Rockwell Automation 2198-KITCON-DSL User Manual

User Manual

Kinetix 5500 Servo Drives

Catalog Numbers 2198-H003-ERS, 2198-H008-ERS, 2198-H015-ERS, 2198-H025-ERS, 2198-H040-ERS, 2198-H070-ERS
2198-H003-ERS2, 2198-H008-ERS2, 2198-H015-ERS2, 2198-H025-ERS2, 2198-H040-ERS2, 2198-H070-ERS2,
2198-CAPMOD-1300

Original Instructions

Important User Information

IMPORTANT

Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

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.

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.

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

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.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, CompactLogix, ControlFLASH, ControlLogix, HPK-Series, Kinetix, Logix5000, MP-Series, PanelView, POINT I/O, RDD-Series, RSLinx, RSLogix, Stratix 5700, Studio 5000, Studio 5000 Automation
Engineering an d Design Environment, Studio 5 000 Logix Desig ner, Rockwell Automation, Ro ckwell Software, and T L-Series are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Summary of Changes

This manual contains new and updated information.

Topic Pag e

Replaced catalog number string 2198-Hxxx-ERS with 2198-Hxxx-ERSx when there’s no need to
distinguish between -ERS or -ERS2.

Added footnotes and other text to note that STO connector does no t apply to 2198-Hxxx-ERS2 drives.

Added references to the Hiperface-to-DSL (series B) feedback converter kit as needed.

Added Kinetix VP (Bulletin VPF) food-grade motors.

Added LDAT-Series integrated linear thrusters.

Added 2198-Hxxx-ERS2 catalog numbers to front cover. Front Cover

Added 2198-Hxxx-ERS2 and GuardLogix safety controller catalog numbers/descriptions to the
System Overview table.

Removed Safety Device from Typical Hardware Configurations. 15…19

Added Safe Torque-off Configurations. 23…25

Added 2198-Hxxx-ERS2 catalog numbers to Catalog Number Explanation. 26

Corrected the short-circuit current rating from 150,000 to 200,000 A. 31

Updated Kinetix 5500 Drive Features and Indicators with 2198-Hxxx-ERS2 drive example. 58

Updated the Absolute Position Feature section with multi-turn catalog number strings for
compatible motors and actuators.

Updated Safe Torque-off Safety Features with 2198-Hxxx-ERS2 drive description. 66

Updated Ethernet Cable Connections with ControlLogix EtherNet/IP communication modules. 97

Updated controller configuration by adding GuardLogix controller and ControlLogix EtherNet/IP
communication module configuration.

Broke out Configure the Kinetix 5500 Drive with separate procedures for 2198-Hxxx-ERS and
2198-Hxxx-ERS2 servo drives.

Updated Tune the Axes with a reference to the load observer feature. 133

Added FLT-S04 - MTR OVERSPEED UL fault code.
Added FLT S09 – MTR PHASE LOSS fault code.
Added FLT S49 – BRAKE SLIP FLT fault code.

Added FLT-M28 - SAFETY COMM fault code. 143

Added INIT FLT-M14 - SAFETY FIRMWARE fault code. 144

Updated NODE FLT fault codes.
Added NODE FLT 03 – HARDWARE 04 fault code.

Added NODE ALARM 04 – CLOCK SKEW ALARM. 145

Updated the configurable stopping action definitions. 149

Added FLT-S04 - MTR OVERSPEED UL fault behavior.
Added FLT S15 – CONV OVERCURRENT fault behavior.
Added FLT S49 – BRAKE SLIP FLT fault behavior.

Added FLT-M28 - SAFETY COMM fault behavior. 151

Added NODE FLT 05 – CLOCK SKEW FLT fault behavior 152

Updated Start and Configure the Drive with step to review an integrated safety configuration after
replacing an integrated safety drive.

Updated Chapter 9 title by adding Hardwired Safety to distinguish it from Chapter 10. 157

Updated System Operation timing diagram with 100 ms. 159

Updated 2198-Hxxx-ERS troubleshooting table with fault code. 159

Added Chapter 10, Kinetix 5500 Safe Torque-off - Integrated Safety. 167

Througho ut

14

65

105

110 and 112

141

144

150

156

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 3

Summary of Changes

Top ic Pag e

Added Kinetix VP (Bulletin VPF) food-grade motors to the Kinetix VP interconnect diagram. 195

Corrected motor power and brake connection pinouts for MP-Series motor and actuator diagrams. 196, 198, 199

Added LDAT-Series linear thrusters interconnect diagram. 197

4 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Table of Contents

Preface

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

Start

Planning the Kinetix 5500 Drive
System Installation

About the Kinetix 5500 Servo Drive System. . . . . . . . . . . . . . . . . . . . . . . . 14

Typical Hardware Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Standalone Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Shared AC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Shared AC/DC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Shared DC Common-bus Configurations . . . . . . . . . . . . . . . . . . . . . . 18

Shared AC/DC Hybrid Configuration. . . . . . . . . . . . . . . . . . . . . . . . . 19

Typical Communication Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Linear Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Ring Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Star Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Safe Torque-off Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Hardwired Safety Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Integrated Safety Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 2

System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Enclosure Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Electrical Noise Reduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Establishing Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Cable Categories for Kinetix 5500 Systems . . . . . . . . . . . . . . . . . . . . . 40

Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 41

Mounting the Kinetix 5500 Drive
System

Chapter 3

Determining Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Zero-stack Tab and Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Shared-bus Connection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Single-axis Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 5

Table of Contents

Connector Data and Feature
Descriptions

Multi-axis Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Drilling Hole Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Mount Your Kinetix 5500 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Chapter 4

Kinetix 5500 Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Safe Torque-off Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Input Power Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

DC Bus and Shunt Resistor Connector Pinouts . . . . . . . . . . . . . . . . . 59

Digital Inputs Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Ethernet Communication Connector Pinout . . . . . . . . . . . . . . . . . . . 60

Motor Power, Brake, and Feedback Connector Pinouts . . . . . . . . . . 61

Motor Feedback Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Understanding Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . 62

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Ethernet Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . 63

Motor Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Safe Torque-off Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Servo Drives with Hardwired Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Servo Drives with Integrated Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Connecting the Kinetix 5500 Drive
System

Chapter 5

Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 69

Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Ungrounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Removing the Grounding Screws in Ungrounded

Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Grounding the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Ground the System Subpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Wiring the Power Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Wire the 24V Control Power Input Connector . . . . . . . . . . . . . . . . . 77

Wire the Input Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Wiring the Digital Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Wire the Safe Torque-off Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Wire the Digital Inputs Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Wiring Kinetix VP Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Motor Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Motor Brake Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Configure and Start the
Kinetix 5500 Drive System

Table of Contents

Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Apply the Single Motor Cable Shield Clamp. . . . . . . . . . . . . . . . . . . . 84

Wiring Other Allen-Bradley Motors and Actuators . . . . . . . . . . . . . . . . . 86

Install the Kinetix 5500 Add-On Profile. . . . . . . . . . . . . . . . . . . . . . . . 86

Motor Power and Brake Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Motor Feedback Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Capacitor Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

External Shunt Resistor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Chapter 6

Understanding the Kinetix 5500 Display. . . . . . . . . . . . . . . . . . . . . . . . . . 100

Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Set the Network Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Configure the Logix Designer Application Project . . . . . . . . . . . . . . . . . 105

Configure the Logix5000 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . 105

Configure the Kinetix 5500 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Configure Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Apply Power to the Kinetix 5500 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Applying Power after Changing Input Voltage Range. . . . . . . . . . . 130

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Understanding Bus Sharing Group Configuration . . . . . . . . . . . . . . . . . 135

Bus Sharing Group Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Configure Bus-sharing Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Troubleshooting the Kinetix 5500
Drive System

Chapter 7

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Display Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Kinetix 5500 Drive Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . 146

Kinetix 5500 Capacitor Module Status Indicators. . . . . . . . . . . . . . 147

General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Logix5000 Controller and Drive Behavior . . . . . . . . . . . . . . . . . . . . . . . . 149

Kinetix 5500 Drive Exception Behavior . . . . . . . . . . . . . . . . . . . . . . . 149

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 7

Table of Contents

Chapter 8

Removing and Replacing Servo Drives

Kinetix 5500 Safe Torque-off ­Hardwired Safety

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Remove and Replace Kinetix 5500 Servo Drives. . . . . . . . . . . . . . . . . . . . 154

Remove Power and All Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Remove the Servo Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Replace the Servo Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Start and Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Chapter 9

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Important Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Category 3 Requirements According to ISO 13849. . . . . . . . . . . . . 158

Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Performance Level (PL) and Safety Integrity Level (SIL) . . . . . . . . 158

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Troubleshoot the Safe Torque-off Function. . . . . . . . . . . . . . . . . . . . 159

Probability of Dangerous Failure Per Hour (PFH) . . . . . . . . . . . . . . . . . 161

PFH Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Safe Torque-off Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Wire the Safe Torque-off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Safe Torque-off Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 163

Safe Torque-off Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Safe Torque-off Feature Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Cascade the Safe Torque-off Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Safe Torque-off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Kinetix 5500 Safe Torque-off ­Integrated Safety

Chapter 10

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Important Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Category 3 Requirements According to ISO 13849. . . . . . . . . . . . . 168

Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Performance Level (PL) and Safety Integrity Level (SIL) . . . . . . . . 169

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

STO State Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Troubleshoot the Safe Torque-off Function. . . . . . . . . . . . . . . . . . . . 170

Probability of Dangerous Failure Per Hour (PFH) . . . . . . . . . . . . . . . . . 171

PFH Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Safe Torque-off Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Out-of-Box State Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Understanding Integrated Safety Drive Replacement . . . . . . . . . . . . . . . 174

Replacing an Integrated Safety Drive in a GuardLogix System . . . . . . . 175

Replacement with Configure Only When

No Safety Signature Exists Enabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Replacement with Configure Always Enabled . . . . . . . . . . . . . . . . . . 179

8 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Table of Contents

Motion Direct Commands in Motion Control Systems . . . . . . . . . . . . 181

Understanding STO Bypass When

Using Motion Direct Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Logix Designer Application Warning Messages . . . . . . . . . . . . . . . . 182

Torque Permitted in a Multi-workstation Environment . . . . . . . . 184

Warning Icon and Text in Axis Properties . . . . . . . . . . . . . . . . . . . . . 184

Functional Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Safe Torque-off Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Appendix A

Interconnect Diagrams

Upgrade the Drive Firmware

Sizing Multi-axis Shared-bus
Configurations

Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Power Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Single-axis Drive Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Bus-sharing Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Shunt Resistor Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Kinetix 5500 Drive and Motor/Actuator Wiring Examples. . . . . . . . . 195

System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Appendix B

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Configure Logix5000 Controller Communication . . . . . . . . . . . . . 205

Inhibit Feedback Only Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Upgrade Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Appendix C

Shared-bus Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Shared AC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Shared DC Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Shared AC/DC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Shared AC/DC Hybrid Configurations. . . . . . . . . . . . . . . . . . . . . . . 217

Power Sharing Sizing Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Shared DC Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Shared AC/DC Hybrid Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Shared AC/DC Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Control Power Current Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Kinetix 5500 System Current Demand Example . . . . . . . . . . . . . . . 221

Energy Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Induction Motor Support

Appendix D

Induction Motor Control Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Basic Volts/Hertz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Sensorless Vector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 9

Table of Contents

Appendix E

EC Certifications

History of Changes

EC Type - Examination Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Appendix F

2198-UM001C-EN-P, February 2014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

2198-UM001B-EN-P, September 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Index

10 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Preface

About This Publication

Audience

Conventions Used in This Manual

This manual provides detailed installation instructions for mounting, wiring, and
troubleshooting the Kinetix® 5500 servo drives, and system integration for your
drive and motor/actuator combination with a Logix5000™ controller.

This manual is intended for engineers or technicians directly involved in the
installation and wiring of the Kinetix 5500 drives, and programmers directly
involved in the operation, field maintenance, and integration of these drives with
the EtherNet/IP communication module or controller.

If you do not have a basic understanding of Kinetix 5500 servo drives, contact
your local Rockwell Automation sales representative for information on available
training courses.

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.

• Catalog number string 2198-Hxxx-ERSx is used when there’s no need to

distinguish between -ERS or -ERS2 servo drives.

Studio 5000 Environment

The Studio 5000 Automation Engineering and Design Environment™ combines
engineering and design elements into a common environment. The first element
in the Studio 5000® environment is the Logix Designer application. The Logix
Designer application is the rebranding of RSLogix™ 5000 software and continues
to be the product to program Logix5000 controllers for discrete, process, batch,
motion, safety, and drive-based solutions.

The Studio 5000 environment is the foundation for the future of Rockwell
Automation® engineering design tools and capabilities. The Studio 5000
environment is the one place for design engineers to develop all of the elements
for their control system.

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 11

Preface

Additional Resources

These documents contain additional information concerning related products
from Rockwell Automation.

Resource Description

Kinetix 5500 servo drives Installation Instructions, publication 2198-IN001 Information on mounting and wiring the Kinetix 5500 servo drive.

Kinetix 5500 Feedback Connector Kit Installation Instructions, publication 2198-IN002

Kinetix 5500 AC Line Filter Installation Instructions, publication 2198-IN003

Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004

Kinetix 5500 Shared-bus Connector Kit Installation Instructions, publication 2198-IN005 Information on installing the Kinetix 5500 shared-bus connector kits.

Hiperface-to-DSL Feedback Converter Kit Installation Instructions, publication 2198-IN006 Information on installing the Hiperface-to-DSL feedback converter kit.

Kinetix 300 Shunt Resistor Installation Instructions, publication 2097-IN002

System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001

EMC Noise Management DVD, publication GMC-SP004

Kinetix Motion Control Selection Guide, publication GMC-SG001

Kinetix 5500 Drive Systems Design Guide, publication GMC-RM009

Kinetix Rotary Motion Specifications Technical Data, publication GMC-TD001

Kinetix Linear Motion Specifications Technical Data, publication GMC-TD002

Kinetix Servo Drives Specifications Technical Data, publication GMC-TD003

Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004

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

Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual,
publication MOTION-UM003

GuardLogix 5570 Controllers User Manual, publication 1756-UM022

GuardLogix 5570 Controller Systems Safety Reference Manual, publication 1756-RM099

Safety Products Catalog website http://www.ab.com/catalogs

ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-QS105

National Electrical Code, published by the National Fire Protection Association of Boston, MA An article on wire sizes and types for grounding electrical equipment.

Rockwell Automatio n Industrial Automation Glossary, publication AG-7. 1

Information on installing and wiring the Kinetix 5500 motor feedback connector kit.

Information on installing and wiring the Kinetix5500 AC line filters.

Information on installing and wiring the Kinetix 5500 capacitor module.

Information on installing and wiring Kinetix 300 shunt resistors.

Information, examples, and techniques designed to minimize system failures caused
by electrical noise.

Overview of Kinetix servo drives, motors, actuators, and motion accessories designed
to help make initial decisions for the motion control products best suited for your
system requirements.

System design guide to select the required (drive specific) drive module, power
accessory, feedback connector kit, and motor cable catalog numbers for your
Kinetix 5500 drive and Kinetix VP motor motion control system.

Product specifications for Kinetix VP (Bulletin VPL, VPF, and VPS), MP-Series™
(Bulletin MPL, MPM, MPF, and MPS), Kinetix 6000M (Bulletin MDF), TL-Series™,
RDD-Series™, and HPK-Series™ rotary motors.

Product specifications for MP-Series (Bulletin MPAS ballscrew, MPAR, and MPAI) and
LDAT-Series linear actuators.

Product specifications for Kinetix Integrated Motion over the EtherNet/IP network,
Integrated Motion over sercos interface, EtherNet/IP networking, and component
servo drive families.

Product specifications for Bulletin 2090 motor and interface cables, low-profile
connector kits, drive power components, and other servo drive accessory items.

Motion Analyzer application analysis software for drive/motor sizing.

Online product selection and system configuration tools, including AutoCAD (DXF)
drawings.

For declarations of conformity (DoC) currently available from Rockwell Automation.

Information on configuring and troubleshooting your ControlLogix® and
CompactLogix™ EtherNet/IP network modules.

Information on designing, installing, programming, or troubleshooting control
systems that use GuardLogix 5570 controllers.

Information for development, operation, or maintenance of a GuardLogix 5570
controller-based safety system that uses the Studio 5000 Logix Designer™ application.

Information regarding Allen-Bradley safety products, including safety relays, light
curtain, and gate interlock applications.

For ControlFLASH™ information not specific to any drive family.

A glossary of industrial automation terms and abbreviations.

You can view or download publications at

http://www.rockwellautomation.com/literature

technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.

12 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

. To order paper copies of

Chapter 1

Start

Use this chapter to become familiar with the design and installation requirements
for Kinetix 5500 drive systems.

Top ic Pa ge

About the Kinetix 5500 Servo Drive System 14

Typical Ha rdware Configurations 15

Typical Communication Configurations 20

Safe Torque-off Configurations 23

Catalog Number Explanation 26

Agenc y Compliance 27

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 13

Chapter 1 Start

About the Kinetix 5500 Servo Drive System

The Kinetix 5500 servo drives are designed to provide a Kinetix Integrated
Motion solution for your drive and motor/actuator application.

Table 1 - Kinetix 5500 Drive System Overview

Drive System
Component

Kinetix 5500
Servo Drives

Kinetix 5500
Capacitor Module

Shared-bus
Connector Kits

Feedba ck
Connector Kit

Hiperface to DSL
Converter Kit

I/O Connector Kits

Connector Sets

Logix5000
Controller Platform

Studio 5000
Environment

Rotary Servo
Motors

Linear Actuators

Induction motors N/A Induction motors with open loop volts/hertz frequency control are also supported.

Cables

AC Line Filters

24V DC Power
Supply

External Shunt
Resistors

Cat. No. Description

2198-Hxxx-ERS

2198-Hxxx-ERS2 Same power structures with standalone and multi-axis bus-sharing capability. Safe torque-off via the EtherNet/IP network.

2198-CAPMOD-1300

2198-H040-x-x Input wiring connectors and DC bus T-connector for frame 1 and 2 servo drives.

2198-H070-x-x Input wiring connectors and DC bus T-connector for frame 3 servo drives.

2198-KITCON-DSL Replacement feedback connector kit with 2-pin connector plug and grounding plate inside the connector housing.

2198-H2DCK

2198-KITCON-IOSP Replacement I/O connector kit (spring clamp) for I/O (IOD) connector.

2198-KITCON-IOSC Replacement I/O connector kit (screw terminal) for I/O (IOD) connector.

2198-KITCON-PWR40 Replacement connector set, 40 A, for frame 1 and frame 2 drives.

2198-KITCON-PWR70 Replacement connector set, 70 A, for frame 3 drives.

2198-KITCON-CAP1300 Replacement connector set, 40 A, for capacitor module.

1769-L18ERM
1769-L27ERM
1769-L3xERM

1756-EN2T module
1756-EN2TR module
1756-EN3TR module

N/A

VPL-Axxxx, VPL-Bxxxx
VPF-Axxxx, VPF-Bxxxx
VPS-Bxxxx

-Series

MP

MP-Series
LDAT-Series

2090-CSxM1DF-xxAxxx Bulletin 2090 single-cable for motor power, feedback, and 24V DC brake power with Kinetix VP motors.

2090-CFBM7DF-CEAxxx Bulletin 2090 motor feedback cables for MP-Series motors and actuators.

2090-CPxM7DF-xxAxxx Bulletin 2090 motor power/brake cables for MP-Series motors and actuators.

1585J-M8CBJM-x Ethernet cables are available in standard lengths. Shielded cable is recommended.

2198-DB08-F
2198-DB20-F
2198-DB42-F

1606-XLxxx Bulletin 1606 24V DC power supply for control circuitry, digital inputs, safety, and motor brake.

2097-R6 and 2097-R7 Bulletin 2097 external passive shunt resistors for when the drive’s internal shunt capability is exceeded.

200V-class (single-phase or three-phase) and 400V-class (three-phase) drives operate in standalone and multi-axis shared AC,
shared DC, shared AC/DC, and shared AC/DC hybrid configurations. Modules are zero-stacked from drive-to-drive and use the shared­bus connection system to extend power in multi-axis configurations. Safe torque-off via hardwired (STO) connector.

Use for energy storage and/or to improve performance in applications producing regenerative energy and requiring shorter duty
cycles (1360 μf). Modules are zero-stacked side-by-side with servo drives and use the shared-bus connection system to extend
power.

Use for Hiperface-to-DSL feedback conversion with 400V-class MP-Series (Bulletin MPL, MPM, MPF, and MPS) rotary motors and
MP-Series (Bulletin MPAS ballscrew, MPAR, MPAI) linear actuators. Series B or later converter kit is required for LDAT-Series linear
thrusters and 200V-class MP-Series motors and actuators.

CompactLogix 5370 controllers with Integrated Motion on the EtherNet/IP network. Linear, ring, and star topology is supported.

ControlLogix 1756-L7x and GuardLogix 1756-L7xS controllers with Integrated Motion on EtherNet/IP networks. Linear, device-level
ring (DLR), and star topology is supported.

Studio 5000 Logix Designer application, version 21.00 or later, provides support for programming, commissioning, and maintaining
the CompactLogix and ControlLogix controller families. Version 24.00 or later is required for 2198-Hxxx-ERS2 servo drives.

Compatible rotary motors include 200V and 400V-class Kinetix VP (Bulletin VPL, VPF, and VPS).

C

ompatible rotary motors include 200V and 400V-class MP-Series (Bulletin MPL, MPM, MPF, and MPS) when used with the

Hiperface-to-DSL feedback converter kit.

Compatible linear actuators include 200V and 400V-class MP-Series (Bulletin MPAS ballscrew, MPAR, and MPAI) and LDAT-Series
when used with the Hiperface-to-DSL feedback converter kit.

Bulletin 2198 three-phase AC line filters are required to meet CE and available for use in all Kinetix 5500 drive systems.

14 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Start Chapter 1

Single-phase or

Three-p hase
Input Power

Bulletin 2090
Single Motor Cable

Line

Disconnect

Device

Input

Fusin g

2198-Hxxx-ERSx Drive
(front view)

2097-Rx
Shunt Resistor
(optional component)

Kinetix VP (Bulletin VPL, VPF,

and VPS) Rotary Motors

(VPL-Bxxxx motor is shown)

2198-Hxxx-ERSx Drive
(top view)

AC Input Power

Bonded Cabinet
Ground Bus

2198-KITCON-DSL (shown)

Motor Feedback Connector Kit

or 2198-H2DCK Hiperface-to-DSL

Feedback Converter Kit

Mains AC and 24V input
wired to standard input
connectors.

2198-DBxx-F
AC Lin e Filter

(required for CE)

Shared DC (DC common bus)

Shared 24V (control power input)

2198-Hxxx-ERSx Drive (top view)
with 2198-CAPMOD-1300
Capacitor Module

2198-H0x0-x-x shared-bus
connection system for bus­sharing configurations.

Mains AC input wired to
standard input connector.

Digital Inputs

to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

MP-Series (Bulletin MPAS, MPAR, MPAI) Linear Actuators

(1)

MPAS-B9xxx (ballscrew) Linear Stage is Shown

MP-Series (Bulletin MPL, MPM, MPF, MPS) Rotary Motors

(1)

(MPL-Bxxxx rotary motor is shown)

LDAT-Series Linear Thrusters

(1)

(LDAT-Sxxxxxx-xDx linear thruster is shown)

Typical Hardware Configurations

Typical Kinetix 5500 systems include single-phase and three-phase standalone
configurations, three-phase shared AC, shared AC/DC, shared DC, and shared
AC/DC hybrid configurations.

Standalone Configurations

In these examples, a single standalone drive is shown with and without the
Bulletin 2198 capacitor module.

Figure 1 - Typical Kinetix 5500 Standalone Installation

Allen-Bradley

1606-XL

Power Supply

Input

(1) Requires the 2198-H2DCK Hiperface-to-DSL feedback converter kit. LDAT-Series linear thrusters and MP-Series (200V-class) motors

and actuators require the 2198-H2DCK (series B or later) converter kit.

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 15

Chapter 1 Start

1606-XL

Power Supply

Input

Allen-Bradley

Kinetix 5500 Servo Drives (top view)

(2198-H008-ERS drives shown)

2097-Rx
Shunt Resistor
(optional component)

Line

Disconnect

Device

Input

Fusing

Three-phase

Input Power

AC Input Power

Bonded Cabinet
Ground Bus

Kinetix 5500 Servo Drives (front view)

(2198-H008-ERS drives shown)

Induction
Rotary Motors

2198-DBxx-F
AC Line Filter

(required for CE)

Bulletin 2090

Single Motor Cables

Share d AC (mains AC input)

Shared 24V (control power input)

Shared-bus connection system
for bus-sharing configurations.

Digital Inputs

to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

MP-Series (Bulletin MPAS, MPAR, MPAI) Linear Actuators

(1)

MPAS-B9xxx (ballscrew) Linear Stage is Shown

MP-Series (Bulletin MPL, MPM, MPF, MPS) Rotary Motors

(1)

(MPL-Bxxxx rotary motor is s hown)

2198-KITCON-DSL (shown)

Motor Feedback Connector Kit

or 2198-H2DCK Hiperface-to-DSL

Feedback Converter Kit

Kinetix VP (Bulletin VPL, VPF,

and VPS) Rotary Motors

(VPL-Bxxxx motor is shown)

LDAT-Series Linear Thrusters

(1)

(LDAT-Sxxxxxx-xDx linear thruster is shown)

IMPORTANT

Shared AC Configurations

In this example, three-phase AC power and 24V control power is shared in a
multi-axis configuration. All drives must have the same power rating (catalog
number).

Figure 2 - Typical Shared AC Installations

(1) Requires the 2198-H2DCK Hiperface-to-DSL feedback converter kit. LDAT-Series linear thrusters and MP-Series (200V-class) motors

and actuators require the 2198-H2DCK (series B or later) converter kit.

In shared AC configurations, all drives must have the same power rating.
Shared AC configurations do not support Bulletin 2198 capacitor modules.

16 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

2097-Rx
Shunt Resistor
(optional component)

Line

Disconnect

Device

Input

Fusing

Three-phase

Input Power

AC Input Power

Bonded Cabinet
Ground Bus

Induction
Rotary Motors

2198-DBxx-F
AC Lin e Filter

(required for CE)

Bulletin 2090

Single Motor Cables

Kinetix 5500 Servo Drives (top view)

(2198-H015-ERS drives shown)

Kinetix 5500 Servo Drives (front view)

(2198-H015-ERS drives shown)

Shared AC (mains AC input)

Shared DC (DC common bus)
Shared 24V (control power input)

2198-CAPMOD-1300 Capacitor Module
(optional component)

Shared-bus connection system for
bus-sharing configurations.

Digital Inputs

to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

2198-KITCON-DSL (shown)

Motor Feedback Connector Kit

or 2198-H2DCK Hiperface-to-DSL

Feedback Converter Kit

MP-Series (Bulletin MPAS, MPAR, MPAI) Linear Actuators

(1)

MPAS-B9xxx (ballscrew) Linear Stage is Shown

MP-Series (Bulletin MPL, MPM, MPF, MPS) Rotary Motors

(1)

(MPL-Bxxxx rotary motor is shown)

Kinetix VP (Bulletin VPL, VPF,

and VPS) Rotary Motors

(VPL-Bxxxx motor is shown)

LDAT-Series Linear Thrusters

(1)

(LDAT-Sxxxxxx-xDx linear thruster is shown)

IMPORTANT

Start Chapter 1

Shared AC/DC Configurations

In this example, three-phase AC input power, 24V control power, and DC bus
power are shared in a multi-axis configuration. All drives must be the same power
rating (catalog number).

Figure 3 - Typical Shared AC/DC Installations

Allen-Bradley

1606-XL

Power Supply

Input

(1) Requires the 2198-H2DCK Hiperface-to-DSL feedback converter kit. LDAT-Series linear thrusters and MP-Series (200V-class) motors

and actuators require the 2198-H2DCK (series B or later) converter kit.

In shared AC/DC configurations, all drives must have the same power rating
(catalog number).

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 17

Chapter 1 Start

1606-XL

Power Supply

Input

Allen-Bradley

Kinetix 5500 Servo Drive System (top view)

2097-Rx
Shunt Resistor
(optional component)

Line

Disconnect

Device

Input

Fusin g

Three-phase

Input Power

2198-H040-ERS

Common-bus Leader Drive

AC Input Power

Bonded Cabinet
Ground Bus

Kinetix 5500 Servo Drive System (front view)

2198-H008-ERS

Common-bus

Followe r Drives

2198-DBxx-F

AC Lin e Filter

(required for CE)

Bulletin 2090 Single Motor Cables

Shared DC (DC common bus)
Shared 24V (control power input)

2198-CAPMOD-1300 Capacitor Module
(optional component)

Shared-bus connection system
for bus-sharing configurations.

Digital Inputs

to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

2198-KITCON-DSL (shown)

Motor Feedback Connector Kit

or 2198-H2DCK Hiperface-to-DSL

Feedback Converter Kit

MP-Series (Bulletin MPAS, MPAR, MPAI) Linear Actuators

(1)

MPAS-B9xxx (ballscrew) Linear Stage is Shown

MP-Series (Bulletin MPL, MPM, MPF, MPS) Rotar y Motors

(1)

(MPL-Bxxxx rotary motor is shown)

Kinetix VP (Bulletin VPL, VPF,

and VPS) Rotary Motors

(VPL-Bxxxx motor is shown)

LDAT-Series Linear Thrusters

(1)

(LDAT-Sxxxxxx-xDx linear thruster is shown)

IMPORTANT

Shared DC Common-bus Configurations

In this multi-axis example, the common-bus leader (sourcing) drive receives
three-phase AC input power and supplies DC power to common-bus follower
(sinking) drives. The common-bus leader drive power rating is greater than or
equal to the power rating of each follower drive.

Figure 4 - Typical Shared DC Common-bus Installations

(1) Requires the 2198-H2DCK Hiperface-to-DSL feedback converter kit. LDAT-Series linear thrusters and MP-Series (200V-class) motors

and actuators require the 2198-H2DCK (series B or later) converter kit.

In shared DC common-bus configurations, the leader drive power rating must
be greater than or equal to the power rating of the follower drives.

18 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Start Chapter 1

Kinetix 5500 Servo Drive System (top view)

2097-Rx
Shunt Resistor
(optional component)

Line

Disconnect

Device

Input

Fusing

Three-phase
Input Power

Digital Inputs

to Sensors and Control String

2198-H040-ERS

Common-bus (converter)

Leader Drives

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

AC Input Power

Bonded Cabinet
Ground Bus

Kinetix 5500 Servo Drive System (front view)

2198-H008-ERS

Common-bus (inverter)

Follower Drives

2198-DBxx-F
AC Lin e Filter

(required for CE)

Bulletin 2090 Single Motor Cables

Share d AC (mains AC input)

Shared DC (DC common bus)
Shared 24V (control power input)

Shared-bus connection system for
bus-sharing configurations.

2198-CAPMOD-1300 Capacitor Module
(optional component)

2198-KITCON-DSL (shown)

Motor Feedback Connector Kit

or 2198-H2DCK Hiperface-to-DSL

Feedback Converter Kit

MP-Series (Bulletin MPAS, MPAR, MPAI) Linear Actuators

(1)

MPAS-B9xxx (ballscrew) Linear Stage is Shown

MP-Series (Bulletin MPL, MPM, MPF, MPS) Rotary Motors

(1)

(MPL-Bxxxx rotary motor is s hown)

Kinetix VP (Bulletin VPL, VPF,

and VPS) Rotary Motors

(VPL-Bxxxx motor is shown)

LDAT-Series Linear Thrusters

(1)

(LDAT-Sxxxxxx-xDx linear thruster is shown)

IMPORTANT

Shared AC/DC Hybrid Configuration

In this multi-axis example, three-phase AC input power is supplied to two
converter drives. The converter drive ratings must be the same, and greater than
or equal to the power ratings of the inverter drives. This parallel converter
configuration increases the DC power supplied to the inverter drives.

Figure 5 - Typical Shared AC/DC Bus Hybrid Installations

Allen-Bradley

1606-XL

Power Supply

Input

(1) Requires the 2198-H2DCK Hiperface-to-DSL feedback converter kit. LDAT-Series linear thrusters and MP-Series (200V-class) motors

and actuators require the 2198-H2DCK (series B or later) converter kit.

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 19

In shared AC/DC hybrid configuration, the converter drives must have the same
power rating and must be greater than or equal to the power ratings of the
inverter drives.

Chapter 1 Start

CompactLog ix 5370 Cont roller

Logix Designer

Application

1585J-M8CBJM-x
Ethernet (shielded) Cable

1734-AENTR POINT I/O™

EtherNet/IP Adapter

CompactLogix Controller Programming Network

Panel View™ Pl us
Display Terminal

1585J-M8CBJM-OM3

0.3 m (1.0 ft) Ethernet cable
for drive-to-drive connections.

Kinetix 5500 Servo Drive System

Typical Communication Configurations

The Kinetix 5500 drives support any Ethernet topology including linear, ring,
and star.

These examples feature the CompactLogix 5370 programmable automation
controllers (catalog number 1769-L36ERM) with support for Integrated Motion
over the EtherNet/IP network. Controller features include the following:

• Supports up to 16 axes

• Supports up to 48 devices in linear configurations

• Dual-port connectivity to support device-level ring (DLR) topology

Refer to CompactLogix Controllers Specifications Technical Data, publication

1769-TD005

, for more information on CompactLogix 5370 L1, L2, and L3

controllers.

Linear Topology

In this example, all devices are connected in linear topology. The Kinetix 5500
drives include dual-port connectivity, however, if any device becomes
disconnected, all devices downstream of that device lose communication. Devices
without dual ports must include the 1783-ETAP module or be connected at the
end of the line.

00:00:BC:2E:69:F6

1 (Front)
2 (Rear)

Figure 6 - Kinetix 5500 Linear Communication Installation

1734-AENTR

02

0

POINT I O

Module
Status

Network
Activity

Network
Status

Point Bus
Status

Link 1
Activity/

System

Status

Power

Field
Power

Link 2
Activity/
Status

20 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Start Chapter 1

1 (Front)
2 (Rear)

00:00:BC:2E:69:F6

02

0

1734-AENTR

Module
Status

Network
Activity

Network
Status

Point Bus
Status

System
Power

Field
Power

POINT I O

Link 1
Activity/
Status

Link 2
Activity/
Status

1734-AENTR POINT I/O
EtherNet/IP Adapter

CompactLogix Controller Programming Network

1783-ETAP

Module

1585J-M8CBJM-OM3

0.3 m (1.0 ft) Ethernet cable
for drive-to-drive connections.

Panel View Plus
Display Terminal

Kinetix 5500 Servo Drive System

CompactLogix 5370 Controller

Logix Designer

Application

1585J-M8CBJM-x Ethernet

(shielded) Cable

Ring Topology

In this example, the devices are connected by using ring topology. If only one
device in the ring is disconnected, the rest of the devices continue to
communicate. For ring topology to work correctly, a device level ring (DLR)
supervisor is required (for example, the Bulletin 1783 ETAP device). DLR is an
ODVA standard. For more information, refer to the EtherNet/IP Embedded
Switch Technology Application Guide, publication ENET-AP005

Devices without dual ports, for example the display terminal, require a
1783-ETAP module to complete the network ring.

Figure 7 - Kinetix 5500 Ring Communication Installation

.

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 21

Chapter 1 Start

1 (Front)
2 (Rear)

00:00:BC:2E:69:F6

1585J-M8CBJM-x
Ethernet (shielded) Cable

1734-AENTR POINT I/O
EtherNet/IP Adap ter

CompactLogix Controller Programming Network

PanelView Plus
Display Terminal

1783-BMS

Stratix 5700™

Switch

1585J-M8CBJM-OM3

0.3 m (1.0 ft) Ethernet cable

for drive-to-drive connections.

Kinetix 5500 Servo Drive System

CompactLogix 5370 Controller

Logix Designer

Application

Star Topology

In this example, the devices are connected by using star topology. Each device is
connected directly to the switch.

Kinetix 5500 drives have dual ports, so linear topology is maintained from drive­to-drive, but Kinetix 5500 drives and other devices operate independently. The
loss of one device does not impact the operation of other devices.

Figure 8 - Kinetix 5500 Star Communication Installation

22 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Start Chapter 1

1 (Front)
2 (Rear)

00:00:BC:2E:69:F6

1606-XL

Power Supply

Input

Allen-Bradley

1585J-M8CBJM-x
Ethernet (shielded) Cable

CompactLogix 5370 Controller,
ControlLogix 1756-L7x Controller, or
GuardLogix 1756-L7xS Safety Controller
(CompactLogix controller is shown)

Logix Designer

Application

(version 21.0 or later)

AC Input Power

Safety
Device

2198-Hxxx-ERS Servo Drives

(top view)

2198-Hxxx-ERS Servo Drives

(front view)

Digital Inputs to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

Kinetix VP

Servo Motors

2198-CAPMOD-1300 Capacitor Module

(optional component)

Module Definition

Configured with

Motion-only

Connection

Safe Torque-off
(STO) Connectors

Safe Torque-off Configurations

Kinetix 5500 servo drives are available with safe torque-off via hardwired
connections or integrated over the EtherNet/IP network. These examples
illustrate the safe torque-off configuration options.

Hardwired Safety Configuration

The 2198-Hxxx-ERS drives use the safe torque-off (STO) connector for
cascading hardwired safety connections from drive-to-drive.

Figure 9 - Safe Torque-off (hardwired) Configuration

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 23

Chapter 1 Start

IMPORTANT

1606-XL

Power Supply

Input

Allen-Bradley

LNK1LNK2NET OK

EtherNet/IP

1

2

1585J-M8CBJM-x
Ethernet (shielded) Cable

GuardLogix 1756-L7xS Safety Controller

Logix Designer

Application

(version 24.0 or later)

AC Inp ut Power

2198-Hxxx-ERS2 Servo Drives

(top view)

2198-Hxxx-ERS2 Servo Drives

(front view)

Digital Inputs to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

Kinetix VP

Servo Motors

2198-CAPMOD-1300 Capacitor Module

(optional component)

1783-BMS

Stratix 5700

Switch

Module Definition

Configured with

Motion and Safety

Conne ction

1734-AENTR
POINT Guard I/O
EtherNet/IP Adapter

Safety
Device

Integrated Safety Configurations

The 1756-L7xS GuardLogix safety controller issues the safe torque-off (STO)
command over the EtherNet/IP network and the 2198-Hxxx-ERS2 integrated
safety drive executes the command.

In this example, a single GuardLogix safety controller makes a Motion and Safety
connection with the 2198-Hxxx-ERS2 integrated safety drives.

If only one controller is used in an application with Motion and Safety
connections, it must be a 1756-L7xS GuardLogix safety controller.

Figure 10 - Motion and Safety Configuration (single controller)

24 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Start Chapter 1

IMPORTANT

1585J-M8CBJM-x

Ethernet (shielded) Cable

GuardLogix 1756-L7xS Controller

Logix Designer

Application

(version 24.0 or later)

AC Inp ut Power

2198-Hxxx-ERS2 Servo Drives

(top view)

2198-Hxxx-ERS2 Servo Drives

(front view)

Digital Inputs to Sensors and Control String

1606-XLxxx

24V DC Control, Digital Inputs,

and Motor Brake Power

(customer-supplied)

Kinetix VP

Servo Motors

2198-CAPMOD-1300 Capacitor Module

(optional component)

1734-AENTR
POINT Guard I/O
EtherNet/IP Adapter

1783-BMS

Stratix 5700

Switch

CompactLogix 5370 Controller or
ControlLogix 1756-L7x Controller
(ControlLogix controller is shown)

Motion Program

Module Definition

Configured with

Motion only

Conne ction

Safety Program

Module Definition

Configured with

Safety only
Conne ction

Safety
Device

In this example, a non-safety controller makes the Motion-only connection and a
separate GuardLogix safety controller makes the Safety-only connection with
2198-Hxxx-ERS2 integrated safety drives.

If two controllers are used in an application with Motion-only and Safety­only connections, the Safety-only connection must be a 1756-L7xS
GuardLogix safety controller and the Motion-only connection must be a
ControlLogix 1756-L7x or CompactLogix 5370 controller.

Figure 11 - Motion and Safety Configuration (multi-controller)

LNK1LNK2NET OK

EtherNet/IP

EtherNet/IP

LNK1LNK2NET OK

2

1

2

1

Allen-Bradley

1606-XL

Power Supply

Input

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 25

Chapter 1 Start

Catalog Number Explanation

Drive Cat. No.
(hardwired STO)

2198-H003-ERS 2198-H003-ERS2

2198-H008-ERS 2198-H008-ERS2

2198-H015-ERS 2198-H015-ERS2

2198-H025-ERS 2198-H025-ERS2

2198-H040-ERS 2198-H040-ERS2

2198-H070-ERS 2198-H070-ERS2 3

Capacitor Module
Cat. No.

2198-CAPMOD-1300 2 650V DC, nom 1360 μF, min

Kinetix 5500 drive catalog numbers and performance descriptions.

Table 2 - Kinetix 5500 Drive Catalog Numbers

Drive Cat. No.
(integrated STO)

Frame Size Input Voltage

1

2

195…264V rms, single-phase
195…264V rms, three-phase
324…528V rms, three-phase

195…264V rms, three-phase
324…528V rms, three-phase

Table 3 - Drive Components Catalog Numbers

Frame Size Rated Voltage Capacitance

Continuous Output
Power

kW

0.2 kW

0.3 kW

0.6 kW

0.5 kW

0.8 kW

1.6 kW

1.0 kW

1.5 KW

3.2 kW

2.4 kW

5.1 kW

4.0 kW

8.3 kW

7.0 kW

14.6 kW

Continuous Output
Current

A 0-pk

1.4

3.5

7.1

11.3

18.4

32.5

Table 4 - Shared-bus Connector Kit Catalog Numbers

Kit Cat. No. Frame Size Application Description

2198-H040-ADP-IN Frame 1 or 2 First drive

2198-H040-A-T

2198-H040-D-T DC sharing only DC bus T-connector

2198-H040-P-T Control power sharing only Control power T-connector

2198-H040-AD-T AC and DC bus sharing AC and DC bus T-connectors

2198-H040-AP-T AC and control power sharing AC and control power T-connectors

2198-H040-DP-T DC and control power sharing DC and control power T-connectors

2198-H040-ADP-T AC, DC, and control power sharing AC, DC, and control power T-connectors

2198-H070-ADP-IN

2198-H070-A-T

2198-H070-D-T DC sharing only DC bus T-connector

2198-H070-P-T Control power sharing only Control power T-connector

2198-H070-AD-T AC and DC bus sharing AC and DC bus T-connectors

2198-H070-AP-T AC and control power sharing AC and control power T-connectors

2198-H070-DP-T DC and control power sharing DC and control power T-connectors

2198-H070-ADP-T AC, DC, and control power sharing AC, DC, and control power T-connectors

Next drive is…
Frame 1 drives:
2198-H003-ERSx
2198-H008-ERSx
Frame 2 drives:
2198-H015-ERSx
2198-H025-ERSx
2198-H040-ERSx

Frame 3 drive:
2198-H070-ERSx

Next drive is…
Frame 3 drives:

2198-H070-ERSx

AC sharing only AC bus T-connector

First drive

AC sharing only AC bus T-connector

• Mains AC input wiring connector

• 24V DC input wiring connector

• DC bus T-connector

• Mains AC input wiring connector

• 24V DC input wiring connector

• DC bus T-connector

26 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Start Chapter 1

Agency Compliance

If this product is installed within the European Union 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 can cause damage to the filter. For grounding examples,
refer to Grounded Power Configurations

on page 69.

For more information on electrical noise reduction, refer to the System Design
for Control of Electrical Noise Reference Manual, publication GMC-RM001

.

To meet CE requirements, these requirements apply:

• Install an AC line filter (catalog number 2198-DBxx-F) for input power as
close to the Kinetix 5500 drive as possible.

• Bond drive, capacitor module, and line filter grounding screws by using a
braided ground strap as shown in Figure 39 on page 73

.

• Use Bulletin 2090 single motor cables with Kinetix VP servo motors. Use
Bulletin 2090 motor power/brake and feedback cables for other
compatible Allen-Bradley® motors and actuators.

• Combined motor cable length for all axes on the same DC bus must not
exceed 250 m (820 ft). Drive-to-motor cables must not exceed 50 m
(164 ft); however, use of continuous-flex cable and 2198-H2DCK
converter kit limits the maximum length.

Table 5 - Drive-to-Motor Maximum Cable Length

Kinetix VP Servo Motors Other Compatible Rotary Motors and Linear Actuators

Kinetix 5500 Servo Drive
Cat. No.

2198-H003-ERSx
2198-H008-ERSx

2198-H015-ERSx
2198-H025-ERSx
2198-H040-ERSx

2198-H070-ERSx 50 (164)

(1) Requires use of the 2198-H2DCK Hiperface- to-DSL feedback converter kit.
(2) Can b e used to repla ce Bulletin 2090 motor po wer/brake cabl es in 2198-H2 DCK convert er kit applic ations to inc rease the maxi mum length up to 50 m (164 ft). Applie s to only power /brake cables. Refer to

Motor Power/Brake Cable Preparation

Standard (non-flex) Cables
(cat. no. 2090-CSxM1DF-xxAAxx)

m (ft)

50 (164) 30 (98.4)

50 (164)

on page 89 for more information.

(2)

Continuous-flex Cables
(cat. no. 2090-CSBM1DF-xxAFxx)

m (ft)

Motor Power/brake Cables (cat. no. 2090-CPxM7DF-xxAxxx)
Feedback Cables (cat. no. 2090-CFBM7DF-CEAxxx)

m (ft)

20 (65.6)

(1)

• Install the Kinetix 5500 system inside an approved enclosure. Run input
power wiring in conduit (grounded to the enclosure) outside of the
enclosure. Separate signal and power cables.

• Segregate input power wiring from control wiring and motor cables.

Refer to Appendix A on page 189

for input power wiring and drive/motor

interconnect diagrams.

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 27

Chapter 1 Start

Notes:

28 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014

Chapter 2

Planning the Kinetix 5500 Drive
System Installation

This chapter describes system installation guidelines used in preparation for
mounting your Kinetix 5500 drive components.

Top ic Pa ge

System Design Guidelines 30

Electrical Noise Reduction 36

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 metal debris from falling into it. Metal debris or other foreign matter can
become lodged in the circuitry and result in damage to the components.

Rockwell Automation Publication 2198-UM001D-EN-P - May 2014 29

Chapter 2 Planning the Kinetix 5500 Drive System Installation

IMPORTANT

System Design Guidelines

Use the information in this section when designing your enclosure and planning
to mount your system components on the panel.

For on-line product selection and system configuration tools, including
AutoCAD (DXF) drawings of the product, refer to

http://www.rockwellautomation.com/en/e-tools

.

System Mounting Requirements

• To comply with UL and CE requirements, the Kinetix 5500 drive systems
must be enclosed in a grounded conductive enclosure offering protection
as defined in standard EN 60529 (IEC 529) to IP54 such that they are not
accessible to an operator or unskilled person. A NEMA 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.

• Size the drive enclosure so as not to exceed the maximum ambient
temperature rating. Consider heat dissipation specifications for all drive
components.

• Combined motor power cable length for all axes on the same DC bus must
not exceed 250 m (820 ft). Drive-to-motor cables must not exceed 50 m
(164 ft), however use of continuous-flex cable and 2198-H2DCK
converter kit limits the maximum length. Refer to Ta b l e 5
specifications by frame size.

on page 27 for

System performance was tested at these cable length specifications.
These limitations also apply when meeting CE requirements.

• Ethernet cable lengths connecting drive-to-drive, drive-to-controller, or
drive-to-switch must not exceed 100 m (328 ft).

• Registration and digital input cables greater than 30 m (98.4 ft) must be
shielded.

• Segregate input power wiring from control wiring and motor cables.

• Use high-frequency (HF) bonding techniques to connect the modules,

enclosure, machine frame, and motor housing, and to provide a low­impedance return path for high-frequency (HF) energy and reduce
electrical noise.

Bond drive, capacitor module, and line filter grounding screws by using a
braided ground strap as shown in Figure 39 on page 73

Refer to the System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001
reduction.

, to better understand the concept of electrical noise

.

30 Rockwell Automation Publication 2198-UM001D-EN-P - May 2014