Ground Jumper in Ungrounded Power Configurations . . . 78
Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and
2099-BM08-S Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Removing the Ground Wires on 2099-BM09-S and 2099-BM10-S
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Removing the Ground Wires on 2099-BM11-S and 2099-BM12-S
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Grounding the Kinetix 7000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 81
Grounding Your System to the Subpanel . . . . . . . . . . . . . . . . . . . . . . . 81
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Motor Power Cable Shield Termination. . . . . . . . . . . . . . . . . . . . . . . . 82
MP-Series (Bulletin MPL) Motor Connectors . . . . . . . . . . . . . . . . . . 83
Input Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Acceptable Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Shielded/Armored Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Wire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Power Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Table of Contents
Wire the Kinetix 7000 Drive Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Wire the Control Power (CP) Connector . . . . . . . . . . . . . . . . . . . . . . 88
Wire AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Wire DC Input Power (Common Bus Configurations Only) . . . . 89
Wire the Safe-off (SO) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wire the General Purpose Relay (GPR) and General Purpose I/O
(GPIO) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Wire Motor Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Wire the Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Flying-lead Feedback Cable Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Wire Feedback and I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connect Premolded Motor Feedback Cables . . . . . . . . . . . . . . . . . . . 95
Wire Panel-mounted Breakout Board Kits. . . . . . . . . . . . . . . . . . . . . . 96
Wire Low-profile Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SERCOS Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . 101
Configure and Startup the Kinetix
7000 Drive System
Troubleshoot the Kinetix 7000 Drive
System
Chapter 5
Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Node Addressing Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Configure the Logix SERCOS interface Module . . . . . . . . . . . . . . . . . . . 110
Configure the Logix Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Configure the SERCOS Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Configure the Kinetix 7000 Drive Modules. . . . . . . . . . . . . . . . . . . . 117
Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Apply Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Configure Drive Parameters and System Variables . . . . . . . . . . . . . . . . . 134
Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Chapter 6
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Interpret Error Codes and Status Indicators . . . . . . . . . . . . . . . . . . . . . . . 138
Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
General System Anomalies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Logix/Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 7
Table of Contents
Appendix A
Specifications and Dimensions
Interconnect Diagrams
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Power Dissipation Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Weight Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
AC Line Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
External Shunt Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Precharge Capacities of the Regenerative Power Supply . . . . . . . . . . . . . 157
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendix B
Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Power Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Kinetix 7000 Drive/Rotary Motor Wiring Examples . . . . . . . . . . . 172
Kinetix Safe-off Feature Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Upgrade Firmware
Index
Appendix C
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Upgrade Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Preface
About This Publication
Who Should Use This Manual
Conventions Used in This Manual
This manual provides detailed installation instructions for mounting, wiring, and
troubleshooting your Kinetix 7000 drive, and system integration for your drive/
motor combination with a Logix controller.
This manual is intended for engineers or technicians directly involved in the
installation and wiring of the Kinetix 7000 drive, and programmers directly
involved in the operation, field maintenance, and integration of the Kinetix 7000
drive with a SERCOS interface module.
If you do not have a basic understanding of the Kinetix 7000 drive, contact your
local Rockwell Automation sales representative before using this product for the
availability of training courses.
These conventions are used throughout this manual.
• Bulleted lists such as this one provide information, not procedural steps.
• Numbered lists provide sequential steps or hierarchical information.
Additional Resources
The following documents contain additional information concerning related
products from Rockwell Automation.
Resource Description
Kinetix 7000 DC-DC Converter and Control Board Kits, publication 2099-IN002 Provides information on removing and replacing the DC-DC converter, DC-DC
Kinetix 7000 Drive Installation Instructions, publication 2099-IN003
Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010
ControlLogix SERCOS interface Module Installation Instructions, publication
1756-IN572
Logix5000 Controllers General Instructions Reference Manual, publication
1756-RM003
ControlLogix System User Manual, publication 1756-UM001
CompactLogix SERCOS interface Module Installation Instructions, publication 1768-IN005 Provides information on installing and troubleshooting a CompactLogix SERCOS
CompactLogix Controllers User Manual, publication 1768-UM001
SoftLogix Motion Card Setup and Configuration Manual, publication 1784-UM003
SoftLogix 5800 User Manual, publication 1789-UM002
8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001 Provides a hardware description and start-up and programming procedures for
System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001
converter fuse, and the control board assembly in a Kinetix 7000 drive.
Provides information on installing a Kinetix 7000 drive.
Provides information on proper handling, installing, testing, and troubleshooting
fiber-optic cables.
Provides details about installing a 3, 8 or 16-Axis ControlLogix SERCOS interface
module.
Provides programmers with details about each available instruction for a
Logix5000 controller. You should be familiar with how the Logix5000 controller
stores and processes data before consulting this publication.
Provides information about configuring and troubleshooting a ControlLogix
system.
interface motion module.
Provides information on installing, configuring, programming, and operating a
CompactLogix system.
Provides information on configuring and troubleshooting a SoftLogix PCI card.
Provides information on configuring, programming, and operating a SoftLogix
system.
the 8720MC-RPS Regenerative Power Supply.
Provides information, examples, and techniques designed to minimize system
failures caused by electrical noise.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 9
Preface
Resource Description
Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 Provides detailed installation instruc tions for wiring and troubleshooting a
Kinetix Motion Control Selection Guide, publication GMC-SG001 Provides descriptions and specifications for the 2099 product family including
Kinetix 7000 Drive Systems Design Guide, publication GMC-RM007
Kinetix Servo Drives Specifications Technical Data, publication GMC-TD003 Provides catalog numbers and product specifications, including performance,
Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004 Provides catalog numbers, product specifications, and dimensions for Allen-
Rockwell Automation Configuration and Selection Tools
website http://www.rockwellautomation.com/en/e-tools
Rockwell Automation Product Certification Website:
http://www.rockwellautomation.com/products/certification/
Kinetix Accelerator Toolkit Quick Start, publication IASIMP-QS002 Provides examples of using a Logix controller to connect to multiple devices
Kinetix Accelerator Toolkit Brochure, publication MOTION-BR004
SERCOS and Analog Motion Configuration and Startup, publication
MOTION-UM001
Motion Coordinate System User Manual, publication MOTION-UM002 Provides, information on configuring and troubleshooting your ControlLogix,
Logix5000 Controllers Motion Instructions Reference Manual, publication MOTION-RM002
National Electrical Code, published by the National Fire Protection Association of Boston, MA Provides access to articles on wire sizes and types for grounding electrical
Safety Products, publication S117-CA001 Provides information on principle standards and implementation of safety
Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls,
publication SGI-IN001
Understanding the Machiner y Directive, publication SHB-900
Allen-Bradley Industrial Automation Glossary, publication AG- 7.1 A glossary of industrial automation terms and abbreviations.
Kinetix 7000 safe-off drive.
motors and accessories.
The purpose of this publication is to assist you in identifying the drive system
components and accessory items you’ll need for your Kinetix 7000 drive/motor
combination.
environmental, certifications, load force, and dimension drawings for AllenBradley® servo drives.
Bradley servo drive accessories.
Provides information and access to the Motion Analyzer ap plication analysis
software for drive/motor sizing.
Provides online product selection and system configuration tools, including
AutoCAD (DXF) drawings.
Provides online access to declarations of conformity (DoC) currently available
from Rockwell Automation.
(servo drives, motors, and HMI) over the EtherNet/IP network in a Kinetix
Integrated Motion applic ation.
Provides information about the Kinetix Accelerator Toolkit.
Provides information to create a motion coordinate system with SERCOS or analog
motion modules.
CompactLogix, and SoftLogix SERCOS interface modules.
Provides programmers with details about the motion instructions that are
available for a Logix5000 controller.
equipment.
products and catalogs available safety products.
Provides general guidelines for the application, installation, and maintenance of
solid-state control in the form of individual devices or packaged assemblies
incorporating solidstate components.
Provides information on the CE marking process, with references to key European
requirements and resources, and examples of safety component applications.
You can view or download publications at
http://literature.rockwellautomation.com
documentation, contact your local Allen-Bradley distributor or Rockwell
Automation® sales representative.
10 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
. To order paper copies of technical
Chapter 1
Start
Use this chapter to become familiar with the design and installation requirements
for Kinetix 7000 drive systems.
Top ic Pa ge
About the Drive System 12
Typical Drive System Diagrams 13
Catalog Number Explanation 18
Agenc y Compliance 18
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 11
Chapter 1 Start
About the Drive System
The Kinetix 7000 high-power servo drive is designed to provide a Kinetix
Integrated Motion solution for applications with output power requirements in
the range of 22…149 kW (40…248 A).
Table 1 - Kinetix 7000 Drive System Overview
Kinetix 7000
Component
Servo Drive 2099-BMxx-S
Regenerative Power
Supply
Logix Controller
Platform
RSLogix 5000 Software 9324-RLD300ENE RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of controllers.
Rotary Servo Motors MP-Series, HPK-Series, and
Cables Motor Power, Feedback, and
AC Line Filters 2090-XXLF-TCxxxx Bulletin 2090-XXLF-TCxxxx three-phase AC line filters are required to meet CE and available for use in all Kinetix 7000 drive
Line Interface Module 2094-BL50/75S, or 2094-
External Shunt
Modules
Catalog Numbers Description
(1)
8720MC-RPS The 8720MC-RPS is a sinusoidal PWM converter that may serve as a regenerative power supply for one or more drives.
1756-L60M03SE module
1756-MxxSE module
1768-M04SE module
1784-PM16SE PCI card
RDD-Series
Brake cables
Communication Bulletin 2090 SERCOS fiber-optic cables are available as enclosure only, PVC, nylon, and glass with connectors at both ends.
XL75S-Cx
NA See External Shunt Modules
The Kinetix 7000 servo drive with safe-off feature is available with 460V AC input power, or capable of operating with a
shared DC bus.
The SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix platform and
Kinetix 7000 drive system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (SERCOS)
protocol over a fiber-optic cable.
Compatible rotary servo motors include MP-Series (Bulletin MPL and MPM) 400V class motors, HPK-Series motors, and
RDD-Series direct-drive motors.
Bulletin 2090 motor power/brake and feedback cables are available with bayonet, threaded, and SpeedTec connectors.
Power/brake cables have flying leads on the drive end and straight connectors that connect to servo motors. Feedback
cables have flying leads that wire to low-profile connector kits on the drive end and straight connectors on the motor end.
Large power motors may require user power wiring to handle larger current requirements.
systems.
The line interface module (LIM) contains the circuit breakers, power supplies, and safety contactor required for Kinetix 7000
operation. Individual components can be purchased separately in place of the LIM.
on page 156 for active shunt solutions from Rockwell Automation Encompass Partners and
intended for use with Kinetix 7000 drives.
(1) See the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002, for more information.
12 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Start Chapter 1
MAIN VACMAIN VAC
24V DC
Control Power
External Shunt Module (optional component). See
External Shunt Modules on page 156
for more
information.
2090-XXLF-TCxxxx
AC Line Fi lter
2094-BL75S
Line Interface Modul e
(optional component)
460V AC
Three- Phase
Input Power
RSLogix 5000 Software
Input
Logix 5000 Controller
Output
1756-MxxSE SERCOS
Interface Module
2090-SCxxx-x
SERCOS Fiber-Optic Ring
Commissioning
2099-BMxx-S Kinetix 7000 Drive
HPK-Series Motors, RDD-Series Direct Drive Motors, MPMB165xx and MPM-B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown) Servo Motors
Control Logix Chass is
Motor Power Cable
Encoder
Feedback
Cable
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback
Safe-off,
General Purpose I/O,
General Purpose Relay
Connections
Typical Drive System Diagrams
Typical Kinetix 7000 system installations include three-phase AC configurations,
with and without the line interface module (LIM), and DC common bus
configurations.
Figure 1 - Kinetix 7000 System Configuration with LIM and External Resistive Shunt
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 13
Chapter 1 Start
1606-XL
Power Supply
Input
Allen-Bradley
1606-XLxxx
24V DC
Control Power
2090-XXLF-TCxxxx
AC Lin e Filter
Input Fusing
Three- Phase
Input Power
Input
Logix 5000
Controlle r
Output
1756-MxxSE
SERCOS Interface Module
2090-SCxxx-x
SERCOS Fiber-Optic Ring
Commi ssionin g
2099-BMxx-S Kinetix 7000 Drive
ControlLog ix
Chassis
Motor Power Cable
Encoder
Feedback
Cable
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback.
Contro l Power Sup ply
Input
Input
Contacto r
Safe-off,
General Purpose I/O,
General Purpose Relay
connections
External Shunt Module (optional component).
See External Shunt Modules on page 156
for more
information.
HPK-Series Motors, RDD-Series Direct Drive Motors, MPMB165xx and MPM-B215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown) Servo Moto rs
RSLogix 5000 Software
Figure 2 - Kinetix 7000 System Configuration without Line Interface Module (LIM)
14 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Start Chapter 1
REGENERA
TIVE POWER
SUPPLY
8720
MC
READY
FAULT
PROGRAM
kW
V
A
Encoder
Feedback
Cable
2090-SCxxx-x
SERCOS Fiber-optic Ring
DC Bus
8720MC-RPS065BM-HV2
Regenerative Power Supply
8720MC-LRxx
Line Reactor
Three-phas e
Input Power
8720MC-VA-B Varistor
Included with
8720MC-RPS065BM-HV2.
8720MC-HF-B2 Harmonic Filter
Included with
8720MC-RPS065BM-HV2.
Magnetic
Contacto r
Motor
Power
Cable
1606-XLxxx
24V DC
Contro l Power
8720MC-RFI80
AC Lin e Filter
(required for CE)
Input
Fusing
Three-phase
Input Power
Magnetic
Contacto r
Input
Fusing
1321-3R Typ e L ine Rea ct or,
3% compatible with
Kinetix 7000 Drive
Regenerative
Power O nly
2099-BMxx-S
Kinetix 7000 Drive
2090-K6CK-Dxxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
Control Power
Supply Input
Logix SER COS
interface Module
ControlLogix Chassis
RSLogix 5000 Software
Logix Cont roller
Programming Network
Kinetix 7000 High Power
Servo Drive System
2090-XXLF-TCxxxx
AC Lin e Filter
(required for CE)
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165xx and MPMB215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xxx, and MPL-B9xxx (shown)
Servo Motors
The Kinetix 7000 drive system shown in Figure 3 below illustrates a regenerative
power only configuration with a 8720MC regenerative power supply (RPS). The
harmonic filter and varistor are available separately, but are included with the
RPS unit when ordering the 8720MC-RPS065BM-HV2. In this configuration
the Kinetix 7000 drive provides motoring power and the 8720MC-RPS065
provides regenerative power.
Figure 3 - Kinetix 7000 System Configuration with AC Input and Regenerative Power Supply
READY
FAULT
PROGRAM
8720
ENT
PRG
RST
MC
RE G E N E R AT IV E P O W E R S U P P LY
kW
Allen-Bradley
1606-XL
Power Supply
Input
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 15
1606-XL
Power Supply
Input
Allen-Bradley
R
EGE
NER
ATIVE PO
WER SUPPLY
REGENERATIVE PO
WER SUPPLY
87208720
MCMC
RST
PRG
ENT
READYREADY
FAULTFAULT
PROGRAMPROGRAM kWkW
V
A
1606-XL
Power Supply
Input
Allen-Bradley
R
EGENE
RA
TIVE
POW
ER
SU
PPLY
87208720
MCMC
RST
PRG
ENT
READYREADY
FAULFAULT
PR
OGRAMPROGRAM kWkW
V
A
2090-SCxxx-x
SERCOS Fiber-optic Ring
DC Bus
Kinetix 7000 Drive
2099-BM11-S
2090-K6CK-Dxxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
8720MC-RPS190BM
Regenerative Power Supply
Three-p hase
Input Power
8720MC-EF190-VB
EMC Line Filter
This unit includes an AC line filter (required for CE), magnetic
contactor, harmonic filter, and varistor.
IMPORTANT The 8720MC-EF190-VB line filter unit and two
8720MC-LR10-100B line reactors are required when using the
8720MC-RPS190 regenerative power supply.
Input
Fusing
Full Regenerative
2099-BM11-S
Kinetix 7000 Drive
2090-K6CK-Dxxx
Low Profile Connector
Kits for I/O, Motor and
Auxiliary Feedback
1606-XLxxx
24V DC
Contro l Power
1606-XLxxx
24V DC
Control Power
Encoder
Feedback Cable
Motor
Power C able
HPK-Series Motors
DC Bus
Fusing
DC Bus
Fusing
Contro l Power
Supply Input
Control Power
Supply Input
Logix SERCOS
interface Module
RSLogix 5000 Software
Logix Controlle r
Programming Network
8720MC-LR10-100B
Line Reactor
(two units in parallel)
Encoder
Feedback
Cable
Motor
Power C able
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165xx and MPMB215xx, and MPL-B5xxx, MPL-B6 xxx,
MPL-B8xxx, and MPL-B9xxx (shown)
Servo Motors
Ground
Faul t
Protection
Fusing
Chapter 1 Start
The Kinetix 7000 drive system shown in Figure 4 below illustrates a DC
common bus configuration with two follower Kinetix 7000 (2099-BM11-S)
drives and an 8720MC regenerative power supply (RPS). In full-line regenerative
mode the 8720MC-RPS190 unit provides motoring and regenerative power.
Figure 4 - Kinetix 7000 System Configuration with AC Input and 8720MC-RPS190 with Full-line
Regeneration
16 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Start Chapter 1
1606-XL
Power Supply
Input
Allen-Bradley
RE G E N E R AT IV E P O W ER
SU P
PLY
REGENERATIVE POWER SUPPLY
87208720
MCMC
RST
PRG
ENT
READYREADY
FAULTFAULT
PROGRAMPROGRAM kWkW
V
A
1606-XL
Power Supply
Input
Allen-Bradley
1606-XLxxx
24V DC
Control Power
8720MC-RF180
AC Line Fi lter
Input
Fusing
Three-P hase
Input Power
RSLogix 5000 Software
Input
Logix 5000
Control ler
Output
1756-MxxSE SERCOS
Interface Module
2090-SCxxx-x
SERCOS Fiber-Optic Ring
Commissioning
2099-BMxx-S
Kinetix 7000 Drive
Control Logix
Chassis
Motor Power Cable
Encoder
Feedback
Cable
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback.
Control Power
Supply Input
(To retain l ogic control
when main DC power is
removed.)
Magnetic
Contacto r
1606-XLxxx
24V DC
Control Power
HPK-Series Motors
Motor Power Cable Encoder Feedback Cable
DC Bus
Fusing
DC Bus
Fusing
Full Reg enerative DC Bus
Control Power
Supply Input
(To retain logic
control when
main DC power
is removed.)
2099-BMxx-S
Kinetix 7000 Drive
2090-K6CK-Dxxx
Low Profile Connector Kits for
I/O, Motor Feedback,
and Auxiliary Feedback
Ground
Faul t
Protection
Fusing
8720MC-LRxx
Line Reactor
8720MC-RPS065BM-HV2
Regenerative Power Supply
Harmonic Filter
(included with
8720MC-RPS065BM-HV2
Regenerative Power Supply)
Vari sto r
(included with
8720MC-RPS065BM-HV2
Regenerative Power Supply)
HPK-Series Motors, RDD-Series Direct
Drive Motors, MPM-B165xx and MPMB215xx, and MPL-B5xxx, MPL-B6xxx,
MPL-B8xx
x, and MPL-B9xxx (shown)
Servo Motors
The Kinetix 7000 drive system shown in Figure 5 below illustrates a DC
common bus configuration with two follower Kinetix 7000 drives and an
8720MC regenerative power supply (RPS). The harmonic filter and varistor are
available separately, but are included when ordering the 8720MC-RPS065BMHV2 RPS unit. In full-line regenerative mode the 8720MC-RPS065BM-HV2
unit provides motoring power and regenerative power. In common bus mode,
you must calculate the total bus capacitance of your DC common bus system.
This allows you to plan your panel layout and sufficiently size the 8720MC-RPS
to precharge the entire system.
Figure 5 - Kinetix 7000 System Configuration with DC Input from 8720MC-RPS065 Providing Fullline Regeneration
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 17
Chapter 1 Start
Catalog Number Explanation
Agency Compliance
Kinetix 7000 drive catalog numbers and descriptions are listed in the table below.
Kinetix 7000 Drive Cat. No.
Kinetix 7000, 460V, 22 kW, 40 A continuous output 2099-BM06-S
Kinetix 7000, 460V, 30 kW, 52 A continuous output 2099-BM07-S
Kinetix 7000, 460V, 37 kW, 65 A continuous output 2099-BM08-S
Kinetix 7000, 460V, 56 kW, 96 A continuous output 2099-BM09-S
Kinetix 7000, 460V, 75 kW, 125 A continuous output 2099-BM10-S
Kinetix 7000, 460V, 112 kW, 180 A continuous output 2099-BM11-S
Kinetix 7000, 460V, 149 kW, 248 A continuous output 2099-BM12-S
If this product is installed within the European Union or EEC regions and has
the CE mark, the following regulations apply.
ATT EN TI ON : Meeting CE requires a grounded system, and the method of
grounding the AC line filter and drive must match. Failure to do this renders the
filter ineffective and may cause damage to the filter.
For grounding examples, see Grounded Power Configurations
on page 75.
For more information on electrical noise reduction, see the System Design for
Control of Electrical Noise Reference Manual, publication GMC-RM001
.
18 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Start Chapter 1
CE Requirements - System without LIM
To meet CE requirements when your Kinetix 7000 system does not use a 2094
line interface module to supply AC line and dc control power, the following
requirements apply:
• Install an 8720MC-RF180 line filter as close to the 8720MC-RPS unit as
possible, and the AC line filter (2090-XXLF-TCxxxx) as close to the
Kinetix 7000 drive as possible.
• For MPx motors, use 2090 series motor power cables or use connector kits.
Terminate cable shields at the chassis and the motor terminal block with a
360° connection.
• For HPK-Series motors, use UL Approved 4 wire, 600V AC, shield, VFD
cabling. Terminate cable shields at the chassis and the motor with a 360°
connection.
• Combined motor power/feedback cables must not exceed 90 m (295.3 ft).
• Use 2090 series motor feedback cables or connector kits and terminate the
feedback shield as shown in Chapter 4 for wiring instructions and
Appendix B for motor feedback connector kit catalog numbers. Drive to
motor feedback cables must not exceed 90 m (295.3 ft).
• Install the Kinetix 7000 system inside an enclosure. Run input power
wiring in conduit (grounded to the enclosure) outside of the enclosure.
Separate signal and power cables.
• Output power, control (I/O), and signal wiring must be braided, shielded
cable with a coverage of 75% or better, metal conduit or equivalent
attenuation.
• All shielded cables should terminate with a properly shielded connector.
See the System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001
, for information on electrical noise reduction and
grounding practices.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 19
Chapter 1 Start
IMPORTANT
IMPORTANT
CE Requirements - System with LIM
To meet CE requirements when your Kinetix 7000 system includes the line
interface module (LIM), follow all the requirements as stated in CE
Requirements - System without LIM on page 19
requirements that also apply to the AC line filter:
• Install the LIM, 2094-XL75S-Cx or 2094-BL50/75S, and line filter
(2090-XXLF-TCxxx) as close to the Kinetix 7000 drive as possible.
The full rated current on the AC input line should not exceed that of the line
interface module.
Catalog numbers 2094-XL75S-Cx or 2094-BL50S for 2099-BM06-S and
2099-BM07-S Kinetix 7000 drives, or 2094-BL75S for 2099-BM08-S Kinetix
7000 drives.
CE requires use of a grounded secondary or source with a 2099-BMxx-S
drive.
Never use a LIM in an ungrounded input, due to the potential for high lineto-neutral voltages damaging components within the line filter.
and these additional
CE Requirements - System with DC Common Bus through 8720MC-RPS
To meet CE requirements when your Kinetix 7000 system includes a common
DC bus with an 8720MC-RPS, follow all the requirements as stated in the CE
Requirements - System without LIM on page 19
and wiring in the 8720MC Regenerative Power Supply Reference Manual,
publication 8720MC-RM001
• Install a three-phase line filter on the AC input power line of the RPS as
indicated in Interconnect Diagrams beginning on page 161
• Install a single-phase line filter when attaching an AC line input to the
RPS MC1/2 circuit as indicated in the Interconnect Diagrams beginning
on page 161
.
, and these additional requirements:
, the recommended installation
.
20 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Chapter 2
Install the Kinetix 7000 Drive System
This chapter describes system installation guidelines in preparation for mounting
your Kinetix 7000 drive components.
Top ic Pa ge
System Design Guidelines 22
Minimizing Electrical Noise 28
Mount the Kinetix 7000 Drive 39
ATT EN TI ON : Plan the installation of your system so that you can perform all
cutting, drilling, tapping, and welding with the system removed from the
enclosure. Because the system is of the open type construction, be careful to
keep any metal debris from falling into it. Metal debris or other foreign matter
can become lodged in the circuitry, which can result in damage to components.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 21
Chapter 2 Install the Kinetix 7000 Drive System
System Design Guidelines
To design your enclosure and plan where to mount the system components on the
panel, use this section and the information in the Kinetix Servo Drives
Specifications Technical Data, publication GMC-TD003
For online product selection and system configuration tools, including
AutoCAD (DXF) drawings of the product, go to:
http://www.rockwellautomation.com/en/e-tools/
.
.
System Mounting Requirements
Follow these system mounting requirements.
• To comply with UL and CE requirements, the Kinetix 7000 drive system
must be enclosed in a grounded conductive enclosure offering protection
as defined in standard EN 60529 (IEC 529) to NEMA/UL Type IP2X
such that they are not accessible to an operator or unskilled person. A
NEMA/UL Type 4X enclosure exceeds these requirements providing
protection to IP66.
• The panel you install inside the enclosure for mounting your system
components must be on a flat, rigid, vertical surface that won’t be subjected
to shock, vibration, moisture, oil mist, dust, or corrosive vapors (as
specified in Environmental Specifications on page 154
• Size the drive enclosure so as not to exceed the maximum ambient
temperature rating. Consider heat dissipation specifications for all drive
components.
• Segregate input power wiring and motor power cables from control wiring
and motor feedback cables. Use shielded cable for power wiring and
provide a grounded 360° clamp termination.
• Use high-frequency (HF) bonding techniques to connect the modules,
enclosure, machine frame, and motor housing, and to provide a lowimpedance return path for HF energy and reduce electrical noise.
).
See the System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001
reduction.
, to better understand the concept of electrical noise
Transformer Selection
The Kinetix 7000 drive does not require an isolation transformer for three-phase
input power. However, a transformer may be required to match the voltage
requirements of the controller to the available service.
22 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Install the Kinetix 7000 Drive System Chapter 2
IMPORTANT
IMPORTANT
To size a transformer for the AC power inputs to devices peripheral to the
Kinetix 7000 drive, refer to the manufacturer continuous output power
specification.
If using an autotransformer, make sure that the phase to neutral/ground
voltages do not exceed the input voltage ratings of the drive.
Use a form factor of 1.5 for three-phase power (where form factor is used to
compensate for transformer, drive module and motor losses, and to account
for utilization in the intermittent operating area of the torque speed curve).
For example: using a secondary of 480 VAC and a 2099-BM06-S with a rated
power output = 22 kW continuous:
22 * 1.5 = 33 kVA transformer
Circuit Breaker/Fuse Selection
The Kinetix 7000 drive uses internal solid-state motor short-circuit protection
and, when protected by suitable branch circuit protection, are rated for use on a
circuit capable of delivering up to 200,000 A. Fuses or circuit breakers, with
adequate withstand and interrupt ratings, as defined in NEC or applicable local
codes, are permitted.
The 2094-BL50 and 2094-BL75S LIMs contain supplementary protection
devices, but require a customer-supplied external line filter. See the Line Interface
Module Installation Instructions, publication 2094-IN005
, for power
specifications and more information on using the LIM module.
The Bulletin 140M motor protection circuit breakers are another acceptable
means of protection. As with fuses and circuit breakers, you must make sure that
the selected components are properly coordinated and meet applicable codes
including any requirements for branch circuit protection. When applying the
140M product, evaluation of the short circuit available current is critical and
must be kept below the short circuit rating of the 140M product.
In most cases, fuses selected to match the drive input current rating will meet the
NEC requirements and provide the full drive capabilities. Dual element, time
delay (slow acting) fuses should be used to avoid nuisance trips during the inrush
current of power initialization.
See Circuit Breaker/Fuse Specifications on page 151
for recommended circuit
breakers and fuses.
See Power Specifications on page 150
for input current and inrush current
specifications for your Kinetix 7000.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 23
Chapter 2 Install the Kinetix 7000 Drive System
Enclosure Selection
To assist you in sizing an enclosure, the following example is provided. The
example system consists of the following components.
• 2-axis Kinetix 7000 servo drive system
• ControlLogix chassis and modules
Size the Kinetix 7000 servo drive using Motion Analyzer software, version 4.2 or
later, and use the results to predict the amount of heat dissipated into the
enclosure. You will also need heat dissipation data from other equipment inside
the enclosure (such as ControlLogix). Once the total amount of heat dissipation
(in watts) is known, the minimum enclosure size can be calculated. It is
recommended that you also contact the enclosure manufacturer for the best
enclosure fit, including possible cooling methods to help reduce enclosure size.
Using Motion Analyzer to Determine Heat Dissipation
To obtain Motion Analyzer software, go to:
http://ab.rockwellautomation.com/Motion-Control/Motion-AnalyzerSoftware
Complete the Motion Analyzer Axis View data to find an acceptable Kinetix
7000 drive and motor solution to meet the application needs. In the Axis View
Solutions window find the Drive Capacity value. In this example, the
2099-BM11-S Drive Capacity characteristic can be used for the estimation of the
Rated Power Output used for the percentage of watts dissipated.
24 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Table 2 - Kinetix 7000 System Heat Dissipation Example
75
60
45
30
15
0
0 20 40 60 80 100
Backplane
Power Load
(Watts)
Real Power (Watts)
1756-P B72
1756-P B75
DC
Install the Kinetix 7000 Drive System Chapter 2
Enclosure
Component
Description Loading
(Motion Analyzer)
(1)
Heat Dissipation
Watts
(2)
2099-BM08-S Kinetix 7000 Servo Drive 50% 452
2099-BM11-S Kinetix 7000 Servo Drive 50% 1275
Total Wattage of Kinetix 7000 system 1727
(1) Loading determined using Motion Analyzer software.
(2) To determine heat dissipation specifications for the Kinetix 7000 drive, see Power Dissipation
Specifications on page 152.
Table 3 - ControlLogix Heat Dissipation Example
Enclosure
Component
Description Backplane Power Load
Watts
1756-M08SE 8-axis SERCOS interface module 3.2 0.0
1756-L5563 L63 ControlLogix processor 4.5 0.0
1756-IB16D 16-point input module 0.84 5.8
1756-OB16D 16-point output module 4.64 3.3
1756-ENxTx EtherNet/IP communication module 4.0 0.0
Backplane total 17.18
(2)
1756-PB72 24V DC ControlLogix power supply N/A 25.0
1756-A7 7-slot mounting chassis N/A N/A
Total ControlLogix system wattage 34.1
(1)
Heat Dissipation
Watts
(1)
N/A
(2)
(1) For ControlLogix module specifications, see the ControlLogix Selection Guide, publication 1756-SG001.
(2) Real power heat dissipation is determined by applying the backplane power load (17.18 W) to the graph below.
Figure 6 - ControlLogix Real Power
For backplane power loading requirements of other ControlLogix power
supplies, see the ControlLogix Selection Guide, publication 1756-SG001
.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 25
Chapter 2 Install the Kinetix 7000 Drive System
A
0.38Q
1.8T 1.1–
--------------------------=
A
4.08Q
T 1.1–
------------------=
A =
0.38 (1761)
1.8 (20) - 1.1
A =
19.2 m
2
In this example, the amount of power dissipated inside the cabinet is the sum of
the Kinetix 7000 drive (2099-BM08-S and 2099-BM11-S) system value (1727
W) and the ControlLogix value (34.1 W) for a total of 1761 W.
With no active method of heat dissipation (such as fans or air conditioning)
either of the following approximate equations can be used.
Metric Standard English
Where T is temperature difference between inside air and
outside ambient (°C), Q is heat generated in enclosure
(Watts), and A is enclosure surface area (m2). The exterior
surface of all six sides of an enclosure is calculated as
A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height) are in meters. Where d (depth), w (width), and h (height) are in inches.
Where T is temperature difference between inside air and
outside ambient (°F), Q is heat generated in enclosure
(Watts), and A is enclosure surface area (ft²). The exterior
surface of all six sides of an enclosure is calculated as
The maximum ambient rating of the Kinetix 7000 drive is 50 °C (122 °F) and if
the maximum environmental temperature is 30 °C (86 °F) then Q=1761 and
T=20 in the equation below.
2
In this example, the enclosure must have an exterior surface of 19.2 m
. If any
portion of the enclosure is not able to transfer heat, it should not be included in
the calculation. For instance, if an externally-mounted shunt system is used with
the Kinetix 7000 system, it should not be included in the equation.
The minimum enclosure size must take into account the physical size and
minimum clearance requirements of the two Kinetix 7000 drives and the
additional ControlLogix and other devices required to meet the application
needs.
If the enclosure size is considerably larger than what is necessary to house the
system components, it may be more efficient to provide a means of cooling in a
smaller enclosure. Contact your enclosure manufacturer for options available to
cool your enclosure.
26 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Install the Kinetix 7000 Drive System Chapter 2
IMPORTANT
50.8 mm (2.0 in.) clearance right
of module is required
Minimum cabinet depth = 300 mm (11.8 in.)
Cable bend radius requires a minimum of
60 mm (2.4 in.) from the front panel connections.
101.6 mm (4.0 in.) clearance for
airflow and installation
50.8 mm (2.0 in.) clearance left
of module is required
101.6 mm (4.0 in.) clearance for
airflow and installation
Minimum Clearance Requirements
This section provides information to assist you in sizing your cabinet and
positioning your Kinetix 7000 system components.
Mount the module in an upright position as shown. Do not mount the
module on its side.
Figure 7 - Minimum Clearance Requirements
See page 152 for power dissipation specifications.
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 27
Chapter 2 Install the Kinetix 7000 Drive System
IMPORTANT
Minimizing Electrical Noise
This section outlines best practices that minimize the possibility of noise-related
failures as they apply specifically to Kinetix 7000 drive installations. For more
information on the concept of high-frequency (HF) bonding, the ground plane
principle, and electrical noise reduction, see the System Design for Control of
Electrical Noise Reference Manual, publication GMC-RM001
.
Bonding Modules
Bonding is the practice of connecting metal chassis, assemblies, frames, shields,
and enclosures to reduce the effects of electromagnetic interference (EMI).
Unless specified, most paints are not conductive and act as insulators. To achieve
a good bond between the drive and subpanel, surfaces need to be unpainted or
plated. Bonding metal surfaces creates a low-impedance return path for highfrequency energ y.
To improve the bond between the drive and subpanel, construct your
subpanel out of zinc plated (unpainted) steel.
Improper bonding blocks the direct return path and routes high-frequency
energy to elsewhere in the cabinet. Excessive high-frequency energ y can effect the
operation of other microprocessor controlled equipment.
The illustrations that follow show details of recommended bonding practices for
painted panels, enclosures, and mounting brackets.
28 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
Install the Kinetix 7000 Drive System Chapter 2
Stud-mounting the Subpanel
to the Enclosure Back Wall
Stud-mounting a Ground Bus
or Chassis to the Subpanel
Subpanel
Weld ed St ud
Scrape Paint
Flat Washer
If the mounting bracket is coated with
a non-conductive material (anodized,
painted, etc.), scrape the material
around the mounting hole.
Star Washer
Nut
Nut
Flat Washer
Mounting Bracket or
Ground Bus
Use a wire brush to rem ove paint from
threads to maximize ground connection.
Back Wall of
Enclosure
Welded Stu d
Subpanel
Star Washer
Use plated panels or scrape paint off
front of panel.
Subpanel
Nut
Nut
Star Washer
Flat Washer
Star
Was her
Star Washer
Scrape paint on both sides of panel
and use star washers.
Tap pe d
Hole
Bolt
Flat Washer
Ground Bus or
Mounting Bracket
If the mounting bracket is coated with a non-co nductive
material (anodized, or painted for example), scrape the
material around the mounting hole.
Bolt-mounting a Ground Bus or Chassis to the Back-panel
Figure 8 - Recommended Bonding Practices for Painted Panels
Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 29
Chapter 2 Install the Kinetix 7000 Drive System
Bond the top and bottom of each subpanel to the cabinet using 25.4
mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Scrape the paint around each fastener to
maximize metal to metal contact.
Cabinet ground bus bonded
to the subpanel.
Bonding Multiple Subpanels
Bonding multiple subpanels creates a common low impedance exit path for the
high frequency energy inside the cabinet. Subpanels that are not bonded together
may not share a common low impedance path. This difference in impedance may
affect networks and other devices that span multiple panels.
Figure 9 - Multiple Subpanels and Cabinet Recommendations
Establish Noise Zones
When designing a panel for a Kinetix 7000 system, observe the following
guidelines with additional attention to zone locations.
30 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012
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