Rockwell Automation 2099-BMxx User Manual

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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.

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

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

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

READY

FAULT

PROGRAM

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

RE G E N E R AT IV E P O W E R S U P P LY

Allen-Bradley

1606-XL

Power Supply

Input

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 15

1606-XL

Power Supply

Input

Allen-Bradley

EGE

NER

ATIVE PO

WER SUPPLY

REGENERATIVE PO

WER SUPPLY

87208720

MCMC

RST

PRG

ENT

READYREADY

FAULTFAULT

PROGRAMPROGRAM kWkW

1606-XL

Power Supply

Input

Allen-Bradley

EGENE

TIVE

POW

PPLY

87208720

MCMC

RST

PRG

ENT

READYREADY

FAULFAULT

OGRAMPROGRAM kWkW

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

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

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

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

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

0.38Q

1.8T 1.1–

--------------------------=

4.08Q

T 1.1–

------------------=

A =

0.38 (1761)

1.8 (20) - 1.1

A =

19.2 m

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.

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

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

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

Install the Kinetix 7000 Drive System Chapter 2

REGENERATIVE POWER SUPPLY

8720

READY

FAULT

PROGRAM

Route Encoder/Analog/Registration Shielded Cable

Shielded Cable or

Conduit

Clean Wireway (Cx)

No sensitive

equipment within

150 mm (6.0 in.)

Dirty Wireway (Dx)

Shield Clamps (beneath cover)

Motor Power Shielded Cable

8720MC

Line Reactor

Registration I/O

24V DC

Kinetix 7000 Drive

24V DC I/O Shielded Cable

GPIO, GPR, and SO Cables Dirty Wireway (Dx)

24V DC

Power

Supply

DC Bus ≤2 m (78.7 in.)

Keep very dirty ( VD) connections as short as

possible and segregated (not in wireway)

Line

Filter

Magnetic Contac tor

Line

Fuses

Circuit

Breaker

8720MC-RPS065BM-HV2

Regenerative Power Supply

Harmonic

Filter

Vari sto r

Encoder Feedback

Noise Zones when Using Regenerative Power Supplies (with/without a Line Filter Unit)

Observe the following guidelines when laying out a Kinetix 7000 system panel if a regenerative power supply (8720-RPSxxxxx) is used (see Figure 10 regenerative power supply and line filter unit are used (see Figure 11

• Mount the regenerative power supply to the right of the drive.

• The clean zone (C) is beneath and left of the Kinetix 7000 drive. This zone

includes the motor feedback, auxiliary feedback and registration signals from the IOD connector (grey wireway).

• The dirty zone (D) is to the right of the Kinetix 7000 drive. This zone includes the motor power, GPIO, GPR, SO, and IOD connections (black wireway).

• The very dirty zone (VD) includes both the 8720MC-RPS DC output to the Kinetix 7000 drive and the fuses, contactors, circuit breakers, and AC line input to the EMC line filter to the right of the 8720MC-RPS. Shielded cable is required only if the very dirty cables enter a wireway.

• The SERCOS fiber-optic cables are immune to electrical noise.

Figure 10 - Establishing Noise Zones (Regenerative Power Supply)

), and if a

on page 32).

READY

FAULT

PROGRAM

8720

ENT

PRG

RST

GE N E R

AT IV

E P

PLY

OW E

R S U

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 31

Chapter 2 Install the Kinetix 7000 Drive System

REGENERATIVE POWER SUPPLY

8720

READY

FAULT

PROGRAM

8720

READY

FAULT

PROGRAMkWkW

Route Encoder/Analog/Registration Shielded Cable

Shielded Cable or

Conduit

Clean Wireway (Cx)

No sensitive

equipment within

150 mm (6.0 in.)

Dirty Wireway (Dx)

Shield Clamps (beneath cover)

Motor Power Shielded Cable

Line

Reactor

Registration I/O

24V DC

Kinetix 7000 Drive

24V DC I/O Shielded Cable

GPIO, GPR, and SO Cables Dirty Wireway (Dx)

24V DC

Power

Supply

Keep very dirty connections as short as

possible and segregated (not in wireway)

Line

Fuses

Circuit

Breaker

8720MC-RPS190BM-HV2 Regenerative Power Supply

Encoder Feedback

DC Bus ≤2 m (78.7 in.)

Line

Reactor

8720MC -LR10-100B Line Reactors

8720MC-EF190-VB EMC Line Filter

1.5 m (5 ft)

Figure 11 - Establishing Noise Zones (Regenerative Power Supply with Line Filter Unit)

READY

FAULT

8720

PROGRAM

PRG

RST

GE N E R AT IV E P

ENT

OW E

R S U

PP LY

READY

FAUL

PROGRAM

ENT

PRG

RST

8720

POWER SUPP

RATIV

REGE

32 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System Chapter 2

Route Encoder/Analog/Registration Shielded Cable

Shielded Cable or

Condu it

Clean Wireway (C)

No sensitive

equipment within 150

mm (6.0 in.)

(1)

Shield Clamps

(beneath cover)

Motor Power

Shielded Cable

Kinetix 7000 Drive

24V DC I/O Shielded Cable

Dirty Wireway (D)

Keep very dirty connections as short as

possible and segregated (not in wireway)

AC Lin e

Filter

Contac tor

Line Fuses

Circuit Breaker

Shielded Clamps

AC Power Noise Zones

Observe the following guidelines when laying out a Kinetix 7000 system panel, if an AC power supply is used (and regenerative power will not be used).

• The clean zone (C) is beneath and left of the Kinetix 7000 drive. This zone includes the motor feedback, auxiliary feedback and registration signals from the IOD connector (grey wireway).

• One dirty zone (D) is beneath and right of the Kinetix 7000 drive. This zone includes fuses, contactors, circuit breakers, AC line input to the EMC line filter (black wireway).

• The very dirty zone (VD) is limited to where the AC line output exits from the EMC line filter and connects to the Kinetix 7000 drive. Shielded cable is required only if the very dirty cables enter a wireway.

• The SERCOS fiber-optic cables are immune to electrical noise.

Figure 12 - Establishing Noise Zones (AC Power)

(1)

When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, see the System Design for Control of electrical Noise Reference Manual, publication GMC-RM001

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 33

Chapter 2 Install the Kinetix 7000 Drive System

AC Line

Filter

Spare Slot(s)

Dirty Wireway (D)

Clean Wireway (C)

Route dirty wireways directly above the ControlLogix rack

(shielded by the chassis).

Line Filter/Power Supply Connections Segregated

(not in wireway)

Dirty I/O

(24V DC I/O, AC I/O)

Clean I/O

(Analog, Encode r

Registration)

1756-MxxSE SERCOS Interface Module Noise Zones

Observe the following guidelines when installing your 1756-MxxSE SERCOS interface module.

• The clean zone (C) is beneath the less noisy I/O modules (analog, encoder, registration) - - (grey wireway).

• The dirty zone (D) is above and below the power supply and noisy modules (black wireway).

• The SERCOS fiber-optic cables are immune to electrical noise.

Figure 13 - Establishing Noise Zones (ControlLogix)

34 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System Chapter 2

Cable Categories for Kinetix 7000 Systems

The table below indicates the zoning requirements of input power cables connecting to the Kinetix 7000 drive.

Table 4 - Kinetix 7000 Drive

Wire/Cable Connector Zone Method

Very Dirty

Control Power CP X DC-/DC+ L1, L2, L3 (shielded cable) X X L1, L2, L3 (unshielded cable) X DPI DPI X X

PTB

The table below indicates the zoning requirements of power and control cables connecting to the Kinetix 7000 system.

Dirty Clean Ferrite

Sleeve

Shielded Cable

Table 5 - Kinetix 7000 System

Wire/Cable Connector Zone Method

Very Dirty

U, V, W ( Motor Power) MP X X GPR+, GPR- (Motor Brake) GPR X 24V DC (PWR), COM, filtered 24V DC (PWR), COM, unfiltered X 24V DC (PWR), COM, safety enable,

and feedback signals for safe-off feature

Motor Feedback MF X X Auxiliary Feedback AF X X Registration and Analog Outputs Others X Fiber-optic Rx and Tx No Restrictions

GPIO, GPR

SO X

IOD

Dirty Clean Ferrite

Sleeve

Shielded Cable

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 35

Chapter 2 Install the Kinetix 7000 Drive System

IMPORTANT

Table 6 - Line Interface Module

Wire/Cable Connector Zone Method

Very Dirty

VAC line (main input) IPL X 230V AC input APL X VAC load (shielded option) VAC load (unshielded option) X Control power output CPL X MBRK PWR, MBRK COM P1L/PSL X Status I/O IOL X Auxiliary 230V AC P2L X

OPL

Dirty Clean Ferrite

Sleeve

Table 7 - External Shunt Resistor Kit

Wire/Cable Connector Zone Method

Very Dirty

COL, DC+ (shielded option) COL, DC+ (unshielded option) X Thermal switch TS X X Fan ( if pr esent ) N /A X

Dirty Clean Ferrite

Sleeve

Shielded Cable

Shielde d Cable

Noise Reduction Guidelines for Drive Accessories

When mounting an AC (EMC) line filter or external shunt resistor refer to the sections below for guidelines designed to reduce system failures caused by excessive electrical noise.

AC Line Filters

Observe the following guidelines when mounting your AC (EMC) line filter.

See the Establishing Noise Zones (AC Power)

• Mount the ac line filter on the same panel as the Kinetix 7000 drive and as close to the power input as possible.

• Good HF bonding to the panel is critical.

For painted panels, refer to the examples on page 29.

• Segregate input and output wiring as far as possible.

CE test certification applies only to ac line filter and single drive. Sharing a line filter with multiple drives may perform satisfactorily, but the user takes legal responsibility.

on page 33 for an example.

36 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Install the Kinetix 7000 Drive System Chapter 2

Kinetix 7000 drive

Clean Wireway Dirty Wireway

No sensitive

equipment within

150 mm (6.0 in.)

Motor Power Cables

Very dirty connections segregated (not

in wireway)

Route 24V DC I/O Shielded Cable

Route Encoder/Analog/

Registration

Shielded Cables

Customer-supplied

metal enclosure

Minimum of 150 mm (6.0 in.) of clearance

on all sides of the shunt module

Enclosure

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice) Shielded twisted pair (2nd choice) Twisted pair, 2 twists per foot min. (3rd choice)

Metal conduit (where required by local code)

I/O and Feedback

Cables

Shunt Resistor

Observe the following guidelines when mounting your external shunt resistor outside the enclosure.

• Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI.

• Mount resistors (other than metal-clad) in a shielded and ventilated enclosure outside the cabinet

• Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible.

• Route thermal switch and fan wires separate from shunt power.

Figure 14 - External Shunt Resistor Outside the Enclosure

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 37

Chapter 2 Install the Kinetix 7000 Drive System

Kinetix 7000

Dirty WirewayClean Wireway

No sensitive

equipment within

150 mm (6.0 in.)

Motor Power Cables

Very dirty connections segregated (not

in wireway)

Route 24V DC I/O Shielded Cable

Route Encoder/Analog/Registration Shielded Cables

Observe minimum clearance requirements for shunt module spacing.

Enclosure

Shunt Module

Shunt Wiring Methods:

Twisted pair in conduit (1st choice). Shielded twisted pair (2nd choice). Twisted pair, 2 twists per foot min. (3rd choice).

I/O and Feedback

Cables

AC Line

Filter

When mounting your shunt module inside the enclosure, follow these additional guidelines.

• Metal-clad modules can be mounted anywhere in the dirty zone, but as close to the Kinetix 7000 system as possible.

• Shunt power wires can be run with motor power cables.

• Keep unshielded wiring as short as possible. Keep shunt wiring as flat to

the cabinet as possible.

• Separate shunt power cables from other sensitive, low voltage signal cables.

• The shunt module watts dissipation must be included in the Kinetix 7000

system heat dissipation calculation for selecting an enclosure.

Figure 15 - External Shunt Resistor Inside the Enclosure

Motor Brake and Thermal Switch

The thermal switch and brake are mounted inside the motor, but how you connect to the axis module depends on the motor series.

See Wire Motor Output Power on page 92

38 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

drive/motor combination, and to Interconnect Diagram Notes the interconnect diagram of your drive/motor combination.

for wiring guidelines specific to your

on page 162 for

Mount the Kinetix 7000 Drive

Install the Kinetix 7000 Drive System Chapter 2

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and

wiring of the drive prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.

Follow these steps to install your Kinetix 7000 drive.

1. Layout and mark the position for your drive in the enclosure.

Follow the Kinetix 7000 mounting information provided in Figure 16 on

page 40. Clearance requirements on page 27 must also be followed.

2. Attach the drive to the cabinet.

The recommended mounting bolts are listed in the table on page 40 Follow the recommended high-frequency (HF) bonding techniques as shown in Bonding Modules

Follow the lifting instructions found in the Kinetix 7000 High Power Servo Drive Installation Instructions, publication 2099-IN003

3. Tighten all mounting fasteners.

beginning on page 28.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 39

Chapter 2 Install the Kinetix 7000 Drive System

M2 M3

2099-BM07 shown

IMPORTANT

Figure 16 - Kinetix 7000 Approximate Mounting Dimensions

Kinetix 7000 Drive Cat. No.

2099-BM06-S 2099-BM07-S 2099-BM08-S

2099-BM09-S 644.5 (25.37) 331.9 (13.07) 286.7 (11.29) 625.0 (24.61) 225.0 (8.86) 37.5 (1.48) M6 (0.25) 2099-BM10-S 690.3 (38.47) 331.9 (13.07) 286.7 (11.29) 625.0 (24.61) 225.0 (8.86) 37.5 (1.48) M6 (0.25) 2099-BM11-S

2099-BM12-S

Dimensions in mm (in.)

Mounting Screw SizeA B C M1M2M3

517.5 (20.37) 254.12 (10.0) 224.3 (8.83) 495.0 (19.49) 192.0 (7.56) 15.3 (0.60) M6 (0.25)

977.1 (38.47) 429.2 (16.90) 282.7 (11.13) 824.0 (32.44) 300.0 (11.81) 49.6 (1.95) M8 (0.3125)

Each Kinetix 7000 drive requires four mounting screws.

40 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Chapter 3

Kinetix 7000 Connector Data

This chapter provides power, feedback, and I/O connector locations and signal descriptions for a Kinetix 7000 drive.

Top ic Pa ge

Locate and Identify Connectors and Indicators 42 Control Signal Specifications 54 Control Power Specifications 65 Motor (MF) and Auxiliary Feedback (AF) Connections 66

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 41

Chapter 3 Kinetix 7000 Connector Data

Status

Auxiliary

Feedback

Motor

Feedback

I/O

Fault/Status

SERCOS

CP_24VDC

CP_COM

Node Address

Drive

Comm

Bus

Status

Fault/Status

SERCOS

Node Address

Drive

Comm

Bus

Auxiliary

Feedback

Motor

Feedback

I/O

Power terminal block located behind protective cover.

2099-BM08-S shown

4 5

Locate and Identify Connectors and Indicators

Although the physical size of the drives vary, the location of the connectors and indicators is identical.

Figure 17 - Kinetix 7000 Front Panel Connectors and Displays

Item Designator/Label Description Connector See Page

1 Node Address SERCOS Node Address Switches – Chapter 6 2 Fault/Status Fault Status Display – Chapter 7 3 Drive Drive Status LED – Chapter 7 4 Comm Communication Status LED – Chapter 7 5Bus Bus Status LED – Chapter 7 6 AF Auxiliary Feedback Connector 15-pin high-density D-shell (male) 49 7 MF Motor Feedback Connector 15-pin high-densit y D-shell (female) 47 8 IOD Digital and Analog Input/Output Connector 26-pin high-density D-shell 45 9– Control Power Status LED – Chapter 7 10 PTB Power Terminal Block Terminal block 51

42 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Figure 18 - Kinetix 7000 Top Panel Connectors and Switches

DO1

DO1_24VDC

DO2

DO2_24VDC

N/C

REGEN_OK+

REGEN_OK-

GPIO

GPR2-

COM

GPR2+

GPR1-

GPR1+

24VDC

GPR

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

DO1

DO1_24VDC

DO2

DO2_24VDC

N/C

REGEN_OK+

REGEN_OK-

GPIO

GPR2-

COM

GPR2+

GPR1-

GPR1+

24VDC

GPR

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

2099-BM08-S shown

Top Vie w

2 3 4 5 6 7

Kinetix 7000 Connector Data Chapter 3

Item Designator/Label Description Connector See Page

1 SO Safe-off Terminal Block 9-position plug/header 50 2 GPIO General Purpose I/O Terminal Block 8-position plug/header 63 3 GPR General Purpose Relay Terminal Block 6-position plug/header 64 4 Rx SERCOS Fiber-optic Receive Port SERCOS fiber-optic 65 5 DPI Device Peripheral Interface Connector – – 6Tx SERCOS Fiber-optic Transmit Port SERCOS fiber-optic 65 7 Baud Rate SERCOS Baud Rate and Optical Power Switches – 65

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 43

Chapter 3 Kinetix 7000 Connector Data

2099-BM06-S and 2099-BM07-S shown

Bottom View

Figure 19 - Kinetix 7000 Bottom Panel Connectors

Item Designator/Label Description Connector See Page

1 CP Control Power Terminal Block 2-position terminal 51 2 PTB Power Terminal Block Access Terminal block 51

44 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Kinetix 7000 Connector Data Chapter 3

Pin 18

Pin 26

Pin 1

Pin 9

Pin 10

Pin 19

IMPORTANT

Digital and Analog Input/Output (IOD) Connector Pinout

The following diagram and table provide the signal description and pin-out information for the 26-pin Digital and Analog Input/Output connector.

See Kinetix 7000 Front Panel Connectors and Displays on page 42

for the location of the 26-pin connector. IOD signals are described in greater detail later in this chapter.

Figure 20 - Pin Orientation for 26-pin I/O (IOD) Connector

Table 8 - Digital and Analog Input/Output 26-pin (IOD) Connector

Pin Description Signal Name Pin Description Signal Name

1 Drive supplied +24V DC HW_Enable_Pwr 14 Registration 1 Input Reg_1_In 2 Hardware Enable Switch Input HW_Enable_In 15 Registration 1 Common Reg_1_Com 3 Hardware Enable Common HW_Enable_Com 16 Drive supplied Registration 2 Output

4 Drive supplied +24V DC Home_Switch_Pwr 17 Registration 2 Input Reg_2_In 5 Home Switch Input Home_Switch_In 18 Registration 2 Common Reg_2_Com 6 Home Common Home_Switch_Com 19 Differential Analog Channel 1 Input Analog_Input_1 7 Drive supplied +24V DC Pos_OverTravel_Pwr 20 Differential Analog Channel 1 Common Analog_Input_1_Ret 8 Positive Over travel Limit Switch Input Pos_ OverTravel_In 21 D ifferential Analog Channel 2 Input Analog_Input_2 9 Positive Overtravel Common Pos_OverTravel_Com 22 Differential Analog Channel 2 Common Analog_Input_2_Re t 10 Drive supplied +24V DC Neg_OverTravel_Pwr 23 Programmable Analog Channel 1

11 Negative Overtravel Limit Switch Input Neg_OverTravel_In 24 Analog Channel 1 Common Analog_Out_1_Ret 12 Negative Overtravel Common Neg_OverTravel_Com 25 Programmable Analog Channel 2

13 Drive supplied Registration 1 Output

Power

Reg_1_Pwr 26 Analog Channel 2 Common Analog_Out_2_Ret

Power

Output

Reg_2_Pwr

Analog_Out_1

Analog_Out_2

The Drive supplied +24V DC and Common source signals (at pins 1, 3, 4, 6, 7, 9, 10, and 12) can only be used for the inputs listed above.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 45

Chapter 3 Kinetix 7000 Connector Data

DO1

DO1_24VDC

DO2

DO2_24VDC

N/C

REGEN_OK+

REGEN_OK-

GPIO

GPR2-

COM

GPR2+

GPR1-

GPR1+

24VDC

GPR

Note: The GPR terminal number orientation is rotated 180 degrees relative to the other I/O connectors.

General Purpose I/O (GPIO) Terminal Block Connections

The following diagram and table provide the orientation and signal description for the General Purpose Input/Output terminal block.

Figure 21 - Orientation for General Purpose I/O (GPIO) Terminal Block

Table 9 - General Purpose I/O (GPIO) Terminal Block

Terminal Description Signal Name

1 Digital Output 1 Digital_Out_1 2 +24V DC for digital output 1 (customer-supplied) DO_24VDC_1 3 +24V DC for digital output 2 (customer-supplied) DO_24VDC_2 4 Digital Output 2 Digital_Out_2 5Reserved N/C 6Reserved N/C 7 Regenerative power supply OK (customer supplied) Regen_OK+ 8 Common for Regenerative power supply OK Regen_OK-

General Purpose Relay (GPR) Terminal Block Connections

The following diagram and table provide the orientation and signal description for the General Purpose Relay terminal block.

Figure 22 - Orientation for General Purpose Relay (GPR) Terminal Block

Table 10 - General Purpose Relay (GPR) Terminal Block

Terminal Description Signal Name

1 24V DC customer-supplied power input for Relay 1 24VDC 2 Programmable N.O. Relay 1 output GPR1+ 3 Programmable Relay 1 common GPR14 24V DC customer-supplied power supply common COM 5 Programmable N.O. Relay 2 output GPR2+ 6 Programmable Relay 2 common GPR2-

46 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Kinetix 7000 Connector Data Chapter 3

Pin 11

Pin 6

Pin 15

Pin 1

Pin 10

Pin 5

Motor Feedback (MF) Connector Pinouts

The following diagram and tables provide the orientation and signal description for the Motor Feedback (MF) connector for each applicable feedback device.

Figure 23 - Pin Orientation for 15-pin Motor Feedback (MF) Connector

Table 11 - Motor Feedback (MF) Connections for Stegmann Hiperface (SRS/SRM)

Pin Description Signal Pin Description Signal

1 Sine differential input+ SIN+ 9 Reserved — 2 Sine differential input- SIN- 10 Hiperface data channel DATA3 Cosine differential input+ COS+ 11 Motor thermal switch (normally-closed) 4 Cosine differential input- COS- 12 Reserved — 5 Hiperface data channel DATA+ 13 Reserved — 6 Common ECOM 14 Encoder power (+5V) EPWR_5V 7 Encoder power (+9V) EPWR_9V

(2)

15 Reserved —

8Reserved —

(1)

(2)

(1) Not applicable unless the motor has integrated thermal protection. (2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

Table 12 - Motor Feedback (MF) Connections for TTL or Sine/Cosine with Index Pulse and Hall Commutation

Pin Description Signal Pin Description Signal

1 AM+ / Sine differential input+ AM+ / SIN+ 9 Reserved — 2 AM- / Sine differential input- AM- / SIN- 10 Index pulse- IM3 BM+ / Cosine differential input+ BM+ / COS+ 11 Motor thermal switch (normally-closed) 4 BM- / Cosine differential input- BM- / COS- 12 Single-ended 5V hall effect commutation S1 5 Index pulse+ IM+ 13 Single-ended 5V hall effect commutation S2 6 Common ECOM 14 Encoder power (+5V) EPWR_5V 7 Encoder power (+9V) EPWR_9V

(2)

15 Reserved —

8 Single-ended 5V hall effect commutation S3

(1) Not applicable unless motor has integrated thermal protection. (2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

(1)

(2)

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 47

Chapter 3 Kinetix 7000 Connector Data

IMPORTANT

Kinetix 7000 drives do not natively support Heidenhain EnDat high-resolution feedback. However, you can use the drive motor feedback connection with the 2090-K7CK-KENDAT feedback module to convert Heidenhain EnDat 2.1 high-resolution feedback from an RDD motor. Use the table below to connect the motor feedback wires to the 2090-K7CK-KENDAT feedback module.

Only 2099-BMxx-S drives with firmware revision 1.104 or higher support the use of 2090-K7CK-KENDAT feedback modules.

Table 13 - Connections for Heidenhain EnDat

Pin Description Signal Pin Description Signal

1 Sine differential input+ SIN+ 8 Serial data clock signal - CLK2 Sine differential input- SIN- 9 Serial data differential signal+ DATA+ 3 Cosine differential input+ COS+ 10 Serial data differential signal - DATA4 Cosine differential input- COS- 11 Motor thermal switch+ 5 Encoder power (+5V) EPWR_5V 12 Reserved — 6 Common ECOM 13 Reserved — 7 Serial data clock signal + CLK+

(1)

TS+

(1) Not applicable unless motor has integrated thermal protection.

Drive-to-motor power cables must not exceed 90 m (295.3 ft).

48 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Kinetix 7000 Connector Data Chapter 3

Pin 1

Pin 11

Pin 10

Pin 5

Pin 6

Pin 15

Auxiliary Feedback (AF) Connector Pinouts

For TTL devices, the position count will increase when A leads B. For sinusoidal devices, the position count will increase when cosine leads sine.

Figure 24 - Pin Orientation for 15-pin Auxiliary Feedback (AF) Connector

Table 14 - Stegmann Hiperface (SRS and SRM only)

Pin Description Signal Pin Description Signal

1 Sine differential input+ SIN+ 9 Reserved — 2 Sine differential input- SIN- 10 Hiperface data channel DATA3 Cosine differential input+ COS+ 11 Reserved — 4 Cosine differential input- COS- 12 Reserved — 5 Hiperface data channel DATA+ 13 Reserved — 6 Common ECOM 14 Encoder power (+5V) EPWR_5V 7 Encoder power (+9V) EPWR_9V 8Reserved —

(1)

15 Reserved —

(1)

(1) Encoder power supply uses either 5V or 9V DC based on encoder used.

Table 15 - TTL or Sine/Cosine with Index Pulse

Pin Description Signal Pin Description Signal

1 A+ / Sine differential input+ A+ / SIN+ 9 Reserved — 2 A- / Sine differential input- A- / SIN- 10 Index pulse- I3 B+ / Cosine differential input+ B+ / COS+ 11 Reserved — 4 B- / Cosine differential input- B- / COS- 12 Reserved — 5 Index pulse+ I+ 13 Reserved — 6 Common ECOM 14 Encoder power (+5V) EPWR_5V 7 Encoder power (+9V) EPWR_9V 8Reserved —

(1) Encoder power supply uses either 5V or 9V DC based on encoder used.

(1)

15 Reserved —

(1)

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 49

Chapter 3 Kinetix 7000 Connector Data

IMPORTANT

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

Safe-off (SO) Terminal Block Connections

Figure 25 - Safe-off (SO) Terminal Block

Table 16 - Safe-off (SO) Terminal Block

Terminal Description Signal Name

1 Normally-closed monitoring contact for safety relay 2 FDBK2+ 2 Return for safety relay 2 FDBK23 Normally-closed monitoring contact for safety relay 1 FDBK1+ 4 Return for safety relay 1 FDBK15 Coil of safety relay 2 ENABLE2+ 6 Common for safety relays 1 and 2 ENABLE7 Coil of safety relay 1 ENABLE1+ 8 24V DC, 500 mA max., power for Safe Off circuit SO_24VDC 9 Common for 24V power Safe off circuit SO_COM

Terminals 8 and 9 (24V+ and Common) are only used by the motionallowed jumper. When using the Safe-off feature, the 24V supply must come from an external source.

50 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Kinetix 7000 Connector Data Chapter 3

IMPORTANT

Terminal Block

(on bottom of drive)

Label

(on front of drive)

Control Power (CP) Terminal Block Connections

Kinetix 7000 drives must be wired to a 24V DC control power source through the Control Input Power (CP) connector. The Control Power input terminal is located on the bottom of the drive as illustrated in Figure 19 on page 44

An external power supply provides the ability to retain control of the drive’s logic independent of its bus power status.

Figure 26 - Control Power (CP) Terminal Block Detail

CP_COM

CP_24VDC

Table 17 - Control Power (CP) Terminal Block

Terminal Description Signal Name

1 2CP_COM

Control Power 24V DC Input

CP_24VDC

Power Terminal Block (PTB) Connections

The power terminals are located behind the lower front panel of the drive. The figures below identify the input power, motor power, DC bus, ground, and cooling fan input terminals.

The 2099-BM09-S or 2099-BM10-S drives (frame 5), and the 2099-BM11-S or 2099-BM12-S drives (frame 6) provide connections for you to supply 120V AC or 240V AC to power an internal cooling fan. The fan VA rating is 100 VA for 2099-BM09-S and 2099-BM10-S, and 138 VA for the 2099-BM11-S and 2099BM12-S drives.

The 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S drives (frame 3) use the internal power supply for fan power and thus no terminals are provided.

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Chapter 3 Kinetix 7000 Connector Data

DC+

DC-

R (L1)

S (L2)

T (L3)

Cable clamps for Motor and AC inputs.

PS+

PS-

DC+

DC-

U V W

R (L1)

S (L2)

T (L3)

PS+

PS-

Motor

FAN

AC Lin e

Fan Te rmin als

Enlarged View

0 VAC

120 VAC

240 VAC

Fan Terminals

Enlarged View

PS+

PS-

0 VAC

120 VAC

240 VAC

DC+

DC-

R (L1)

S (L2)

T (L3)

FAN

Motor AC Line

Figure 27 - 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S

Figure 28 - 2099-BM09-S

Figure 29 - 2099-BM10-S

52 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Figure 30 - 2099-BM11-S and 2099-BM12-S

FAN

PS+

PS-

Motor

AC Lin e

Fan Terminals

Enlarged View

0 VAC

120 VAC

240 VAC

Kinetix 7000 Connector Data Chapter 3

Table 18 - Power Terminal Block

Terminal Description Name

DC+ DC Bus Power DC Bus (+) DC- DC Bus (-) PE Main Ground of the Drive System PE Ground GND Motor Ground Motor Ground U-T1 Motor Phase U Output U (T1) V-T2 Motor Phase V Output V (T2) W-T3 Motor Phase W Output W (T3) R-L1 Main 380…480V AC +/-10% Input Power, Three-phase to R, S and T Input Terminals R S-L2 S T-L 3 T 120VAC +120V AC Input for Fan Power VAC_FAN_1 240VAC +240V AC Input for Fan Power VAC_FAN_2 0VAC Fan Common GND_FAN PS- For factory use only – PS+ For factory use only –

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 53

Chapter 3 Kinetix 7000 Connector Data

IMPORTANT

Control Signal Specifications

IOD Pin Signal Description Capture Time Edge/Level

IOD-2 ENABLE Sin gle optically isolated, single-ended active high signal. Current loading is nominally 10

IOD-5 HOME S ingle optically isolated, single-ended active high signal. Current loading is nominally 10

IOD-14 IOD-17

IOD-8 IOD-11

REG1 REG2

OT+ OT-

This section provides specifications for the Kinetix 7000 drive input/output (IOD), SERCOS, motor feedback (MF), auxiliary feedback (AF) and brake (BC) connectors.

Digital Inputs (IOD Connector)

Two fast registration inputs and four other inputs are available for the machine interface on the Kinetix 7000 drive. The drive supplies 24V DC @ 300 mA for the purpose of registration, home, enable, over-travel positive, and over-travel negative inputs. These are sinking inputs that require a sourcing device. A 24V DC power and common connection is provided for each input.

To improve registration input EMC performance, see the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Table 19 - Digital Input Descriptions

Sensitive

mA. A 24V DC input is applied to this terminal to enable each axis.

mA. Home switch (normally-open contact) inputs for each axis require 24V DC (nominal). Fast registration inputs are required to inform the motor interface to capture the

positional information with less than 3 μs uncertainty. Single optically isolated, single- ended active high signal. Current loading is nominally 10mA. A 24V DC input is applied to this terminal to enable each axis.

Overtravel detection is available as a dual-input, optically isolated, single-ended active high signal. Current loading is nominally 10 mA per input. The pos/neg limit switch (normally-closed contact) inputs for each axis require 24V DC (nominal).

20 ms Level

500 ns Edge

20 ms Level

Table 20 - Digital Input Specifications

Parameter Description Min Max Leakage

ON-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an ON-state. 10.8V 26.4V — ON-state current Current flow to guarantee an ON-state 3.0 mA 10.0 mA — OFF-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an OFF-state. -1.0V 3.0V <1.5 mA

24V I/O Power

Signals +24V_PWR and +24V_COM are a 24V DC source that can be used only for the inputs listed below.

The Kinetix 7000 drive provides 24V DC power @ 300 mA total for the HW_Enable_Pwr, Home_Switch_Pwr, Pos_OverTravel_Pwr, Neg_OverTravel_Pwr, Reg_1_Pwr, and Reg_2_Pwr inputs on the specific drive. The supply is protected with an automatically reset fuse. A temperature versus time curve automatically controls closing of the fuse.

A common mode choke filters the registration power connection. An additional common mode choke is provided for the remaining inputs.

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Kinetix 7000 Connector Data Chapter 3

2k Ω

0.1 μF

511 Ω

VCC

INPUT

IO_COM

I/O SUPPLY

1k Ω

Kinetix 7000 DriveCustomer-supplied Input Device

+24V DC

(1)

CTRL_INPUT

IOD-1

IOD-3

IOD-2

Hardware Enable

The Hardware Enable input is an optically isolated (500V), single-ended, active high signal. A 24V DC input applied to this pin enables the drive.

The status of this digital input can be monitored in the axis servo drive tag in RSLogix.

If the Drive Hardware Enable option is selected in Logix, an MSO (Motion Servo On) instruction must be executed in RSLogix software. This causes IOD-1 to supply 24V DC to IOD-2, and completes the enable circuit for servo loop and drive power structure.

If the Drive Hardware Enable option is not selected in Logix, an MSO instruction will enable the drive without the need for a Drive Enable signal confirmation.

This input is level sensitive. See Ta b l e 1 9

Ta b l e 2 0

- Digital Input Specifications starting on page 54 for On/Off signal

- Digital Input Descriptions and

voltages and current levels.

Kinetix 7000 drive Hardware Enable functions and faults actions are programmed through RSLogix software. Kinetix 7000 dive firmware provides an additional 50 ms of debounce.

ATT EN TI ON : Overvoltage protection is not provided for the Hardware Enable input signal.

It is recommended to use the on-drive power to power the Hardware Enable signal. If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.

The schematic below depicts the Hardware Enable circuit. It is provided as a reference only.

Figure 31 - Hardware Enable Digital Input Circuit Diagram

(1) +24V DC source (range) = 21.6V…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 55

Chapter 3 Kinetix 7000 Connector Data

2k Ω

0.1 μF

511 Ω

VCC

INPUT

IO_COM

I/O SUPPLY

1k Ω

Kinetix 7000 DriveCustomer-supplied Input Device

24V DC

(1)

CTRL_INPUT

IOD-4

IOD-6

IOD-5

Home

The Home input is an optically isolated (500V), single-ended, active high signal. A 24V DC input applied to this pin by a normally-open contact indicates this axis is in the home position. Firmware provides an additional 50 ms of debounce.

You can configure the required Home type in the axis servo drive properties in RSLog ix. You can monitor the Home input “on/off ” status in the axis ser vo drive tag.

This input is level sensitive. See Ta b l e 1 9

Ta b l e 2 0

- Digital Input Specifications starting on page 54 for On/Off signal

- Digital Input Descriptions and

voltages and current levels.

ATT EN TI ON : Overvoltage protection is not provided for the Home input signal. It is recommended to use the on-drive power to power the Home signal. If an

external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.

The schematic below depicts the Home circuit. It is provided as a reference only.

Figure 32 - Home Digital Input Circuit Diagram

(1) +24V DC source (range) = 21.6…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

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Kinetix 7000 Connector Data Chapter 3

IMPORTANT

2k Ω

0.1 μF

511 Ω

VCC

INPUT

IO_COM

I/O SUPPLY

1k Ω

Kinetix 7000 DriveCustomer-supplied Input Device

+24V DC

(1)

Positive Overtravel or Negative Overtravel

IOD-7, 10

IOD-9, 12

IOD-8, 9

Positive and Negative Overtravel

The Positive and Negative Overtravel detection is provided by two optically isolated (500V), single-ended, normally-closed, active high signals. Breaking the 24V DC input at either pin indicates an overtravel condition.

You can enable hard travel limits on the axis servo drive Limit tab in RSLogix. Hard travel limits require power to both the positive and negative overtravel inputs. You can monitor the positive and negative overtravel input status in the axis servo drive tag.

Notes:

• A status of “1” indicates a normally closed input and a drive ready for movement.

• Hard overtravel limits can only be selected in a linear conversion selection.

This input is level sensitive. See Ta b l e 1 9

Ta b l e 2 0

- Digital Input Specifications starting on page 54 for On/Off signal

- Digital Input Descriptions and

voltages and current levels.

Overtravel limit input devices must be normally-closed.

Kinetix 7000 drive Positive and Negative Overtravel functions and faults actions are programmed through RSLogix software. Kinetix 7000 drive firmware provides an additional 50ms of debounce.

ATT EN TI ON : Overvoltage protection is not provided for the Positive and Negative Overtravel input signal.

It is recommended to use the on drive power to power the Positive and Negative Overtravel signals. If an external power source is used, you must take responsibility to be sure that the voltage/current does not exceed the rating of the input.

The schematic below depicts the Positive and Negative Overtravel circuits. It is provided as a reference only.

Figure 33 - Positive and Negative Overtravel Input Diagram

(1) +24V DC source (range) = 21.6…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 57

Chapter 3 Kinetix 7000 Connector Data

Registration

The two fast Registration inputs are provided on the Kinetix 7000 drive, Reg 1 (IOD-14) and Reg 2 (IOD-17). Unlike the Drive Enable, Home, and Overtravel signals, these inputs are either positive-edge or negative-edge triggered. They are based on the user-defined MAR (Motion Axis Registration) configured using RSLogix software.

Figure 34 - MAR (Motion Axis Registration) Entry in RSLogix Software

The MAR instruction captures position data within a 3 μs uncertainty. The position is directly input to the axis_servo_drive.Registration_Position register in Logix software.

Figure 35 - Logix Position Register Entry

Power for the inputs is supplied by an internally supplied 24V DC supply.

See Ta b l e 1 9

- Digital Input Descriptions and Ta b l e 2 0 - Digital Input

Specifications starting on page 54 for On/Off signal voltages and current levels.

Registration functions and faults actions are programmed through RSLogix software. Kinetix 7000 firmware provides an additional 50 ms of debounce.

ATT EN TI ON : Overvoltage protection is not provided for the Registration input signal.

It is recommended to use the on drive power to power Registration. If an external power source is used, you must take responsibility to be sure that the voltage/ current does not exceed the rating of the input.

The schematic below depicts the Registration circuits. It is provided as a reference only.

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Kinetix 7000 Connector Data Chapter 3

3k Ω

0.001 μF

511 Ω

VCC

INPUT

IO_COM

I/O SUPPLY

1k Ω

+24V DC

HCPL-0631

Customer-Supplied

Registration Input Device

Kinetix 7000 Drive

IOD-13, or -16

IOD-15, or -18

IOD-14, or -17

REG_INPUT

(1)

Figure 36 - Registration Digital Input Circuit Diagram

(1) +24V DC source (range) = 21.6V…26.4V (supplied by the drive, not to exceed 300 mA total).

Maximum current input = 10 mA.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 59

Chapter 3 Kinetix 7000 Connector Data

IMPORTANT

0.1 μF

IOD-19

IOD-20

–

V+

V–

100 Ω

IOD-21

IOD-22

–

V+

V–

100 Ω

0.1 μF

Analog_Input_1_Ret

Kinetix 7000 Drive

Customer-supplied

Input Device

Anlg In 1

Anlg In 2

Sense

Out

Ref

Analog_Input_1

Analog_Input_2_Ret

Analog_Input_2

Sense

Out

Ref

Analog Inputs (IOD Connector)

RSLogix 5000 software, version 15, does not support analog input utilization.

Two analog inputs are provided, with 14-bit resolution (13 data bits, plus sign). The analog data streamed to RSLogix by these inputs is useful for managing dynamic machine operations, for example tension transducers in an outer tension control loop.

The input range of these inputs is ±10V, and overvoltage protection is ±12V. Inputs are updated at the drive every 125 μs. Frequency response of the input is up to 4 kHz, and input impedance is 12 kΩ.

Analog inputs are available as a real time attribute and Get System Value (GSV) within RSLogix software.

ATT EN TI ON : Gain and offset attributes are not provided for the Analog Inputs input signals, and no drive faults are issued.

The schematic below depicts the Analog Input circuits. It is provided as a reference only.

Figure 37 - Analog Input Circuit Diagram

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Kinetix 7000 Connector Data Chapter 3

Reading Analog Input Voltage Values

When connecting to the Kinetix 7000 drive via DriveExecutive or DriveExplorer, the input voltage is displayed as a percentage in parameters 691 [AnaInput 1 Value] and 692 [AnaInput 2 Value].

In the example above, analog input 1 displays 69.79%. This value equals 100% of ±10V DC. Therefore the actual value of analog input 1 is 6.98V DC.

When viewed in RSLogix 5000 using a real time attribute on the Drive/Motor tab on the Module Properties dialog, the corresponding bit value displays as in the example below.

Divide the value displayed by 100 to determine the actual voltage on the input. 6978 / 100 = 69.78% or 6.98V DC.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 61

Chapter 3 Kinetix 7000 Connector Data

IOD-26

IOD-25

–

V+

V–

–

V+

V–

3.9 μF

IOD-24

IOD-23

0.1 μF 0.1 μF

–

V+

V–

4.09 kΩ

–

V+

V–

2.2 μF

3.9 μF

10 kΩ 10 kΩ

4.09 kΩ

100 kΩ

10 kΩ

2.2 μF

Analog_Out_1

Analog_Out_1_Ret

Analog_Out_2

Analog_Out_2_Ret

VDD SCLK SDIN

SYNC LDAC

SDO

CLR

GND

RFSA IOUT1A IOUT2A

RFSB

IOUT1B IOUT2B

VRBFA VRBFB

Analog Outputs (IOD Connector)

The two analog outputs (Analog_Out_1 and Analog_Out_2) are strictly for troubleshooting and cannot be used to drive other loads.

The analog outputs provide 12-bit resolution (11 data bits, plus sign) of the gain and filtering parameters within RSLogix software. In this way a data stream can be displayed by a meter or scale as velocity, torque, or following error information.

The ±10V outputs provide positive and negative direction range, with a null setting of 0V. For example, ±10V range, with 0V = 0. The drive update rate for these outputs is 125 μs, and is current limited to 25 mA.

Analog output functions are programmed in RSLogix software using a message instruction. The default pin assignments and the default gain values for the velocity, torque, and following error parameters are listed below.

Signal Default Pin Parameter Gain Value Analog Output

Analog_Out_1 IOD-23 Velocity 0.0060 1V = 1000 rpm Analog_Out_2 IOD-25 Torque 0.1 1V = 100% torque

A single pole low pass digital filter is provided for each analog output. The digital filter frequency range is 1…4 kHz.

The schematic depicts the Analog Output circuits. It is provided as a reference only.

Figure 38 - Analog Outputs Circuit Diagram

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Kinetix 7000 Connector Data Chapter 3

1 kΩ

0.1 μF

3.32 kΩ

10 Ω

1 kΩ

0.1 μF

3.32 kΩ

DO_24VDC_1

Digital_Out_1

DO_24VDC_2

Digital_Out_2

Dig_Out_1

Dig_Out_2

General Purpose I/O (GPIO Connector)

Two 24V digital outputs are user programmable. You can monitor the status the an optional regenerative power supply. An isolated, external 24V DC power source must be customer supplied to power the digital outputs.

Table 21 - General Purpose I/O Digital Output Specifications

Pin Signal Description On Condition Off Condition Leakage

1 Digital_Out_1 Optically isolated to 500V, current sourcing up to 75 mA 24…40V DC <0.25 mA 2 DO_24VDC_1 24V DC power source to digital inputs (customer-supplied) — — 3DO_24VDC_2 4 Digital_Out_2 Optically isolated to 500V, current sourcing up to 75 mA 24…40V DC <0.25 mA 5Reserved 6

The two DC current sourcing outputs default settings are Zero_Speed (Digital_Out_1) and In_Position (Digital_Out_2). Zero_Speed is the motor at 0 rpm velocity. In_Position can be set to the commanded position by the Position Lock Tolerance (set in Axis Properties/Limits). Default parameter selections can also be set with an IDN function.

Figure 39 - General Purpose I/O Digital Output Diagram

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Chapter 3 Kinetix 7000 Connector Data

1 kΩ

511 Ω

2 kΩ

0.1 μF

VCC

Regen_OK+

Regen_OK-

Regen_OK

The regenerative power supply OK provides status on the regenerative converter; in doing so, provides status to the Kinetix 7000 drive that there is DC bus power. Selecting the 8720MC-RPSxxx on the Power tab in the Kinetix 7000 drive I/O configuration in RSLogix requires the customer to provide a 24V DC power source to GPIO pins 7 and 8 as shown in Ta b l e 2 2

and in the interconnect diagrams in Appendix B. A failure to do so will cause a Regen_PS_OK (E111) fault, which indicates that he Regen_OK signal is missing at pins 7 and 8 of the GPIO connector. Kinetix 7000 drive firmware provides an additional 50 ms debounce.

Table 22 - General Purpose I/O Regenerative Power Supply OK Specifications

Pin Signal Description On Condition Off Condition

7 Regen_OK+ Optically isolated (500V), single-ended active high signal 12…38V DC @ 8 Regen_OK-

3.3…12 mA

Figure 40 - General Purpose I/O Regenerative Power Supply OK Diagram

less than 6.6V DC, less than 1.5 mA

General Purpose Relay (GPR Connector)

Two general purpose relay connections are accessed through the GPR connector. GPR1+ is a normally-open, dry relay contact, supporting 2 A at 30V DC ±10% with suppression. This relay defaults to Motor Brake control, and specifically provides suppression. GPR2+ is a normally-open, dry relay contact, supporting 2 A at 250V AC or 2 A at 30V DC without suppression. This relay defaults to Drive OK. An external 24V DC power source must be supplied.

The following are default values for the general purpose relays.

Table 23 - General Purpose Relay Outputs Descriptions

Output: Default Relay Setting in

RSLogix Software

GPR1+ Motor Brake Turn-on and turn-off delays are specified by the Brake

GPR2+ Drive OK (DROK)

Description

Engage Delay Time and Brake Release Delay Time in RSLogix software.

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Kinetix 7000 Connector Data Chapter 3

Motion-allowed Jumper

Wiring Plug Header

Safe-off (SO) Connector

SERCOS Connections

Two fiber-optic connectors (transmit and receive) are provided on the Kinetix 7000 drive.

Table 24 - SERCOS Communications Specifications

Specification Description

Data Rates 4 and 8 Mbps Node Addresses 01…99

(1) Node addresses for additional axes on the same system are assigned by sequentially incrementing each additional axis. See Node

Addressing Examples on page 108

(1)

for more information.

Safe-off (SO Connector)

Kinetix 7000 drives provide safety functions and system integrity.

The Kinetix 7000 drive ships with a (9-pin) wiring-plug header having a motionallowed jumper installed in the safe-off (SO) connector. With the motionallowed jumper installed, the safe-off feature is disabled.

Control Power Specifications

For safe-off wiring information, see the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002

Figure 41 - Safe-Off, Motion-allowed Jumper

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

ENABLE1+

SO_24VDC

SO_COM

FDBK2+

FDBK2-

FDBK1+

FDBK1-

ENABLE2+

ENABLE-

6 7 8 9

ENABLE1+

SO_24VDC

SO_COM

The following table provides specifications for the Control Power (CP) connector.

Attribute Value

Auxiliary DC input voltage 24V DC, 3 A max, range 18…30 V DC

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Chapter 3 Kinetix 7000 Connector Data

Motor (MF) and Auxiliary Feedback (AF) Connections

The motor interface and auxiliary feedback interfaces are consistent across the Kinetix product line. This section provides information on motor and auxiliary feedback connections.

The Kinetix 7000 motor (MF) and auxiliary (AF) feedback ports can accept the following encoder types:

• SRM/SRS Stegmann Hiperface encoders

• 5V TTL differential line driver with index pulse and hall commutation

• Sin/Cos differential input with index pulse and hall commutation

Motor feedback requires RSLogix 5000 motion.db file to properly commutate the motor. Motors available in RSLogix software include feedback types designated as S and M in Allen-Bradley catalog numbers. Following are further definitions of these feedback types.

• S type - single-turn 1024 cycles per rotation (interpolated to over 2 million counts in the drive) For example, the MPL-B980D-SJ72AA has this feedback type.

• M type - multi-turn 1024 cycles per rotation (interpolated to over 2 million counts in the drive). For example, the MPL-980D-MJ72AA has this feedback type. The “M” type allows for 4096 cycles absolute retention when the encoder is powered down.

RDD motor feedback from Heidenhain EnDat high-resolution encoders is also accepted, but only when using drive firmware revision 1.104 or higher and the 2090-K7CK-KENDAT low-profile feedback module.

Third-party motor requests must be pre-qualified and a custom motor file developed. Contact your local distributor or Rockwell Automation Sale Representative for more information.

Kinetix 7000 drives cannot drive open loop (no feedback) or other motor types not defined in the Kinetix motor database.

Motor and Auxiliary Feedback Specifications

AM, BM, and IM input encoder signals are filtered using analog and digital filtering. The inputs also include illegal state change detection. Figure 42 schematic of the AM, BM, and IM inputs.

is a

66 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Figure 42 - AM, BM, and IM Motor Encoder Inputs

+5 V

56 pF

10k Ω

1k Ω

100 pF

56 pF

1k Ω

56 pF

10k Ω

1k Ω

AM and BM Channel Inputs

IM Channel Input

Drive Drive

Table 25 - Motor Encoder Feedback Specifications

Kinetix 7000 Connector Data Chapter 3

Attribute Value

Encoder Types Incremental, A quad B, Sine/Cosine, Intelligent, and Absolute Maximum Input Frequency 5.0 MHz (TTL input) per channel

250 kHz (Sine/Cosine input)

Commutation Feedback Hall sensor

Ta b l e 2 6 provides a description of the AM, BM, and IM inputs for TTL

encoders.

Table 26 - TTL Encoder Specifications

Parameter Description Minimum Maximum

AM, BM, and IM ON-state Input Voltage

AM, BM, and IM OFF-state Input Voltage

Common Mode Input Voltage

DC Current Draw Current draw into the + or - input. -30 mA 30 mA AM, BM Input

Signal Frequency

Input voltage difference between the + input and the - input that is detected as an ON-state.

Input voltage difference between the + input and the - input that is detected as an OFF-state.

Potential difference between any encoder signal and logic ground.

Frequency of the AM or BM signal inputs. The count frequency is 4 times this frequency, since the circuitr y counts all four transitions.

+1.0V +7.0V

-1.0V -7.0V

-7.0V +12.0V

—5.0 MHz

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 67

Chapter 3 Kinetix 7000 Connector Data

Parameter Description Minimum Maximum

IM Pulse Width Pulse width of the index input signal. Since the index

AM, BM Phase Error

2.5 MHz Line Frequenc y

AM, BM Phase Error 1 MHz Line Frequenc y

is active for a percentage of a revolution, the speed will determine the pulse width.

Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.

125 nS —

-22.5° +22.5°

-45° +45°

The table provides a description of the AM and BM inputs for Sine/Cosine encoders.

Table 27 - AM, BM and IM Input Specifications for Sine/Cosine Encoders

Parameter Description Minimum Maximum

Sine/cosine Input Signal Frequenc y

Sine/cosine Input Voltage

Frequency of the Sine or Cosine signal inputs. — 250 kHz

Peak-to-peak input voltages of the Sine or Cosine inputs.

0.5V (p-p) 2.0V (p-p)

Table 28 - Specifications for Heidenhain EnDat Encoders

Command Set Order

Designation

EnDat 2.1 EnDat 01 1V (p-p) Sin/Cos, <2 MHz clock frequency

Description

Auxiliary Feedback (AF)

These requirements apply to the Auxiliary Feedback signals.

• For TTL devices, the position count increases when A leads B.

• For sinusoidal devices, the position count increases when cosine leads sine.

• TTL devices must be 5V devices within the input voltage specification.

• Use the Low Profile Connector Kit, catalog number 2090-K6CK-D15F to

access the Auxiliary Feedback signals. You must supply cabling that has shielding, and other EMI protection for motor feedback cables.

Feedback Power Supply

The power circuit board generates the +5V and +9V DC for the motor and auxiliary feedback power supplies. Short-circuit protection and separate common mode filtering for each channel is included.

• MPx-B, and HPK-B and -E motors all use 9V power sources from the MF connector.

• Compatible Auxiliary Feedback devices include Stegmann Hiperface, Sine/Cosine, and 5V TTL encoder types. Note: Heidenhain EnDat 2.1 encoders are only compatible when using the 2090-K7CK-KENDAT feedback module, however an interface module does not exist for the auxiliary encoder input.

68 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Kinetix 7000 Connector Data Chapter 3

• See the Kinetix Motion Control Selection Guide, publication GMC-

SG001, for cables compatible with the Kinetix 7000 drive and motor.

• Low profile connector let you develop a custom cable for the Motor Feedback (MF) or Auxiliary Feedback (AF) connectors.

The following table details power supply specifications for the motor and auxiliary feedback connectors.

Table 29 - Motor and Auxiliary Feedback Power Supply Specifications

Power Supply

+5V EPWR_5V 5.13 5.4 5.67 10 400 +9V EPWR_9V 8.3 9.1 9.9 10 275

(1) 400 mA on the 5V supply split in any manner between the channels with no load on the 5V supply. (2) 275 mA on the 9V supply split in any manner between the channels with no load on the 9V supply. (3) 300 mA on the 5V supply on one channel with 150 mA on the 9V supply on the second channel.

Signal Name Voltage (V DC) Current (mA)

Min Nom Max Min Max

(1) (3)

(2) (3)

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Chapter 3 Kinetix 7000 Connector Data

Notes:

70 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Chapter 4

IMPORTANT

Connect the Kinetix 7000 Drive System

This chapter provides procedures for wiring your Kinetix 7000 drive system components and making cable connections.

Top ic Pag e

Basic Wiring Requirements 71 Determine the Input Power Configuration 75 Setting the Ground Jumper in Ungrounded Power Configurations 78 Grounding the Kinetix 7000 Drive System 81 Input Power Wiring Requirements 85 Power Wiring Guidelines 88 Wire the Kinetix 7000 Drive Connec tors 88 Feedback and I/O Cable Connections 93 Wire Feedback and I/O Connectors 95 External Shunt Module Connections 101 SERCOS Fiber-optic Cable Connections 101

Basic Wiring Requirements

This section contains basic wiring information for the Kinetix 7000 drive.

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.

This section contains common PWM servo system wiring configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 71

Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

Stranded Drain Wire

Foil Sh ield

Oversized Insulation

Cable Jacket

Stranded Tinned Copper Conduc tors

Tinned Copper Braid with 85% Coverage

Building Your Own Motor Cables

Factory-made cables are designed to minimize EMI and are recommended over hand-built cables to optimize system performance.

• Connect the cable shield to the connector shells on both ends of the cable with a complete 360° connection. If separate power wires are used in a customer-supplied power cable, the shield may alternatively be connected to a ground terminal.

• Use a twisted pair cable whenever possible. Twist differential signals with each other and twist single-ended signals with the appropriate ground return.

• Discrete power cables require 360° shielding. Connect the shield to a ground terminal.

See the Kinetix Motion Control Selection Guide, publication GMC-SG001

, for low-profile connector kit, drive-end (mating) connector kit, and motor-end connector kit catalog numbers.

Shielded Motor Cable

The use of a four-wire type Variable Frequency Drive (VFD), 600 volt, UL listed cable is strongly recommended for all motor currents at or below 130 Amperes. The illustration below illustrates the type of cable required.

Figure 43 - Type of Cable Required for Kinetix 7000 Drive Interconnects

Required Cable Types

You should always use shielded motor cable. The shield must connect to the drive chassis (PE) connection and the motor frame. Make the connection at both ends to minimize the external magnetic field. If you use cable trays or large conduits to distribute the motor leads for multiple drives, use shielded cable to reduce noise from the motor leads.

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Connect the Kinetix 7000 Drive System Chapter 4

Cable Sizes

In the table below the appropriate VFD shielded cable to use based on 150% overload capability and 25 °C (77 °F) operating temperature is shown.

For applications above 130 Amps, use thick insulation lead wire, such as RHW-2 or equal. Make sure you thread the four wires (U, V, W, and ground) through a single, grounded, metal conduit.

Table 30 - 1.5x Rated Continuous Motor Current Cable Size

Motor Current Cable Size

12 A 1.5 16 17 A 2.5 14 21 A 4 12 30 A 6 10 55 A 10 8 65 A 16 6 95 A 25 4 130 A 35 2

AWG

Conduit

For applications above 130 Amperes, metal conduit is required for cable distribution. Follow these guidelines:

• Drives are normally mounted in cabinets, and ground connections are made at a common ground point in the cabinet. If the conduit is connected to the motor junction box and the drive end is connected to the ground panel in the cabinet, you do not need any additional conduit connections.

• Route no more than three sets of motor leads and a ground wire through a single conduit. This minimizes cross talk that also reduces the effectiveness of the noise reduction methods described. If more than three drive/motor connections per conduit are required, use shielded cable. If practical, each conduit should contain only one set of motor leads.

• You should use a thick insulation lead wire, such as type RHW-2 or equal.

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Chapter 4 Connect the Kinetix 7000 Drive System

General Wire Guidelines

Observe all applicable safety and national and local regulations when selecting the appropriate wire size for your system. Due to the drive overload capacity of 150% of the continuous current rating, the conductors for the transformer primary and secondary must be sized (at a minimum) for 125…160% of the maximum continuous input current for the motor selected. The motor conductors must also be rated for a minimum of 125…160% of the full load motor continuous current. If less than 150% overload is required the torque limit parameters must be set in the drive accordingly. The distance between the drive and motor may affect the size of the conductors used. To protect against interference, use shielded wire in motor and control circuits. A shielded cable is required for all feedback signal wires.

ATT EN TI ON : To avoid a possible shock hazard caused by induced voltages, ground unused wires in the conduit at both ends.

For the same reason, if a drive sharing a conduit is being serviced or installed, disable all drives using this conduit. This removes the possible shock hazard from cross-coupled drive motor leads.

Routing the Power and Signal Cables

Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic drives can be induced into motor or encoder feedback signals, input/output communications, or other sensitive low voltage signals. This can cause system faults and communication problems.

See Minimizing Electrical Noise on page 28 voltage cables in wireways, and to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

for examples of routing high and low

, for more information.

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Connect the Kinetix 7000 Drive System Chapter 4

2099-BM08-S shown with

Lower Front Panel Removed

Transformer (WYE) Secondary

Three-phase

Input VAC

Phase Ground

Transformer

Bonded Cabinet

Ground

Ground Grid or

Power Distribution Ground

To G ro und Stud

Line

Filter

Determine the Input Power Configuration

Before wiring input power to your Kinetix 7000 drive system you must determine the type of input power to which you are connecting. The Kinetix 7000 drive is configured at the factory to operate in a grounded power environment.

ATT EN TI ON : When using a LIM with your Kinetix 7000 drive, the AC line input power must come from a grounded configuration.

When not using a LIM with your Kinetix 7000 drive, ungrounded configurations are acceptable, but you must set the jumper to prevent high electrostatic build-up.

See Setting the Ground Jumper in Ungrounded Power Configurations on page 78 for additional information.

Grounded Power Configurations

Grounded (WYE) power wiring lets you ground your three-phase power at a neutral point.

Figure 44 - Grounded Three-phase Power Wiring - WYE Secondary (Recommended)

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Chapter 4 Connect the Kinetix 7000 Drive System

2099-BM08-S Shown with Lower

Front Panel Removed

Transformer (Delta) Secondary

Tra ns fo rm er

Bonded Cabinet

Ground

Ground Grid or

Power Distribution Ground

To G ro und Stu d

Line Filter

This is an example of a grounded B-phase (delta secondary).

Figure 45 - Grounded B-phase Power Wiring - Delta Secondary

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Connect the Kinetix 7000 Drive System Chapter 4

2099-BM08-S Shown with Lower

Front Panel Removed

Conduit/4-Wire Cable

Three-Phase Input

VAC

Ground

Bonded Cabinet

Ground

Ground Grid or Power

Distribution Ground

to Ground Stud

Power Distribution Systems Without a Ground Reference

Kinetix 7000 drives contain protective MOVs and Common Mode Capacitors that are referenced to ground. To guard against unstable operation and/or drive damage, these devices must be disconnected ungrounded, impedance grounded, high resistive grounded, B phase grounded, or common DC bus power distribution system.

ATT EN TI ON : Disconnect the protective MOVs and capacitors if the drive is installed on a high resistive grounded or ungrounded system where the line-toground voltages on any phase exceed 125% of the nominal line-to-voltage.

Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth ground.

A Kinetix 7000 drive application using a common DC bus is considered an ungrounded power distribution system.

Figure 46 - Ungrounded Power Wiring

if the drive is installed on an

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Chapter 4 Connect the Kinetix 7000 Drive System

Setting the Ground Jumper in Ungrounded Power Configurations

To disconnect the ground reference for Kinetix 7000 drives in an ungrounded, impedance grounded, high-resistive grounded, B-phase grounded, or common DC bus power distribution system, remove the jumpers or wires as instructed in the following table.

ATT EN TI ON : Kinetix 7000 drives contain protective metal oxide varistors (MOVs) and common mode capacitors that are referenced to ground. In a grounded power distribution system, these devices assist in isolating the drive from electromagnetic interference (EMI).

These devices must be disconnected if the drive is installed in an ungrounded, unbalanced, impedance grounded, or common DC bus power distribution system.

ATT EN TI ON : To avoid an electrical shock, verify that the voltage on the bus capacitors has discharged before removing or installing jumpers.

Measure the DC bus voltage at the DC+ and DC- terminals on the power terminals. The voltage must be zero.

Table 31 - Jumper/Wire Location and Removal Instructions

Drive Jumper/Wire ID No. Component Location

2099-BM06-S, 2099-BM07-S and 2099-BM08-S

PEA Common mode capacitor Remove the two jumpers located above the power terminal block. See

PEB MOVs

Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and 2099BM08-S Drives on page 79.

2099-BM09-S and 2099-BM10-S

2099-BM11-S and 2099-BM12-S

Green/yellow wire

Common mode capacitor Remove DC-DC conver ter and drive top cover, and disconnect the green/

MOVs/input filter cap Disconnect the green/yellow wire next to the power terminal block. Insulate

Common mode capacitor Disconnect the two green/yellow wires from the PE terminals on the power

MOVs

yellow wire from the drive chassis. Insulate and secure the wire to prevent unintentional contact with the chassis or components. See Removing the

Ground Wires on 2099-BM09-S and 2099-BM10-S Drives on page 80.

and secure the wire to prevent unintentional contact with the chassis or components. See Removing the Ground Wires on 2099-BM09-S and 2099-

BM10-S Drives on page 80.

terminal block. Insulate and sec ure each of these wires to prevent unintentional contact with the chassis or components. See Removing the

Ground Wires on 2099-BM11-S and 2099-BM12-S Drives on page 80.

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Connect the Kinetix 7000 Drive System Chapter 4

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3

PE B

PE A

75C Cu Wire

3 AWG [25MM2] Max.

16 IN. LBS.

1.8 N-M

} TORQUE

WIRE STRIP

CONTROL

POWER

AUX IN + –

SHLD

75C Cu Wire

6 AWG [10MM2] Max.

BR1 BR2

12 IN. LBS.

1.4 N-M

} TORQUE

PE A

PE B

CM Cap

MOV

Important: Do not discard or replace the grounding hardware.

Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S Drives

Figure 47 shows the location of the jumpers in 2099-BM06-S, 2099-BM07-S,

and 2099-BM08-S drives on the power chassis. The common mode capacitor jumper is indicated by callout 1 (PEA) and the MOV jumper is indicated by callout 2 (PEB).

Remove each jumper by carefully pulling it straight out.

Figure 47 - Ground Jumper Location on 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S

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Chapter 4 Connect the Kinetix 7000 Drive System

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2) TORQUE: 32 IN-LB (3.6 N-M) STRIP LENGTH: 0.67 IN (17 MM) USE 75 C CU WIRE ONLY

POWER TERMINAL RATINGS

WIRE RANGE: 6-1/0 AWG (16-35 MM

) TORQUE: 44 IN-LB (5 N-M) STRIP LENGTH: 0.83 IN (21 MM)

GROUND TERMINAL RATINGS (PE)

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM

) TORQUE: 5.3 IN-LB (0.6 N-M) STRIP LENGTH: 0.35 IN (9 MM)

INPUT ACOUTPUT

Optional

Communications

Module

Note: You must remove the DC-DC converter and drive top cover to access and remove the common mode capacitor ground wire. See the Kinetix 7000 DC-DCConverter and ControlBoard Kits Installation instructions, publication

2099-IN002

, for instructions.

CM Cap Older Drives

CM Cap Newer Drives

MOV

MOV/Input Filter Cap

DO NOT REMOVE

Removing the Ground Wires on 2099-BM09-S and 2099-BM10-S Drives

Figure 48 shows the locations of the common mode capacitor and MOV/input

filter capacitor ground wires in 2099-BM09-S and 2099-BM10-S drives. The common mode capacitor ground wire is indicated by callout 3 and the MOV/ input filter cap ground wire is indicated by callout 4.

Figure 48 - Ground Wire Locations on Terminal Block of 2099-BM09-S and 2099-BM10-S

Removing the Ground Wires on 2099-BM11-S and 2099-BM12-S Drives

Figure 49 shows the locations of the common mode capacitor and MOV ground

wires in 2099-BM11-S and 2099-BM12-S drives. The common mode capacitor ground wire is indicated by callout 5 and the MOV ground wire is indicated by callout 6.

Figure 49 - Ground Wire Location on Power Terminal Block of 2099-BM11-S and 2099-BM12-S

UT1VT2W

CM Cap

PE PE

MOV

PE PE

RL1S

INPUTOUTPUT

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Connect the Kinetix 7000 Drive System Chapter 4

IMPORTANT

Ground grid or power

distribution ground *

Bonded Cabinet Ground *

Braided Ground Strap *

* Indicates customer-supplied item.

Kinetix 7000

Drive

Grounding the Kinetix 7000 Drive System

All equipment and components of a machine or process system must have a common earth ground point connected to their chassis.

A grounded system provides a ground path for short-circuit protection. Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short-circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.

See Agency Compliance on page 18

for CE grounding requirements.

To improve the bond between the drive and subpanel, construct your subpanel out of zinc-plated (paint-free) steel.

Grounding Your System to the Subpanel

In Figure 50, the drive is shown properly grounded to the bonded cabinet ground on the subpanel.

ATT EN TI ON : The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system.

See the Interconnect Diagram Notes diagrams beginning on page 162

Figure 50 - Drive Chassis Ground Connection

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Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

Always follow NEC and applicable local codes

Ground grid or power distribution ground

Bonded Ground Bus

Grounding Multiple Subpanels

To extend the chassis ground to multiple subpanels, see Figure 51.

HF bonding is not illustrated. For HF bonding information, see Bonding Multiple Subpanels on page 30

Figure 51 - Subpanels Connected to a Single Ground Point

Motor Power Cable Shield Termination

Factory-supplied motor power cables for MP-series motors are shielded, and the braided cable shield must terminate at the drive when installed. A small portion of the cable jacket must be removed to expose the shield braid. The exposed area must be clamped (using the clamp provided on the 2099-BM06-S, -BM07-S and

-BM08-S drives) to the drive to provide a 360° termination. Factory-supplied power cables must also be terminated in the motor power (MP) connector plug.

ATT EN TI ON : To avoid hazard of electrical shock, be sure the shielded power cables are grounded at a minimum of one point for safety.

Customer-supplied power cables must be shielded, and the braided cable shield or conduit must terminate at the drive when installed. An area of the power cable shield must be exposed and terminated for 360° at the drive. In a similar manner, conduit enclosing discrete power cables must be terminated for 360° at the drive.

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Connect the Kinetix 7000 Drive System Chapter 4

Drive

Conduit or Cable Braid Clamped at Drive Frame Provides 360° Shield Termination. Clamp Also Connects to the Nearest Available Bonded Cabinet Ground.

Enclosure

Wire Restraint

Cable Shield Under Clamp

Cable with Braided Shield

Metallic Conduit with Wires

Conduit in Contact with Clamp

1) For examples of shield clamp attachment, see the System Design for Control of Electric al Noise Reference Manual, publication

GMC-RM001

2) If enclosure is painted, remove paint to provide metal-to-metal contact.

Junction Box Beneath Drive (2099-BM10-S, 2099-BM11-S, and 2099-BM12-S Only)

Three-phase Power with Ground

Enclosure Clamp Terminates 360° Shield at Enclosure

(1)(2)

Bayonet Connectors

with Brake

Bayonet Connectors

without Brake

Feedback / Power

Motor Connectors

Feedba ck / Power / B rake

Motor Connectors

Circular DIN Connectors

Power and Bra ke Motor Connector

Feedback Motor

Conne ctor

Figure 52 - Power Cable Shielding Techniques Recommended for Kinetix 7000 Drives

MP-Series (Bulletin MPL) Motor Connectors

Bulletin MPL motors equipped with circular DIN connectors (specified by 7 in the catalog number) are not compatible with cables designed for motors equipped with bayonet connectors (specified by 2 in the catalog number). The motors with bayonet connectors are being discontinued.

Bayonet connectors can be mounted facing the motor shaft or end plate and provide a separate connector for power, feedback, and brake connections. Circular DIN connectors rotate up to 180° and combine power and brake wires in the same connector, eliminating the brake connector.

Figure 53 - Bayonet and Circular DIN Motor Connectors

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Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

Table 32 - Motor Power Cable Compatibility

Motor/Actuator Connector Motor/Actuator Cat. No. Motor Power Cables

MP-Series (Bulletin MPL) Circular DIN MPL-B5xxx, MPL-B6xxx, MPL-B8xxx, and

MPL-B9xxx

Bayonet MPL-A/B5xxx, MPL-B6xxx, and

MPL-B8xxx MPL-B960B, MPL-B960C, MPL-B980B, and MPL-B980C

MPL-B960D and MPL-B980D 2090-MCNPMP-6Sxx

MP-Series (Bulletin MPM) Circular DIN MPM-B165 and MPM-B215 2090-CPBM7DF-xxAAxx or

RDD-Series Circular DIN RDB-Bxxxx N/A 2090-CPWM7DF-xxAAxx

HPK-Series N/A HPK-Bxxxxx, HPK-Exxxxx Customer-supplied

(1) You must remove the motor-side o-ring when using 2090-CPxM7DF-xxAxxx cables. (2) For Bulletin MPL motors equipped with bayonet connectors. These cables are available as standard, non-flex (catalog number 2090-XXNPMP-xxSxx) and continuous-flex (catalog number 2090-XXTPMP-

xxSxx).

(with brake wires)

2090-CPBM7DF-xxAAxx or 2090-XXNPMF-xxSxx (standard, non-flex)

2090-CPBM7DF-xxAFxx (continuous-flex)

N/A 2090-XXxPMP-xxSxx

2090-XXNPMF-xxSxx (standard, non-flex) 2090-CPBM7DF-xxAFxx (continuous-flex)

(1)

Motor Power Cables (without brake wires)

2090-CPWM7DF-xxAAxx (standard, non-flex) 2090-CPWM7DF-xxAFxx (continuous-flex)

(2)

2090-CPWM7DF-xxAAxx (standard, non-flex) 2090-CPWM7DF-xxAFxx (continuous-flex)

(standard, non-flex) 2090-CPWM7DF-xxAFxx (continuous-flex)

(1)

Motors may have a separate brake connector or need routing of thermal switch wires. These are often separately shielded and routed in an existing cable.

See Wiring Examples beginning on page 162 Power Terminal Block (PTB) Connections diagram on page 51

for interconnect diagrams, and the

for the location

of the U, V, W, and ground (PE) motor power terminals.

Securing the cable shield in the clamp with a tie wrap is recommended to improve stress relief.

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Connect the Kinetix 7000 Drive System Chapter 4

Input Power Wiring Requirements

National codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices.

ATT EN TI ON : To avoid personal injury and/or equipment damage, make sure installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment.

To avoid personal injury and/or equipment damage, make sure motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.

To avoid personal injury and/or equipment damage, make sure shielded power cables are grounded to prevent potentially high voltages on the shield.

Acceptable Cable Types

Do not use cable with an insulation thickness less than or equal to 15 mils (0.4 mm/0.015 in.). Use copper wire only. Wire gauge requirements and recommendations are based on 75 ° C. Do not reduce wire gauge when using higher temperature wire.

As an approximate guide, provide spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communications and networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks.

Consideration should be given to the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.

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Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

A good example of recommended cable is Belden/E 295xx (xx determines gauge). This cable has four XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket.

Other types of shielded cable are available, but the selection of these types may limit the allowable. Particularly, some of the newer cables twist four conductors of THHN wire and wrap them tightly with a foil shield. This construction increases the cable charging current required and reduces the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.

The table below describes the recommended shielded cables.

Table 33 - Shielded Cable Ratings and Types

Location Rating/Type Description

Standard (Option 1)

Standard (Option 2)

Class I & II; Division 1 & II

600V, 90 °C (194 °F), XHHW2/RHW-2 Anixter B209500-B209507, Belden B29501-B229507, or equivalent

600V, 90 °C (194 °F), RHH/RHW-2 Anixter OLF-7xxxxx, or equivalent

Tray rated 600V, 90 ° C (194 ° F), XHHW2/RHW-2 Anixter 7V-7xxxxx-3g, or equivalent

• Four tinned copper conductors with XLPE insulation

• Copper braid/aluminum foil combination shield and

tinned copper drain wire

• PVC jacket

• Three tinned copper conductors with XLPE insulation

• 5 mil single helical copper tape (25% overlap

minimum) with three bare copper grounds in contact with shield

• PVC jacket

• Three bare copper conductors with XLPE insulation

and impervious corrugated continuously welded aluminum armor

• Black sunlight resistant PVC jacket overall

• Three copper grounds on 5 mm

(10 AWG) and smaller

Contactors

A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed four cycles per minute maximum, or damage will occur to the drive precharge circuit.

The start/stop/enable control circuitry for the drive includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional stop circuitry may be required to remove the AC line to the drive. An auxiliary braking method also may be required.

It is recommended that the drive safe-off function be used to minimize contactor cycling.

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Connect the Kinetix 7000 Drive System Chapter 4

Power Wire Specifications

Wire should 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.

For additional information see Power Specifications on page 150 Interconnect Diagram Notes on page 162

for interconnect diagrams.

ATT EN TI ON : This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures.

See publication 8000-4.5.2

, Guarding Against Electrostatic Damage or any other

applicable ESD protection handbook.

ATT EN TI ON : To avoid personal injury and/or equipment damage, be sure the installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment

To avoid personal injury and/or equipment damage, be sure the motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.

To avoid personal injury and/or equipment damage, be sure the shielded power cables are grounded to prevent potentially high voltages on the shield.

, and

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 87

Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

Power Wiring Guidelines

Use these guidelines when wiring the power connectors on your Kinetix 7000 drive (without a LIM).

To achieve system performance, run wires and cables in the wireways as established in Chapter

To limit coil switching transients generated by the LINE contactor, use of a surge suppressor is recommended. For an example, see Appendix

This procedure assumes you have separate power supply/line filter components mounted on your panel and are ready to wire the AC input power to the drive.

1. Prepare the wires for attachment to each connector by removing insulation equal to an acceptable strip length.

The actual strip length will vary based on the wire gauge and terminal size of the Kinetix 7000 drive.

2. Route the wires to your Kinetix 7000 drive.

3. Insert the wires into the connector or connect the wires to the terminals.

Wire the Kinetix 7000 Drive Connectors

4. Tighten the terminal screws/nuts to the recommended torque for the specific terminal.

5. Pull on each wire to make sure it does not come out of its terminal. If any wires are loose, reinsert/connect and tighten the wire to the recommended torque.

See Appendix B for all Kinetix 7000 drive interconnect diagrams.

Wire the Control Power (CP) Connector

Wire the 24V DC control power supply to your Kinetix 7000 drive as described in Ta b l e 3 4 information.

Table 34 - Control Power Connections

Signal Terminal Recommended Wire Size

CP_24VDC 1 0.75 (18) CP_COM 2

. See Control Power (CP) Terminal Block Connections for more

mm2 (AWG)

(stranded wire with ferrule)

1.5 (16) (solid wire)

Strip Length

(in.)

7.0 (0.275) 0.235 (2.0)

Tor que N

•m (lb•in)

88 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Connect the Kinetix 7000 Drive System Chapter 4

IMPORTANT

Wire AC Input Power

Wire 460V AC input power to your Kinetix 7000 drive as described in Ta b l e 3 5 . See Power Terminal Block (PTB) Connections for more information.

Table 35 - AC Input Power Connections

Kinetix 7000 Drive Cat. No.

2099-BM06-S 2099-BM07-S 2099-BM08-S

2099-BM09-S L1

2099-BM10-S L1

2099-BM11-S 2099-BM12-S

Signal Terminal Recommended Wire Size

L1 L2 L3 Ground

L2 L3

Ground PE 50…4 (1/0…12) 5 (44)

L2 L3

Ground PE 50…4 (1/0…12) 5 (44) L1

L2 L3

Ground PE 50…4 (1/0…12) 5 (44)

R S T PE

R S T

mm2 (AWG)

25…2.5 (3…14) 1.8 (16)

50…4 (1/0…12) 3.6 (32)

70…10 (2/0…8) 15 (133)

100…10 (4/0…8) 12 (104)

Wire DC Input Power (Common Bus Configurations Only)

Tor qu e N•m (lb•in)

Wire the DC input power from a leader regenerative power supply (8720MCRPS) to a Kinetix 7000 drive as described in Ta b l e 3 6 (PTB) Connections on page 51

for more information.

. See Power Terminal Block

DC power from the regenerative power supply (8720MC-RPS) is typically routed to a power distribution box. Fusing will be placed before and after the distribution box, providing protection for both the 8720MC-RPS and Kinetix 7000 drive.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 89

Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

Table 36 - DC Input Power Connections

Kinetix 7000 Drive Cat. No.

2099-BM06-S 2099-BM07-S 2099-BM08-S

2099-BM09-S DC+

2099-BM10-S DC+

2099-BM11-S 2099-BM12-S

Signal Description Terminal(s) Recommended Wire Size

DC+ DC-

DC-

DCDC+

DC-

DC+ DC- 25…2.5 (3…14) 1.8 (16)

DC+ DC-

mm2 (AWG)

50…4 (1/0…12) 3.6 (32)

70…10 (2/0…8) 15 (133)

100…10 (4/0…8) 12 (104)

Tor qu e N•m (lb•in)

Wire the Safe-off (SO) Connector

Wire the Safe-off connections to your Kinetix 7000 drive as described in

Ta b l e 3 7

. See Safe-off (SO) Terminal Block Connections for more information.

Terminals 8 and 9 (24V+ and Common) are only used by the motionallowed jumper. When using the Safe-off feature, the 24V supply must come from an external source.

Table 37 - Safe-off Connections

Signal Terminal Recommended Wire Size

FDBK2+ 1 FDBK2- 2 FDBK1+ 3 FDBK1- 4 ENABLE2+ 5 ENABLE- 6 ENABLE1+ 7 SO_24VDC 8 SO_COM 9

mm2 (AWG)

0.75 (18) (stranded wire with ferrule)

1.5 (16) (solid wire)

Strip Length mm2 (in.)

7.0 (0.275) 0.235 (2.0)

Tor que N•m (lb•in)

90 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Connect the Kinetix 7000 Drive System Chapter 4

Wire the General Purpose Relay (GPR) and General Purpose I/O (GPIO) Connectors

Wire the control and interface signals on the General Purpose Relay (GPR) and General Purpose I/O (GPIO) connectors as described in Ta b l e 3 8 See General Purpose I/O (GPIO) Terminal Block Connections on page 46 General Purpose Relay (GPR) Terminal Block Connections on page 46 information.

ATT EN TI ON : Wiring the DRIVE OK signal on the General Purpose Relay is required. To avoid injury or damage to the drive, wire the DRIVE OK relay into your safety control string.

In common bus configurations, a REGEN connection on the General Purpose Input/ Output connector is also required for the drives. This connection must be wired in series to the safety control string, and also wired from the 8720MC-RPS to the Kinetix 7000 drive to indicate bus voltage is present.

Table 38 - General Purpose Relay Connections

and Ta b l e 3 9 .

and

for more

Signal Terminal Description Recommended Wire Size

DRIVE OK+ 5 Programmable N.O. Relay 2 output 0.75 (18) DRIVE OK- 6 Programmable Relay 2 common

mm2 (AWG)

(stranded wire with ferrule)

1.5 (16) (solid wire)

Table 39 - General Purpose I/O Connections

Signal Terminal Description Recommended Wire Size

Regen_OK+ 7 Regenerative power supply status 0.75 (18) Regen_OK- 8 Regenerative power supply status common

mm2 (AWG)

(stranded wire with ferrule)

1.5 (16) (solid wire)

Strip Length mm (in.)

7.0 (0.275) 0.235 (2.0)

Strip Length mm (in.)

7.0 (0.275) 0.235 (2.0)

Tor que V alue N•m (lb•in)

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 91

Chapter 4 Connect the Kinetix 7000 Drive System

IMPORTANT

Wire Motor Output Power

Wire motor output power as described in Ta b l e 4 0 . See Power Terminal Block (PTB) Connections on page 51

Table 40 - HPK-Series and MP-Series Servo Motor Power Connections

for more information.

Kinetix 7000 Drive Cat. No.

2099-BM06-S 2099-BM07-S 2099-BM08-S

2099-BM09-S U / Brown

2099-BM10-S U / Brown

2099-BM11-S 2099-BM12-S

Signal Terminal Recommended Wire Size

U / Brown V / Black w / Blue

Green/Yellow

V / Black w / Blue

Green/Yellow 50…4 (1/0…12) 5 (44)

V / Black w / Blue

Green/Yellow 50…4 (1/0…12) 5 (44)

U / Brown V / Black w / Blue

Green/Yellow 50…4 (1/0…12) 5 (44)

Wire the Motor Brake

mm2 (AWG)

U V W

25…2.5 (3…14) 1.8 (16)

50…4 (1/0…12) 3.6 (32)

70…10 (2/0…8) 15 (133)

100…10 (4/0…8) 12 (104)

Tor qu e N•m (lb•in)

Wire the motor brake (if applicable) as described in Ta b l e 4 1 . See Power Terminal Block (PTB) Connections on page 51 motor power connections.

Use surge suppression when controlling a brake coil.

Table 41 - Motor Brake Connections

Motor Brake Terminal (Signal) Drive Terminal

Bulletin MPL w/Bayonet Connector

A (BR+) F (BR+) 2 (GPR1+) C (BR-) G (BR-) 3 (GPR1-)

Bulletin MPx w/Circular DIN Connector

(Signal)

See Figure 81 on page 172

Recommended Wire Size mm2 (AWG)

2.5 (14) 10 (0.38)

Notes: HPK-Series motor brake terminations are BR+ and BR-. RDD-Series motors do not have a motor brake.

92 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

for more information on the

Strip Length mm (in.)

Tor que V alue N•m (lb•in)

0.5…0.6 (4.4…5.3)

Connect the Kinetix 7000 Drive System Chapter 4

Motor brake wiring varies slightly, depending on the motor connector type. The table below identifies the brake wire option for your servo motor and the appropriate brake cable or connector kit catalog number required.

Feedback and I/O Cable Connections

Motor Series Connector

Type

Bulletin MPL Circular DIN The brake terminals are in the motor power

Bayonet The motor has a s eparate brake connector and

Bulletin MPM Circular DIN The brake terminals are in the motor power

HPK-Series N/A The motor has a separate brake wiring

UXNBMP-18Sxx) and continuous-flex (catalog number 2090-UXTBMP-18Sxx).

Brake Wire Option Cable Cat. No.

connector. Drive to motor power cables must be ordered with the brake option.

requires a brake power cable.

connector. Drive to motor power cables must be ordered with the brake option.

connection.

2090-CPBM7DF-xxAAxx 2090-XXNPMF-xxSxx

(standard, non-flex) 2090-CPBMxDF-xxAFxx (continuous-flex)

2090-UXxBMP-18Sxx brake cable

2090-CPBM7DF-xxAAxx 2090-XXNPMF-xxSxx (standard, non-flex)

2090-CPBMxDF-xxAFxx (continuous-flex)

Custom er-sup plied

(1)

Factory-made cables with premolded connectors are designed to minimize EMI and are recommended over hand-built cables to improve system performance. However, other options are available for building your own feedback and I/O cables.

(2)

Table 42 - Motor Feedback Cable Compatibility - Bayonet Connectors

Motor/Actuator

MPL-Bxxxx-S Bayonet High-resolution encoder 2090-UXNFBMP-Sxx

(1) For Bulletin MPL and 1326AB (M2L/S2L) motors equipped with bayonet connectors. These cables are available as standard, non-flex

(catalog number 2090-XXNFMP-Sxx) and continuous-flex (catalog number 2090-XXTFMP-Sxx).

Connector Type

Feedback Type

Premolded Flying-lead

Feedback Cable

2090-XXxFMP-Sxx

(1)

Table 43 - Motor Feedback Cable Compatibility - Circular DIN Connectors

(1)

2090-CFBM7DF-CEAAxx (standard, non-flex) or 2090-CFBM7DF-CEAFxx (continuous-flex)

2090-XXNFMF-Sxx (standard, non-flex) or 2090-CFBM7DF-CDAFxx (continuous-flex)

2090-XXNFMF-Sxx (standard, non-flex) 2090-CFBM4DF-CDAFxx (continuous-flex)

Motor/Actuator

MPL-B5xxx-S/Mx7xAA, MPL-B6xxx-S/Mx7xAA, MPL-B8xxx-S/Mx7xAA MPL-B9xxx-S/Mx7xAA

MPM-Bxxxxx-S/M

RDB-Bxxxx-7/3

HPK-Series

Connector Type

SpeedTec DIN

Feedback Type

High-resolution encoder

Feedback Cable

Premolded Flying-lead

2090-CFBM7DD-CEAAxx (standard, non-flex) or 2090-CFBM7DD-CEAFxx (continuous-flex)

N/A

(1) You must remove the motor-side o -ring when using 2090-CFBM7xx-xxAxxx cables.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 93

Chapter 4 Connect the Kinetix 7000 Drive System

Flying-lead Feedback Cable Pinouts

Signal

(1)

Drive MF Connector Pin

Table 44 - 2090-XXxFMP-Sxx Feedback Cable

Motor Bayonet Connector Pin

ASine+1

BSine-2

CCos+3

DCos-4

EData+5

FData-10

KReserved–

LReserved–

NEPWR_9V7

PECOM6

RTS+11

STS-–

TReserved–

UReserved–

VReserved–

(1) The 2090-XXxFMP-Sxx cables are available as standard, non-flex (catalog number 2090-XXNFMP-Sxx) and continuous-flex (catalog

number 2090-XXTFMP-Sxx).

Rotary Motors with High Resolution Feedback: MPL-B5xxxx-M/Sx2xAA, MPL-B6xxxx-M/Sx2xAA, MPL-B8xxxx-M/Sx2xAA, and MPL-B9xxxx-M/Sx2xAA

Table 45 - 2090-XXNFMF-Sxx and 2090-CFBMxDF-CDAFxx Feedback Cable

Motor Circular DIN Connector Pin

10 Reserved –

11 EPWR_9V 7

12 ECOM 6

13 TS+ 11

14 TS- –

15 Reserved –

16 Reserved –

17 Reserved –

Motors with High Resolution Feedback: MPL-B5xxxx-M/Sx7xAA, MPL-B6xxxx-M/Sx7xAA,

MPL-B8xxxx-M/Sx7xAA, MPL-B9xxxx-S/M-M/Sx7xAA, HPK-Bxxxx-S/M, and HPK-Exxxx-S/M

Signal

1Sine+ 1

2Sine- 2

3Cos+ 3

4Cos- 4

5 Data+ 5

6 Data- 10

9Reserved –

Drive MF Connector Pin

94 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Connect the Kinetix 7000 Drive System Chapter 4

IMPORTANT

Table 46 - 2090-XXNFMF-Sxx and 2090-CFBMxDF-CDAFxx Feedback Cable

Motor Circular DIN Connector Pin

1Sine+ 1

2Sine- 2

3Cos+ 3

4Cos- 4

5Data+ 9

6Data-10

7CLK+ 7

8CLK- 8

9EPWR_5V 5

10 ECOM 6

11 Reserved –

12 Reserved –

13 TS+ 11

14 TS- –

15 Reserved –

16 Reserved –

17 Reserved –

RDB-Bxxxxx-3/7 Motors

Signal

2090-K7CK-KENDAT Pin

Wire Feedback and I/O Connectors

Wire your feedback and I/O cables.

To make this type of connection Go to

Premolded Cable Connect Premolded Motor Feedback Cables below. Panel-mounted Breakout Board Wire Panel-mounted Breakout Board Kits on page 96 Low-profile Connector Wire Low-profile Connectors on page 98.

Connect Premolded Motor Feedback Cables

Motor feedback cables (with premolded connectors) plug directly into 15-pin motor feedback (MF) connectors on Kinetix 7000 drive (no wiring is necessary).

When using Bulletin 2090 cables with premolded connectors, tighten the mounting screws (finger tight) to improve system performance.

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 95

Chapter 4 Connect the Kinetix 7000 Drive System

Premolded Connector Cable:

2090-CFBM7DD-CEAAxx (standard, non-flex)

2090-CFBM7DD-CEAFxx (continuous flex)

Kinetix 7000 Drive

(Side View)

Figure 54 - Premolded Motor Feedback Cable Connection

Wire Panel-mounted Breakout Board Kits

The panel-mounted breakout board kit (catalog number 2090-UXBK-D15xx) includes a (DIN rail) terminal block and cable. The cable connects between the terminal block and the motor feedback (MF) connector. Wires from your flyinglead motor feedback cable connect to the terminals.

96 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Connect the Kinetix 7000 Drive System Chapter 4

2090-UXBC-D15xx

Breakout Cable

See the Motor Feedback Breakout Board Installation Instructions, publication 2090-IN006

for Connector Breakout Board Specifications.

Kinetix 7000 Drive

(Side View)

2090-UXBB-D15xx Panel-mounted Breakout Board

Figure 55 - Panel-mounted Breakout Board Connection Example

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 97

Chapter 4 Connect the Kinetix 7000 Drive System

2090-Kxxx-Dxxx

Low-profile Connector Kit

with Flying-lead Feedback or

I/O Cable

Kinetix 7000 Drive

(Side View)

IMPORTANT

Tightening the mounting screws is essential to be sure of shield integrity between the low-profile connector covers and the drive feedback connector D-shells. Tightening torque is 0.4 N

•m

(35 lb

•in).

Wire Low-profile Connectors

Low-profile connectors (2090-K6CK-Dxxx) are suitable for motor feedback (MF), auxiliary feedback (AF), and I/O connections (IOD) on Kinetix 7000 drive.

Table 47 - Low-profile Connector Kits

Connector Kit Cat. No.

2090-K7CK-KENDAT Low-profile feedback module for connecting to Heidenhain EnDat high-resolution feedback device (15-pin, male, D-sub).

2090-K6CK-D15M Low-profile connector kit for motor feedback (15-pin, male, D-sub). Use with any Kinetix 7000 drive and compatible

2090-K6CK-D15F Low-profile connector kit for auxiliary feedback (15-pin, female, D-sub). Use with any Kinetix 7000

2090-K6CK-D26M Low-profile connec tor kit for I/O (26-pin, male, D-sub). Use with any Kinetix 7000 drive or 2094-BL02 LIM module for

Description Cable Compatibility

Use with any Kinetix 7000 drive and Bulletin RDB direct-drive motor with EnDat high-resolution feedback. NOTE: Only 2099-BMxx-S drives with firmware revision 1.104 or higher support the use of this feedback module.

motors.

drive for auxiliary feedback applications.

making I/O connections.

2090-XXxFMP-Sxx, 2090-XXNFMF-Sxx, 2090-CFBMxDF-CxAxxx

Customer supplied

98 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Connect the Kinetix 7000 Drive System Chapter 4

Pin 1

Pin 11

Pin 10

Pin 5

Pin 6

Pin 15

Pin 1

Pin 10

Pin 5

Pin 11

Pin 6

Pin 15

1 2 34

5 678

91011121314150

15-pin (male) Motor Feedback

Low-profile Connector

15-pin (female) Auxiliary Feedback

Low-profile Connector

See page 66

for Feedback Signal Descriptions.

See Appendix

B for the Motor Feedback

Interconnect Drawing for Your Application.

Tie Wrap

Exposed Braid Under Clamp

Bulletin 2090 Feedback Cable

Shield Clamp

Outer insulation

Braided shield

Foil sh ield

Wire i nsulat ion

Bare wi res

Bulletin 2090

Feedback Cable

Turn Clamp Over to Hold

Small Wires Secure

Mounting

Screws

See the Low Profile Connector Kit Installation Instructions, Publication

2094-IN007

, for Connector Kit Specifications.

2090-K6CK-D15x

Low-profile Connector Kit

15-pin (male) Motor Feedback

Low-profile Connector

See page 66

for Feedback Signal

Descriptions.

Exposed Braid Under Clamp

Shield Clamp

Outer Insulation

Braided Shield

Foil Shi eld

Wire I nsulation

Bare Wires

Turn Clamp Over to Hold

Small Wires Secure.

Mounting

Screws

See Appendix

B for the Motor Feedback

Interconnect Drawing for Your Application.

2090-K7CK-KENDAT

Low-profile Feedback Module

Bulletin 2090 Feedback Cable

Bulletin 2090

Feedback Cable

Status

Indicator

See the Low Profile Connector Kit Installation Instructions, Publication

2094-IN007

, for Connector Lit Specifications.

IMPORTANT

Figure 56 - Wiring (15-pin) Flying-lead Feedback Cable Connections 2090-K6CK-D15M and 2090-K6CK-D15F Connector Kits

Figure 57 - Wiring (15-pin) Flying-lead Feedback Cable Connections 2090-K7CK-KENDAT Feedback Module

Rockwell Automation Publication 2099-UM001D-EN-P - December 2012 99

Pin 10

Pin 5

Pin 1

1 2 34

5 678

910111213

The purpose of the cable shield clamp is to provide a proper ground and improve system performance, not stress relief.

Clamping the exposed braid under the shield clamp is critical. Turn the clamp over, if necessary, to be sure of a proper ground.

Pin 15

Pin 11

Pin 6

Chapter 4 Connect the Kinetix 7000 Drive System

26-pin (male) I/O

Low-profile Connector

Discrete I/O Wire

Tie Wrap Slot

Three Cond uctor

I/O Cable(s)

Tur n Cl amp Ove r to

Hold Small Wires

Secure

Mounting

Screws

See the Low Profile Connector Kit Installation Instructions, Publication

2094-IN007

, for Connector Kit Specifications.

2090-K6CK-D26M

Low-profile Connector Kit

IMPORTANT

Figure 58 - Wiring (26-pin) I/O Cable Connections 2090-K6CK-D26M Connector Kit

Pin 18

Pin 9

Pin 26

Pin 1

13 14 1516

12 17 181920

2122

23 S242526S

678 5

34 2 1

Pin 19

Pin 10

The purpose of the cable shield clamp is to provide a proper ground and improve system performance, not stress relief.

Clamping the exposed braid under the shield clamp is critical. Turn the clamp over, if necessary, to be sure of a proper ground.

100 Rockwell Automation Publication 2099-UM001D-EN-P - December 2012

Rockwell Automation 2099-BMxx User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

New and Updated Information

Table of Contents

Preface

About This Publication

Who Should Use This Manual

Conventions Used in This Manual

Additional Resources

About the Drive System

Typical Drive System Diagrams

Catalog Number Explanation

Agency Compliance

CE Requirements - System without LIM

CE Requirements - System with LIM

CE Requirements - System with DC Common Bus through 8720MC-RPS

System Design Guidelines

System Mounting Requirements

Transformer Selection

Circuit Breaker/Fuse Selection

Enclosure Selection

Minimum Clearance Requirements

Minimizing Electrical Noise

Bonding Modules

Bonding Multiple Subpanels

Establish Noise Zones

Cable Categories for Kinetix 7000 Systems

Noise Reduction Guidelines for Drive Accessories

Mount the Kinetix 7000 Drive

Locate and Identify Connectors and Indicators

Digital and Analog Input/Output (IOD) Connector Pinout

General Purpose I/O (GPIO) Terminal Block Connections

General Purpose Relay (GPR) Terminal Block Connections

Motor Feedback (MF) Connector Pinouts

Auxiliary Feedback (AF) Connector Pinouts

Safe-off (SO) Terminal Block Connections

Control Power (CP) Terminal Block Connections

Power Terminal Block (PTB) Connections

Control Signal Specifications

Digital Inputs (IOD Connector)

Analog Inputs (IOD Connector)

Analog Outputs (IOD Connector)

General Purpose I/O (GPIO Connector)

General Purpose Relay (GPR Connector)

SERCOS Connections

Safe-off (SO Connector)

Control Power Specifications

Motor (MF) and Auxiliary Feedback (AF) Connections

Motor and Auxiliary Feedback Specifications

Basic Wiring Requirements

Building Your Own Motor Cables

Shielded Motor Cable

Required Cable Types

Cable Sizes

Conduit

General Wire Guidelines

Routing the Power and Signal Cables

Determine the Input Power Configuration

Grounded Power Configurations

Power Distribution Systems Without a Ground Reference

Setting the Ground Jumper in Ungrounded Power Configurations

Removing the Ground Jumper on 2099-BM06-S, 2099-BM07-S, and 2099-BM08-S Drives

Removing the Ground Wires on 2099-BM09-S and 2099-BM10-S Drives

Removing the Ground Wires on 2099-BM11-S and 2099-BM12-S Drives

Grounding the Kinetix 7000 Drive System

Grounding Your System to the Subpanel

Grounding Multiple Subpanels

Motor Power Cable Shield Termination

MP-Series (Bulletin MPL) Motor Connectors

Input Power Wiring Requirements

Acceptable Cable Types

Shielded/Armored Cable

Contactors

Power Wire Specifications

Power Wiring Guidelines

Wire the Kinetix 7000 Drive Connectors

Wire the Control Power (CP) Connector