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Rockwell Automation Allen-Bradley 2198-CAPMOD-1300, User Manual

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

33

Planning the Kinetix 5500 Drive System Installation

Chapter 2

Shared AC Drive Systems

Table 10 - Fuse Selection (Bussmann part numbers)

Table 11 - Circuit Breaker Selection (Allen-Bradley catalog numbers)

Shared AC/DC and Hybrid Systems

Table 12 - Fuse Selection (Bussmann part numbers)

Table 13 - Circuit Breaker Selection (Allen-Bradley catalog numbers)

Kinetix 5500 Drive
Cat. No.

2 Axes

3 Axes

4 Axes

5 Axes

2198-H003-ERS

x

KTK-R-15

2198-H008-ERS

x

KTK-R-15

2198-H015-ERS

x

KTK-R-20

KTK-R-25

N/A

2198-H025-ERS

x

KTK-R-30

N/A

2198-H040-ERS

x

LPJ-35SP

LPJ-45SP

N/A

2198-H070-ERS

x

LPJ-60SP

N/A

Kinetix 5500 Drive
Cat. No.

2 Axes 

(1)

(1) UL has not approved circuit breakers for use as branch circuit protection for Kinetix 5500 drive systems.

3 Axes 

(1)

4 Axes 

(1)

5 Axes 

(1)

2198-H003-ERS

x

N/A

2198-H008-ERS

x

2198-H015-ERS

x

140U-D6D3-C15

140U-D6D3-C20

N/A

2198-H025-ERS

x

140U-D6D3-C25

140U-D6D3-C30

N/A

2198-H040-ERS

x

N/A

2198-H070-ERS

x

N/A

Kinetix 5500 Drive
Cat. No.

2 Axes

3 Axes

4 Axes

5 Axes

6 Axes

7 Axes

8 Axes

2198-H003-ERS

x

KTK-R-10

KTK-R-15

2198-H008-ERS

x

KTK-R-15

KTK-R-20

2198-H015-ERS

x

KTK-R-20

N/A

2198-H025-ERS

x

KTK-R-30

N/A

2198-H040-ERS

x

KTK-R-30

LPJ-45SP

LPJ-50SP

N/A

2198-H070-ERS

x

LPJ-50SP

N/A

Kinetix 5500 Drive
Cat. No.

2 Axes 

(1)

3 Axes 

(1)

4 Axes 

(1)

5 Axes 

(1)

6 Axes 

(1)

7 Axes 

(1)

8 Axes 

(1)

2198-H003-ERS

x

N/A

2198-H008-ERS

x

N/A

2198-H015-ERS

x

140U-D6D3-C15

140U-D6D3-C20

N/A

2198-H025-ERS

x

140U-D6D3-C20

140U-D6D3-C30

N/A

2198-H040-ERS

x

140U-D6D3-C30

N/A

2198-H070-ERS

x

N/A

(1) UL has not approved circuit breakers for use as branch circuit protection for Kinetix 5500 drive systems.

Summary of Contents for Allen-Bradley 2198-CAPMOD-1300

Page 1: ...g 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 User Manual Original Instructions ...

Page 2: ...ssary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions 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 and Design Environment Studio 5000 Logix Designer Rockwell Aut...

Page 3: ...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 105 Broke out Configure the Kinetix 5500 Drive with separate procedures for 2198 Hxxx ERS and 2198 Hxxx ERS2 servo drives 110 and 112 Updated Tune the Axes with a reference to the l...

Page 4: ...hanges 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 Topic Page ...

Page 5: ... 22 Safe Torque off Configurations 23 Hardwired Safety Configuration 23 Integrated Safety Configurations 24 Catalog Number Explanation 26 Agency Compliance 27 Chapter2 PlanningtheKinetix5500Drive SystemInstallation System Design Guidelines 30 System Mounting Requirements 30 Transformer Selection 31 Circuit Breaker Fuse Selection 31 Enclosure Selection 34 Minimum Clearance Requirements 35 Electrica...

Page 6: ...fications 65 Absolute Position Feature 65 Safe Torque off Safety Features 66 Servo Drives with Hardwired Safety 66 Servo Drives with Integrated Safety 66 Chapter5 ConnectingtheKinetix5500Drive System 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 Groundin...

Page 7: ...re 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 C...

Page 8: ...e 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 Chapter10 Kinetix5500SafeTorque off IntegratedSafety Certification 167 Important Safety Considerations 168 Safety Application Requirements 168 Category 3 Requirements According to ISO 13849 168 Stop Catego...

Page 9: ...rive and Motor Actuator Wiring Examples 195 System Block Diagrams 200 AppendixB UpgradetheDriveFirmware Before You Begin 204 Configure Logix5000 Controller Communication 205 Inhibit Feedback Only Axis 206 Upgrade Firmware 207 Verify the Firmware Upgrade 211 AppendixC SizingMulti axisShared bus Configurations Shared bus Configurations 213 Shared AC Configurations 214 Shared DC Configurations 214 Sh...

Page 10: ...dixE ECCertifications EC Type Examination Certificate 229 EC Declaration of Conformity 230 European Union Directives 233 CE Conformity 233 EMC Directive 233 Low Voltage Directive 233 AppendixF HistoryofChanges 2198 UM001C EN P February 2014 235 2198 UM001B EN P September 2013 236 Index ...

Page 11: ... This Manual 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 Environm...

Page 12: ...t 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 Kinetix Linear Motion Specifications Technical Data publication GMC TD002 Product specifications for MP Series Bulletin MPAS ballscrew MPAR and MPAI and LDAT Series linear actuators Kinetix Servo Drives Specifications Technical...

Page 13: ...e familiar with the design and installation requirements for Kinetix 5500 drive systems Topic Page About the Kinetix 5500 Servo Drive System 14 Typical Hardware Configurations 15 Typical Communication Configurations 20 Safe Torque off Configurations 23 Catalog Number Explanation 26 Agency Compliance 27 ...

Page 14: ... 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 Logix5000 Controller Platform 1769 L18ERM 1769 L27ERM 1769 L3xERM CompactLogix 5370 controllers with Integrated Motion on the EtherNet IP network Linear ring and star topology is supported 1756 EN2T module 1756 EN2TR module 1756 EN3TR modul...

Page 15: ...x Drive front view 2097 Rx Shunt Resistor optional component Kinetix VP BulletinVPL 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 Line Filter requ...

Page 16: ...ves front view 2198 H008 ERS drives shown Induction Rotary Motors 2198 DBxx F AC Line Filter required for CE Bulletin 2090 Single Motor Cables Shared 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 Bulle...

Page 17: ...gle 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 C...

Page 18: ...wer Bonded Cabinet Ground Bus Kinetix 5500 Servo Drive System front view 2198 H008 ERS Common bus Follower Drives 2198 DBxx F AC Line 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 Str...

Page 19: ... 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 Line Filter required for CE Bulletin 2090 Single Motor Cables Shared AC mains AC input Shared DC DC common bus Shared 24V control power input...

Page 20: ...ers 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 Figure 6 Kinetix 5500 Linear Communication Installation 1 Front ...

Page 21: ...T 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 1 Front 2 Rear 00 00 BC 2E 69 F6 0 2 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 EtherNe...

Page 22: ...ices operate independently The loss of one device does not impact the operation of other devices Figure 8 Kinetix 5500 Star Communication Installation 1 Front 2 Rear 00 00 BC 2E 69 F6 1585J M8CBJM x Ethernet shielded Cable 1734 AENTR POINT I O EtherNet IP Adapter CompactLogix Controller Programming Network PanelView Plus Display Terminal 1783 BMS Stratix 5700 Switch 1585J M8CBJM OM3 0 3 m 1 0 ft E...

Page 23: ...figuration 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 Drive...

Page 24: ...ication with Motion and Safety connections it must be a 1756 L7xS GuardLogix safety controller 1606 XL Power Supply Input Allen Bradley LNK1LNK2 NET 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 Input Power 2198 Hxxx ERS2 Servo Drives top view 2198 Hxxx ERS2 Servo Drives front view Digital Inputs...

Page 25: ...put Allen Bradley LNK1LNK2 NET OK EtherNet IP 1 2 LNK1LNK2 NET OK EtherNet IP 1 2 1585J M8CBJM x Ethernet shielded Cable GuardLogix 1756 L7xS Controller Logix Designer Application version 24 0 or later AC Input 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...

Page 26: ...nnector 24V DC input wiring connector DC bus T connector 2198 H040 A T Next drive is Frame 1 drives 2198 H003 ERSx 2198 H008 ERSx Frame 2 drives 2198 H015 ERSx 2198 H025 ERSx 2198 H040 ERSx AC sharing only AC bus T connector 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 connec...

Page 27: ...de 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 ATTENTION Meeting CE requires a groundedsystem and the method of grounding the AC line filter andd...

Page 28: ...28 Rockwell Automation Publication 2198 UM001D EN P May 2014 Chapter 1 Start Notes ...

Page 29: ...nts Topic Page System Design Guidelines 30 Electrical Noise Reduction 36 ATTENTION Plan the installation of your system so that you can perform all cutting drilling tapping and welding with the system removed from the enclosure 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 circu...

Page 30: ...erature 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 Table 5 on page 27 for specifications by frame size Ethernet cable length...

Page 31: ...ements for branch circuit protection Evaluation of the short circuit available current is critical and must be kept below the short circuit current rating of the circuit breaker Refer to Power Wiring Examples on page 190 for the wiring diagram IMPORTANT When using an autotransformer make sure that the phase to neutral ground voltage does not exceed the input voltage ratings of the drive IMPORTANT ...

Page 32: ...ix 5500 Drive Cat No Three phase 1 1 UL has not approved circuit breakers for use as branch circuit protection for Kinetix 5500 drive systems Single phase 1 2198 H003 ERSx 140U D6D3 B20 140U D6D2 B10 2198 H008 ERSx 140U D6D3 B60 140U D6D2 B20 2198 H015 ERSx 140U D6D3 C12 140U D6D2 B80 2198 H025 ERSx 140U D6D3 C20 N A 2198 H040 ERSx 140U D6D3 C25 2198 H070 ERSx N A Kinetix 5500 Drive Cat No Three p...

Page 33: ...se as branch circuit protection for Kinetix 5500 drive systems 3 Axes 1 4 Axes 1 5 Axes 1 2198 H003 ERSx N A 2198 H008 ERSx 2198 H015 ERSx 140U D6D3 C15 140U D6D3 C20 N A 2198 H025 ERSx 140U D6D3 C25 140U D6D3 C30 N A 2198 H040 ERSx N A 2198 H070 ERSx N A Kinetix 5500 Drive Cat No 2 Axes 3 Axes 4 Axes 5 Axes 6 Axes 7 Axes 8 Axes 2198 H003 ERSx KTK R 10 KTK R 15 2198 H008 ERSx KTK R 15 KTK R 20 219...

Page 34: ...cause the minimum cabinet depth to house the Kinetix 5500 system selected for this example is 300 mm 11 8 in the cabinet needs to be approximately 1500 x 700 x 300 mm 59 0 x 27 6 x 11 8 in HxWxD 1 5 x 0 300 x 0 70 1 5 x 0 300 x2 0 1 5 x 0 70 x 2 0 3 31 m2 Because this cabinet size is considerably larger than what is necessary to house the system components it can be more efficient to provide a mea...

Page 35: ...unted adjacent to noise sensitive equipment or clean wire ways The recommended minimum cabinet depth is 300 mm 11 81 in Figure 12 Minimum Clearance Requirements Kinetix 5500 Drive Cat No Frame Size Usage as of Rated Power Output watts 20 40 60 80 100 2198 H003 ERSx 1 12 25 37 50 62 2198 H008 ERSx 2198 H015 ERSx 2 40 80 120 160 200 2198 H025 ERSx 2198 H040 ERSx 2198 H070 ERSx 3 64 128 192 256 320 C...

Page 36: ...g 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 power rail and the subpanel surfaces need to be paint free or plated Bonding metal surfaces creates a low impedance return path for high f...

Page 37: ... non conductive material anodized orpainted scrapethematerialaround the mounting hole Star Washer Nut Nut Flat Washer Mounting Bracket or Ground Bus Use a wire brush to remove paint from threads to maximize ground connection Back Wall of Enclosure Welded Stud Subpanel Star Washer Use plated panels or scrape paint on front of panel Subpanel Nut Nut Star Washer Flat Washer Star Washer Star Washer Sc...

Page 38: ...This difference in impedance can affect networks and other devices that span multiple panels Bond the top and bottom of each subpanel to the cabinet by using 25 4 mm 1 0 in by 6 35 mm 0 25 in wire braid As a rule the wider and shorter the braid is the better the bond Scrape the paint from around each fastener to maximize metal to metal contact Figure 15 Multiple Subpanels and Cabinet Recommendatio...

Page 39: ...able is required only if the very dirty cables enter a wireway Figure 16 Noise Zones 1 When space to the right of the drive does not permit 150 mm 6 0 in segregation use a grounded steel shield instead For examples refer to the System Design for Control of Electrical Noise Reference Manual publication GMC RM001 2 When 2198 H2DCK converter kit is used feedback cable routes in the clean wireway 1 C ...

Page 40: ...X DC DC DC bus DC Bus bar only no wiring connector DC SH shunt RC X U V W motor power Motor feedback 1 Motor brake MP MF BC X X X X X X 24V DC CP X Safety enable for safe torque off 2 STO X Registration input greater than 30 m 98 4 ft IOD X X Registration input less than 30 m 98 4 ft X Ethernet PORT1 PORT2 X X 1 When the 2198 H2DCK converter kit is used the feedback cable routes in the clean wirew...

Page 41: ... line filter refer to the figure on page 39 for an example Mount the AC line filter on the same panel as the Kinetix 5500 drive and as close to the power rail as possible Good HF bonding to the panel is critical For painted panels refer to the examples on page 37 Segregate input and output wiring as far as possible IMPORTANT CE test certification applies to only the AC line filter used with a sing...

Page 42: ...losure C C D D VD D D C VD Dirty Wireway Clean Wireway Single Motor Cable Very Dirty Connections Segregated not in wireway Customer supplied Metal Enclosure 150 mm 6 0 in clearance min onall four sides of the shunt resistor Enclosure Metal Conduit where required by local code No sensitive equipment within 150 mm 6 0 in Shunt Power Wiring Methods Twistedpair in conduit 1st choice Shielded twisted p...

Page 43: ...ables Figure 18 External Shunt Resistor Inside the Enclosure C C D D VD D D C VD Dirty Wireway Clean Wireway Single Motor Cable Very Dirty Connections Segregated not in wireway Enclosure No sensitive equipment within 150 mm 6 0 in Shunt Power Wiring Methods Twistedpair in conduit 1st choice Shielded twisted pair 2nd choice Twisted pair two twists per foot min 3rd choice Circuit Breaker Digital Inp...

Page 44: ...44 Rockwell Automation Publication 2198 UM001D EN P May 2014 Chapter 2 Planning the Kinetix 5500 Drive System Installation Notes ...

Page 45: ...etermining Mounting Order 46 Drilling Hole Patterns 49 Mount Your Kinetix 5500 Drive 56 SHOCKHAZARD Toavoidhazardofelectricalshock performallmountingand wiring of the Kinetix 5500 drives prior to applying power Once power is applied connector terminals can have voltage present even when not in use ATTENTION Plan the installation of your system so that you can perform all cutting drilling tapping a...

Page 46: ... must mount left of frame 1 or 2 drives and frame 2 drives must mount left of frame 1 drives Capacitor modules can mount to the right of any frame size but are always rightmost in any drive configuration Figure 20 Shared bus Connection System Example IMPORTANT Engaging the zero stack tab and cutout from drive to drive is required for shared bus multi axis drive systems This is done to make sure th...

Page 47: ...ightly larger than connectors for frame 1 and 2 drives catalog number2198 H040 ADP IN 2 Due tothe extra width of frame 3 drives bus bar connectors between frame 3 drives are slightly longer 85 mm than connectors between frame 3 frame 2 and frame 1 drives 55 mm 3 DC bus T connectors latch on both sides when inserted into the drive To remove the DC bus T connector at least one latch must be pried aw...

Page 48: ...does not apply and must not be used For a single axis example configuration refer to Typical Kinetix 5500 Standalone Installation on page 15 Multi axis Configurations Each multi axis configuration has restrictions that apply The shared bus connection system must be used Do not attach discrete wires from drive to drive The maximum number of drives in Shared AC bus power sharing groups cannot exceed...

Page 49: ...are compatible with Bulletin 2198 capacitor modules Table 17 Hole Pattern Overview Table 18 Capacitor Module Support Drive Cat No Frame Size Frame Size Patterns Page 2198 H003 ERSx 2198 H008 ERSx Frame 1 As many as eight frame 1 drives 51 2198 H015 ERSx 2198 H025 ERSx 2198 H040 ERSx Frame 2 As many as 8 frame 2 drives One frame 2 drive followed by as many as seven frame1 drives 52 2198 H070 ERSx F...

Page 50: ...tem These hole patterns apply to standalone drives Figure 22 Frame 1 Frame 2 and Frame 3 Standalone Hole Patterns 0 0 243 84 9 6 5 00 0 2 193 68 7 6 0 0 4 51 0 2 273 70 10 8 0 52 50 2 1 0 34 00 1 3 8x ØM4 8 32 Frame 3 Standalone Drive Frame 1 Standalone Drive Frame 2 Standalone Drive Dimensions are in mm in ...

Page 51: ...Frame 2 243 84 9 6 Axis 4 Axis 5 Axis 6 Axis 7 Axis 8 Axis 2 A B A B A B A B A B A B A B A B 0 0 50 0 2 0 50 0 2 0 Frame Size Dimension Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 7 Axis 8 1 A 4 51 0 2 54 51 2 1 104 51 4 1 154 51 6 1 204 51 8 1 254 51 10 0 304 51 12 0 354 51 14 0 B 0 50 0 2 0 100 0 3 9 150 0 5 9 200 0 7 9 250 0 9 8 300 0 11 8 350 0 13 8 2 A 5 00 0 2 60 0 2 4 115 0 4 5 170 0 6 7...

Page 52: ...ransitioning from frame 2 drives to frame 1 drives To mount additional frame 1 drives to the right of Axis 2 in this figure refer to the frame 1 hole pattern in Figure 23 Figure 24 Frame 2 to Frame 1 Hole Pattern 4x ØM4 8 32 Axis 1 frame 2 243 84 9 6 0 0 5 00 0 2 57 00 2 2 52 50 2 1 50 15 2 0 Axis 2 frame 1 243 83 9 6 Dimensions are in mm in ...

Page 53: ...shown Figure 25 Frame 3 Hole Pattern 273 70 10 8 0 52 50 2 1 85 20 3 4 137 70 5 4 0 170 40 6 7 222 90 8 8 255 60 10 1 308 10 12 1 340 80 13 4 393 30 15 5 426 0 16 8 478 50 18 8 511 20 20 1 563 70 22 2 596 40 23 5 648 90 25 5 Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 7 Axis 8 32x ØM4 8 32 34 00 1 3 119 20 4 7 204 40 8 0 289 60 11 4 374 80 14 8 460 0 18 1 545 20 21 5 630 40 24 8 85 20 3 4 85 20...

Page 54: ...ioning from frame 3 drives to frame 1 drives To mount additional frame 1 drives to the right of Axis 2 in this figure refer to the frame 1 hole pattern in Figure 23 Figure 26 Frame 3 to Frame 1 Hole Pattern 273 70 10 8 0 52 50 2 1 0 6x ØM4 8 32 Axis 1 frame 3 Axis 2 frame 1 272 23 10 7 78 55 3 1 92 70 3 7 97 20 3 8 34 00 1 3 Dimensions are in mm in ...

Page 55: ...oning from frame 3 drives to frame 2 drives To mount additional frame 2 drives to the right of Axis 2 in this figure refer to the frame 2 hole pattern in Figure 23 Figure 27 Frame 3 to Frame 2 Hole Pattern 273 70 10 8 0 52 50 2 1 0 6x ØM4 8 32 Axis 1 frame 3 Axis 2 frame 2 272 24 10 7 28 40 1 1 95 00 3 7 100 00 3 9 34 00 1 3 Dimensions are in mm in ...

Page 56: ... Hole Patterns beginning on page 49 3 Loosely attach the mounting hardware to the panel The recommended mounting hardware is M4 8 32 steel bolts Observe bonding techniques as described in Bonding Modules on page 36 4 Attach the leftmost drive to the cabinet panel 5 Attach additional drives if any just to the right of the previous drive by using the same method but also making sure the zero stack t...

Page 57: ...criptions This chapter illustrates drive connectors and indicators including connector pinouts and provides descriptions for Kinetix 5500 drive features Topic Page Kinetix 5500 Connector Data 58 Understanding Control Signal Specifications 62 Feedback Specifications 65 Safe Torque off Safety Features 66 ...

Page 58: ...9 DC bus DC connector under cover 2 6 Ethernet PORT2 RJ45 connector 13 Link Activity status indicators 20 24V control input power CP connector 7 Zero stack mounting tab cutout 14 Motor power MP connector 21 Safe torque off STO connector 3 does not apply to 2198 Hxxx ERS2 drives 1 Protective knock out covers the 2198 H2DCK Hiperface to DSL feedback converter kit mounting hole Remove knock out for u...

Page 59: ...ts Table 19 Mains Input Power Connector Table 20 24V Input Power Connector DC Bus and Shunt Resistor Connector Pinouts Table 21 DC Bus Power Connector Table 22 Shunt Resistor Connector IPD Pin Description Signal Chassis ground L3 Three phase input power L3 L2 L2 L1 L1 CP Pin Description Signal 1 24V power supply customer supplied 24V 2 24V common 24V DC Pin Description Signal 1 DC bus connections ...

Page 60: ...registration home position input A low high or high low transition triggers a registration event This is a dual function input IN1 1 1 This signal has dual functionality You can use IN1 IOD 1 as registration or Home input 2 I O common for customer supplied 24V supply COM 3 High speed registration input A low high or high low transition triggers a registration event IN2 4 I O cable shield terminati...

Page 61: ...T Drive to motor power cables must not exceed 50 m 164 ft System performance was tested at this cable length These limitations also apply when meeting CE requirements BC Pin Description Signal 1 Motor brake connections MBRK 2 MBRK MF Pin Description Signal 1 Bidirectional data and power for digital encoder interface D 2 D SHIELD Cable shield and grounding plate internal to 2198 KITCON DSL connecto...

Page 62: ...Control of Electrical Noise Reference Manual publication GMC RM001 Function Description Default Behavior Home Reg1 An active state indicates to a homing sequence that the referencing sensor has been seen Typically a transition of this signal is used to establish a reference position for the machineaxis The function is always inactive You can enable in the Logix Designer application Registration 1 ...

Page 63: ... Drive 24V DC Attribute Value Communication The drive auto negotiates speed and duplex modes These modes can be forced through the Logix Designer application 100BASE TX full duplex is recommended for maximum performance Cyclic update period 500 μs min Embedded switch features Three port cut through time correction on IEEE 1588 packets limited filtering quality of service with four priority levels ...

Page 64: ...Designer application Refer to Kinetix 5500 Drive and Motor Actuator Wiring Examples beginning on page 195 for wiring examples Figure 33 Motor Brake Circuit Control Power The Kinetix 5500 drive requires 24V DC input power for control circuitry Table 27 Control Power Input Power Specifications ISP772 MBRK BC 1 MBRK BC 2 24V PWR 24V COM INT PWR Kinetix 5500 ServoDrive Control Board Noise Suppression ...

Page 65: ...e s absolute position feature tracks the position of the motor within the multi turn retention limits while the drive is powered off The absolute position feature is available with only multi turn encoders Table 29 Absolute Position Designator Examples Figure 34 Absolute Position Retention Limits TIP Auto configuration in the Logix Designer application of intelligent absolute high resolution encod...

Page 66: ...adjacent drives over duplex wiring For applications that do not require the STO safety function you must install jumper wires to bypass the safe torque off feature Refer to Chapter 9 on page 157 for the STO connector pinout installation and wiring information Servo Drives with Integrated Safety For 2198 Hxxx ERS2 integrated safety servo drives the 1756 L7xS GuardLogix safety controller issues the ...

Page 67: ...quirements 68 Determine the Input Power Configuration 69 Removing the Grounding Screws in Ungrounded Power Configurations 71 Grounding the Drive System 73 Wiring Requirements 75 Wiring Guidelines 76 Wiring the Power Connectors 77 Wiring the Digital Input Connectors 79 Wiring Kinetix VP Motors 80 Wiring Other Allen Bradley Motors and Actuators 86 Capacitor Module Connections 95 External Shunt Resis...

Page 68: ...he System Design for Control of Electrical Noise Reference Manual publication GMC RM001 for more information ATTENTION Plan the installation of your system so that you can perform all cutting drilling tapping and welding with the system removed from the enclosure Because the system is of the open type construction be careful to keep metal debris from falling into it Metal debris or other foreign m...

Page 69: ...inetix 5500 drive has factory installed grounding screws for grounded power distribution Refer to Power Wiring Examples beginning on page 190 for input power interconnect diagrams ATTENTION Ungroundedandcorner groundedinputpowerconfigurationsare permitted but you must remove the ground screws Refer to Removing the Grounding Screws in Ungrounded Power Configurations on page 71 for more information ...

Page 70: ...L1 1 2 Transformer Delta Secondary Bonded Cabinet Ground Transformer Ground Grid or Power Distribution Ground Connect to ground stud Three phase AC Line Filter Input Fusing Kinetix 5500 Servo Drive top view IMPORTANT Even though corner grounded power configurations have a ground connection treat them as ungrounded when installing Kinetix 5500 drive systems IMPORTANT If you determine that you have ...

Page 71: ...and placed on its side on a solid surface equipped as a grounded static safe workstation L3 L2 L1 1 2 L3 L2 L1 1 2 Transformer Three phase Input VAC Chassis Ground Bonded Cabinet Ground Ground Grid or Power Distribution Ground Connect to ground stud Three phase AC Line Filter Input Fusing Kinetix 5500 Servo Drive top view ATTENTION Ungrounded systems do not reference each phase potential to a powe...

Page 72: ...iguration screws installed is default setting Remove screws forungrounded power Grounding Screws Access Door Kinetix 5500 Drive side view Lift door to meet arrow at left ATTENTION Risk of equipment damage exists The drive ground configuration must be accurately determined Leave the grounding screws installed for grounded power configurations default Remove the screws for ungrounded power Ground Co...

Page 73: ...to a bonded cabinet ground bus with a braided ground strap or 4 0 mm2 12 AWG copper wire Figure 39 Connecting the Ground Terminal Refer to the System Design for Control of Electrical Noise Reference Manual publication GMC RM001 for more information ATTENTION The National Electrical Code contains grounding requirements conventions and definitions Follow all applicable local codes and regulations to...

Page 74: ... In this figure the chassis ground is extended to multiple subpanels Figure 40 Subpanels Connected to a Single Ground Point High frequency HF bonding is not illustrated For HF bonding information refer to Bonding Multiple Subpanels on page 38 Follow NEC and applicable local codes Bonded Ground Bus Ground Grid or Power Distribution Ground ...

Page 75: ...28 0 22 0 25 1 9 2 2 Brake power BC 1 BC 2 MBRK MBRK N A 3 DC Bus power DC 1 DC 2 DC DC N A 4 N A 4 N A 4 Shunt resistor frame 2 and 3 RC 1 RC 2 DC SH 4 0 5 12 20 8 0 0 31 0 5 0 6 4 4 5 3 Shunt resistor frame 1 RC 1 RC 2 SH DC Safety 5 ST0 1 ST0 2 ST0 3 ST0 4 ST0 5 SB SB S1 SC S2 1 5 0 2 16 24 10 0 0 39 N A 6 Digital inputs IOD 1 IOD 2 IOD 3 IOD 4 IN1 7 COM IN2 SHLD 1 5 0 2 16 24 10 0 0 39 N A 6 1...

Page 76: ...or ATTENTION To avoid personal injury and or equipment damage observe the following 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 Use motor power connectors for connection purposes only Do not use ...

Page 77: ...eparately Figure 41 CP Connector Wiring Single Axis Table 32 Single Axis CP Connector Wiring Specifications Figure 42 CP Connector Wiring Shared Bus Table 33 Shared Bus CP Connector Wiring Specifications 24V 24V 1 2 R e m o ve Fo r D C B u s O n ly Kinetix 5500 Drive Top View 24V CP Connector Plug Drive Cat No CP Pin Signal Recommended Wire Size mm2 AWG Strip Length mm in Torque Value N m lb in 21...

Page 78: ...ns ATTENTION Make sure the input power connections are correct when wiring theIPDconnectorplugorinputwiringconnectorandthattheplug connectoris fully engaged in the drive connector Incorrect wiring polarity or loose wiring can cause explosion or damage to equipment L3 L2 L1 R e m o ve Fo r D C B u s O n ly Kinetix 5500 Drive Top View Input Power IPD Connector Plug Kinetix 5500 Drive Cat No Pin Sign...

Page 79: ...the Safe Torque off Connector For the hardwired safe torque off STO connector pinouts feature descriptions and wiring information refer to Chapter 9 beginning on page 157 L 3 L 2 L 1 Kinetix 5500 Drives Top View Mains AC Input Wiring Connector Kinetix 5500 Drive Cat No Pin Signal Input Current max A rms Recommended Wire Size mm2 AWG Strip Length mm in Torque Value N m lb in 2198 H003 ERSx 2198 H00...

Page 80: ...s 1 IN1 COM IN2 SHLD Digital Inputs IOD Connector Plug Kinetix 5500 Servo Drive front view Drive Cat No DC Pin Signal Recommended Wire Size mm2 AWG Strip Length mm in Torque Value N m lb in 2198 Hxxx ERSx IOD 1 IOD 2 IOD 3 IOD 4 IN1 1 COM IN2 SHLD 1 This signal has dual functionality You can use IN1 IOD 1 as registration or Home input 1 5 0 2 16 24 10 0 0 39 N A 2 2 This connector uses spring tens...

Page 81: ...t view ATTENTION Make sure the motor power connections are correct when wiring the MP connector plug and that the plug is fully engaged in the module connector Incorrect wiring polarity or loose wiring can cause an explosion or damage to equipment Drive Cat No Pin Signal Wire Color Recommended Wire Size mm2 AWG Strip Length mm in Torque Value N m lb in 2198 H003 ERSx 2198 H008 ERSx 2198 H015 ERSx ...

Page 82: ...ke BC Connector Specifications MBRK MBRK 2 1 Motor Cable Shield Clamp Motor Brake BC Connector Plug Kinetix 5500 ServoDrive front view Drive Cat No Pin Signal Wire Color Recommended Wire Size AWG Strip Length mm in Torque Value N m lb in 2198 Hxxx ERSx BC 1 MBRK Black N A 1 1 Motor brake wires are part of the 2090 CSBM1DF xxAAxx motor cable 7 0 0 28 0 22 0 25 1 9 2 2 BC 2 MBRK White ...

Page 83: ... publication 2198 IN002 forconnectorkitspecifications Internal Grounding Plate Clamp Screws 2 Mounting Screws 2 Exposed Shield Feedback Cable EPWR EPWR Cover Kinetix 5500 Servo Drive front view 2090 CSxM1DF 18AAxx Motor Cable IMPORTANT Cable preparation and positioning that provides a high frequency bond between the shield braid and grounding plate is required to optimize system performance Drive ...

Page 84: ... screws and remove at least one of the screws Figure 49 18 AWG Cable Installation When the drive motor combination calls for 18 AWG cable the feedback cable routes around the motor cable shield clamp SHOCKHAZARD Toavoidhazardofelectricalshock makesureshieldedpower cables are grounded according to recommendations TIP Cables for Kinetix VP motors catalog numbers 2090 CBxM1DF 18AAxx do not route the ...

Page 85: ...ten the clamp screws Torque value 2 0 N m 17 7 lb in max 4 Repeat step 1 through step 3 for each drive in multi axis configurations Motor Cable Shield Clamp Motor Power MP Connector Motor Brake BC Connector Exposed shield braid under clamp Shield Clamp Screws 2 Feedback cable routed within the shield braid Kinetix 5500 Servo Drives Frame 2 or 3 Front View frame 2 is shown 2198 KITCON DSL Motor Fee...

Page 86: ...On Profiles website Motor Actuator Families 1 1 The 2198 H2DCK converterkit is required for all 400V class MP Series motors and actuators The 2198 H2DCK series B or later converter kit is required for LDAT Series linear thrusters and all 200V class MP Series motors and actuators Encoder Feedback Type MP Series low inertia motors Bulletin MPL Single turn or multi turn high resolution absolute MP Se...

Page 87: ... and Motor Brake Connections on page 82 for the MP and BC connector specifications Motor Actuator Cat No 1 1 The 2198 H2DCK converterkit is required for all 400V class MP Series motors and actuators The 2198 H2DCK series B or later converter kit is required for LDAT Series linear thrusters and all 200V class MP Series motors and actuators Motor Power Cat No 2 with brake wires 2 Refer to the Kineti...

Page 88: ...able length for Kinetix 5500 drive and MP Series motor actuator combinations is limited to 20 m 65 6 ft however you can replace the existing motor power brake cable with a 2090 CSBM1DF xxAAxx single motor cable to extend the length up to 50 m 164 ft Motor Cable Description Motor Power Cat No Standard Power brake threaded 2090 XXNPMF xxSxx Power only bayonet 2090 XXNPMP xxSxx Continuous flex Power ...

Page 89: ...mm 0 5 in of the shield ends and an equal length of the conductors with 25 mm 1 0 in of electrical tape or heat shrink Do the same on the other side of the cable shield This keeps the shield ends from fraying and holds the conductors together 4 Cut the brake conductors back to 163 mm 6 4 in and trim the shield braid at the base of the jacket The shield braid covering the brake conductors is not ne...

Page 90: ...a good bond between the cable shield and the drive chassis Figure 52 Cable Clamp Attachment IMPORTANT Ifthepower brakecableshieldhasaloosefitinsidetheshieldclamp insert the clamp spacer between the shield clamp and the drive to reduce the clampdiameter Whentheclampscrewsaretight 2 0N m 17 7lb in the result must be a high frequency bond between the cable shield and the drive chassis Clamp Compresse...

Page 91: ...n absolute encoders are compatible Motor Actuator Cat No 1 1 The 2198 H2DCK converterkit is required for all 400V class MP Series motors and actuators The 2198 H2DCK series B or later converter kit is required for LDAT Series linear thrusters and all 200V class MP Series motors and actuators Feedback Kit Cat No Feedback Cable Cat No MPL A B15xxx V Ex7xAA MPL A B2xxx V Ex7xAA 2198 H2DCK 2090 CFBM7D...

Page 92: ...0 2 0 22 0 25 1 9 2 2 2 SIN White Black 3 COS Red 4 COS White Red 5 DATA Green 6 ECOM 1 1 The ECOM and TS connections are tied together and connect to the cable shield White Gray 7 EPWR_9V 2 2 The converter kit generates 5V and 9V from a 12V supply coming from the drive The 5V supply is used by 5V encoders in 230V motors The 9V supply is used by 9V encoders in 460V motors Orange 10 DATA White Gree...

Page 93: ...o each screw 2 Route and insert each wire to its assigned terminal Include a service loop as shown in Figure 54 and refer to the connector pinout in Figure 53 3 Tighten each terminal screw Apply 0 22 0 25 N m 1 9 2 2 lb in torque to each screw 4 Gently pull on each wire to make sure it does not come out of its terminal reinsert and tighten any loose wires 5 Attach the tie wrap for added stress rel...

Page 94: ... Axxxxx VxxSxA MPAR Axxxx MPAI Axxxx 1 Sin Sin 1 2 Sin Sin 2 3 Cos Cos 3 4 Cos Cos 4 5 Data Data 5 6 Data Data 10 9 Reserved EPWR_5V 14 10 ECOM ECOM 6 1 11 EPWR_9V Reserved 7 12 ECOM ECOM 6 13 TS TS 11 1 The ECOM and TS connections are tied together and connect to the cable shield 14 11 10 7 6 5 4 3 2 1 2 1 Shield Clamp Clamp Screws 2 Service Loops TieWrap for Stress Relief and Wire Management Mou...

Page 95: ... performance run wires and cables in the wireways as established in Chapter 2 Connections to the DC bus and 24V control power must be made with the shared bus connection system 2 1 3 4 1 2 Kinetix 5500 Capacitor Module Top View Kinetix 5500 Capacitor Module Front View Item Description 1 Module status MS connector relay output 2 Module status indicator 3 DC bus DC connector under cover 1 2 1 The DC...

Page 96: ...0 Shunt Resistor Selection IMPORTANT To improve system performance run wires and cables in the wireways as established in Chapter 2 R e m o ve Fo r D C B u s O n ly 1 2 Kinetix 5500 Drive Top View Drive Cat No Pin Signal Recommended Wire Size mm2 AWG Strip Length mm in Torque Value N m lb in 2198 H003 ERSx 2198 H008 ERSx RC 1 RC 2 SH DC 4 0 5 12 20 8 0 0 31 0 5 0 6 4 4 5 3 2198 H015 ERSx 2198 H025...

Page 97: ...s connecting drive to drive drive to controller or drive to switch must not exceed 100 m 328 ft Figure 57 ControlLogix and CompactLogix Ethernet Port Locations These Logix5000 controllers accept linear ring DLR and star network configurations Refer to Typical Communication Configurations on page 20 for linear ring and star configuration examples 1 Front 2 Rear 00 00 BC 2E 69 F6 1 2 LNK1LNK2 NET OK...

Page 98: ...98 Rockwell Automation Publication 2198 UM001D EN P May 2014 Chapter 5 Connecting the Kinetix 5500 Drive System Notes ...

Page 99: ... Topic Page Understanding the Kinetix 5500 Display 100 Configure the Drive 104 Configure the Logix Designer Application Project 105 Apply Power to the Kinetix 5500 Drive 129 Test and Tune the Axes 131 Understanding Bus Sharing Group Configuration 135 TIP Before you begin make sure you know the catalog number for each drive component the Logix module and or controller and the servo motor used in yo...

Page 100: ...BUS 0 3V Soft Menu Navigation Buttons Status Indicators seepage 146 Press to go back Pressing enough times results in theHOME screen Pressingeitherarrowmoves theselectiontothenext or previous item Whenchangingvalues pressingtheuparrowincrementsthehighlightedvalue Valuesrolloverafterreachingtheendof the list Presstoselectvaluestochange movingfromrighttoleft Valuesrolloverwhenreachingtheend of the l...

Page 101: ...Resolution RESOLUTION 262144 Number of turns NO OF TURNS 1 Encodertemperature ENC TEMP 33 7C Supply voltage SUPP VOLT 11 3V Link quality Thelinkqualityattributeindicateshownoisyacommunicationlinkisandalsoindicates if there is a communication link already established at the drive end The LINK QUAL value must always be 100 Persistent values below 100 indicates a poor feedback ground connection LINK ...

Page 102: ...utes Default Description Network Static IP 1 IP address 192 168 1 1 Indicates current IP address Subnet mask 255 255 255 000 Indicates current subnet mask Gateway 192 168 001 001 Indicates current gateway DHCP On Turns DHCP on Off Turns DHCP off Display Backlight Timeout 30 sec NEVER NEVER no timeout period the backlight is always on 3 min 1 Sets backlight timeout period of the display Contrast 10...

Page 103: ...PED The drive is fully configured but the control loops are not enabled PRECHARGE The drive is ready for mains input power STARTING The drive is enabled and checking various conditions before entering the RUNNING or TESTING state For example the drive checks the Brake Release delay time during the STARTING state RUNNING Thedriveisenabled configuredwithanactivecontrolmode andactivelytrackingacomman...

Page 104: ...ication Set the Network Parameters You must program network parameters by using the LCD display 1 From the LCD display select SETUP NETWORK and choose between STATIC IP and DHCP The default setting is STATIC IP 2 If STATIC IP then press to configure the following parameters IP address Gateway Subnet mask Settings are stored in nonvolatile memory IP addressing can also be changed through the Module...

Page 105: ...software and the Logix Designer application as it applies to configuring the ControlLogix or CompactLogix controllers refer to Additional Resources on page 12 Configure the Logix5000 Controller Follow these steps to configure the controller 1 Apply power to your controller and open your Logix Designer application 2 From the Create menu choose New Project The New Project dialog box appears IMPORTAN...

Page 106: ...ision pull down menu choose your software revision 5 Click Finish The new controller appears in the Controller Organizer under the I O Configuration folder Controller Organizer with CompactLogix 5370 controller Controller Organizer with GuardLogix 1756 L7xS controller IMPORTANT If your project includes a ControlLogix or GuardLogix controller you need to add an Ethernet communication module to your...

Page 107: ...he Select Module Type dialog box appears 7 By using the filters check Communication and Allen Bradley and select 1756 EN2T 1756 EN2TR or 1756 EN3TR as appropriate for your actual hardware configuration In this example the 1756 EN2T module is selected 8 Click Create The New Module dialog box appears a Configure the new module b Type the module Name c Enter the Logix EtherNet IP module slot leftmost...

Page 108: ...From the Time Sync Connection pull down menu choose Time Sync and Motion 10 Click OK to close the Module Definition dialog box 11 Click Yes when prompted to confirm your module definition changes 12 Click OK to close the New Module dialog box Your new 1756 ENxT Ethernet module appears under the I O Configuration folder in the Controller Organizer 13 From the Edit menu choose Controller Properties ...

Page 109: ... tab 15 Check Enable Time Synchronization The motion modules set their clocks to the module you assign as the Grandmaster 16 Click OK IMPORTANT Check Enable Time Synchronization for all controllers that participate in CIP Sync The overall CIP Sync network automatically promotes a Grandmaster clock unless the priority is set in the Advanced tab ...

Page 110: ...alog box appears 2 By using the filters check Motion and Allen Bradley and select your 2198 Hxxx ERS servo drive as appropriate for your actual hardware configuration 3 Click Create IMPORTANT To configure 2198 Hxxx ERS hardwired safety drives you must be using the Logix Designer application version 21 00 or later To configure 2198 Hxxx ERS2 integrated safety drives you must be using the Logix Desi...

Page 111: ... Private Network address is selected c Enter the address of your 2198 Hxxx ERS drive In this example the last octet of the address is 1 5 Click OK to close the New Module dialog box Your 2198 Hxxx ERS servo drive appears in the Controller Organizer under the Ethernet controller in the I O Configuration folder 6 Click Close to close the Select Module Type dialog box 7 Jump to Continue Drive Configu...

Page 112: ...teps to configure Kinetix 5500 drives with integrated safety 1 Above the controller you just created right click Ethernet and choose New Module The Select Module Type dialog box appears 2 By using the filters check Motion and Allen Bradley and select your 2198 Hxxx ERS2 servo drive as appropriate for your actual hardware configuration 3 Click Create The New Module dialog box appears ...

Page 113: ...uardLogix Controller Systems Safety Reference Manual publication 1756 RM099 5 Click OK to close the Module Definition dialog box 6 Click OK to close the New Module dialog box Your 2198 Hxxx ERS2 servo drive appears in the Controller Organizer under the Ethernet controller in the I O Configuration folder TIP When Safety appears in the Connection mode integrated safety is implied Connection Mode Con...

Page 114: ...198 Hxxx ERS2 servo drive is based on the following Servo drive catalog number must be 2198 Hxxx ERS2 integrated Servo drive safety network number GuardLogix slot number GuardLogix safety network number Path from the GuardLogix controller to the 2198 Hxxx ERS2 drive Configuration signature If any differences are detected the connection between the GuardLogix controller and the 2198 Hxxx ERS2 drive...

Page 115: ... each safety channel to determine the appropriate settings The smallest Input RPI allowed is 6 ms Selecting small RPI values consumes network bandwidth and can cause nuisance trips because other devices cannot get access to the network 10 Click OK For more information about the Advanced Connection Reaction Time Limit Configuration refer to the GuardLogix 5570 Controllers User Manual publication 17...

Page 116: ...in the Logix Designer application the remaining configuration steps are the same regardless of the drive catalog number 1 Right click the 2198 Hxxx ERSx servo drive you just created and choose Properties The Module Properties dialog box appears 2 Click the Associated Axes tab 3 Click New Axis The New Tag dialog box appears 4 Type the axis Name AXIS_CIP_DRIVE is the default Data Type 5 Click Create...

Page 117: ...as Axis 1 6 Click Apply 7 Click the Power tab TIP You can configure an axis as Feedback Only Refer to Configure Feedback Only Axis Properties on page 124 for more information IMPORTANT Single phase operation is possibleonly when Module Properties Power tab Bus Configuration is configured as Standalone IMPORTANT The Logix Designer application enforces shared bus configuration rules for Kinetix 5500...

Page 118: ...ybridinput configurations Shared DC Applies to inverter drives with Shared DC input common bus configurations Bus Sharing Group 3 2 3 For more information on bus sharing groups refer to Understanding Bus Sharing Group Configuration on page 135 Standalone Applies to standalone bus configurations Group1 Group2 Group3 Applies toany bus sharing configuration 4 4 Alldrivesphysicallyconnectedtothesamesh...

Page 119: ...dialog box appears 2 Type the new motion group Name 3 Click Create Your new motion group appears in the Controller Organizer under the Motion Groups folder 4 Right click the new motion group and choose Properties The Motion Group Properties dialog box appears 5 Click the Axis Assignment tab and move your axes created earlier from Unassigned to Assigned 6 Click the Attribute tab and edit the defaul...

Page 120: ...er devices ConfigureServoMotorAxisProperties Follow these steps to configure servo motor axis properties 1 In the Controller Organizer right click an axis and choose Properties 2 Select the General category The General and Associated Module dialog box appears 3 From the General pull down menus change configuration settings as needed for your application 4 From the Associated Module Module pull dow...

Page 121: ...wn menu choose Catalog Number 8 Click Change Catalog The Change Catalog Number dialog box appears 9 Select the motor catalog number appropriate for your application To verify the motor catalog number refer to the motor name plate 10 Click OK to close the Change Catalog Number dialog box 11 Click Apply Motor data specific to your motor appears in the Nameplate Datasheet Phase to Phase parameters fi...

Page 122: ...5500 Drive System 12 Select the Scaling category and edit the default values as appropriate for your application 13 Click Apply if you make changes 14 Select the Load category and edit the default values as appropriate for your application 15 Click Apply if you make changes 16 Select the Actions category ...

Page 123: ...s faults Refer to Logix5000 Controller and Drive Behavior on page 149 for more information 17 Select the Parameter List category The Motion Axis Parameters dialog box appears From this dialog box you can set brake engage and release delay times for servo motors For recommended motor brake delay times refer to the Kinetix Rotary Motion Specifications Technical Data publication GMC TD001 18 Click OK...

Page 124: ...f you are using the 842E CM integrated motion encoder on the EtherNet IP network 1 In the Controller Organizer right click Ethernet under the I O Configuration folder and choose New Module The Select Module Type dialog box appears 2 By using the filters check Motion and Allen Bradley and select your 842E CM encoder as appropriate for your actual hardware configuration 3 Click Create The New Module...

Page 125: ...zer under the Ethernet controller in the I O Configuration folder 6 Click Close to close the Select Module Type dialog box 7 Right click the 842E CM encoder you just created and choose Properties The Module Properties dialog box appears 8 Configure the Associated Axis tab and the motion group for your 842E CM encoder In this example the feedback only axis is named Master_Fdbk 9 In the Controller O...

Page 126: ...der as needed for your actual hardware In this example the multi turn M resolution and number of turns is shown For single turn S resolution the number of turns is 1 14 Click OK 15 Repeat step 1 through step 14 for each feedback only axis For more information on configuring Bulletin 842E CM encoders refer to the 842E CM Integrated Motion Encoder on EtherNet IP User Manual publication 842E UM002 ...

Page 127: ...r Control Methods on page 223 Follow these steps to configure induction motor axis properties 1 In the Controller Organizer right click an axis and choose Properties 2 Select the General category The General and Associated Module dialog box appears 3 From the Axis Configuration pull down menu choose Frequency Control 4 From the Module pull down menu choose the drive to associate with your Frequenc...

Page 128: ...ate or datasheet enter the phase to phase values 10 Click Apply 11 Select the Frequency Control category 12 From the Frequency Control Method pull down menu choose the method appropriate for your application 13 If you chose the Basic Volts Hertz method enter the nameplate data for your motor in the Basic Volts Hertz fields If you chose the Sensorless Vector method the Basic Volts Hertz fields are ...

Page 129: ...tion regarding skip frequency refer to Skip Frequency on page 226 20 Click OK 21 Repeat step 1 through step 20 for each induction motor axis Download the Program After completing the Logix Designer application and saving the file you must download your program to the Logix5000 processor Apply Power to the Kinetix 5500 Drive This procedure assumes that you have wired and configured your Kinetix 550...

Page 130: ... level check the three phase input power connections Also it can take as many as 1 8 seconds after input power is applied before the drive can accept motion commands 5 Verify that the axis state changes to STOPPED If the axis state does not change to STOPPED refer to Fault Codes on page 140 Applying Power after Changing Input Voltage Range This step applies to any drive or multi axis drive configu...

Page 131: ...ning your axes with ControlLogix EtherNet IP modules or CompactLogix 5370 controllers refer to Additional Resources on page 12 Test the Axes Follow these steps to test the axes 1 Verify the load was removed from each axis 2 In your Motion Group folder right click an axis and choose Properties The Axis Properties dialog box appears 3 Click the Hookup Tests category IMPORTANT Before proceeding with ...

Page 132: ...e changes from Executing to Passed 7 Click OK This dialog box appears asking if the direction was correct 8 Click Yes 9 Click Accept Test Results 10 If the test fails this dialog box appears a Click OK b Verify the DC bus voltage c Verify unit values entered in the Scaling category d Return to step 5 and run the test again Test Description Marker Verifies marker detection capability as you rotate ...

Page 133: ...eps to tune the axes 1 Verify the load is still removed from the axis being tuned 2 Click the Autotune category 3 Type values for Travel Limit and Speed In this example Travel Limit 5 and Speed 10 The actual value of programmed units depend on your application 4 From the Direction pull down menu choose a setting appropriate for your application Forward Uni directional is default 5 Edit other field...

Page 134: ...es Actual bandwidth values Hz depend on your application and can require adjustment once motor and load are connected 7 Click Accept Tuned Values 8 Click OK to close the Logix Designer Autotune dialog box 9 Click OK to close the Axis Properties dialog box 10 If the test fails this dialog box appears a Click OK b Make an adjustment to motor velocity c Refer to the controller user manual for more in...

Page 135: ...servo systems into multiple bus sharing power groups A drive that faults in Group 1 does not affect the operation of Group 2 even though all of the drives in Groups 1 and 2 are in the same Motion group in the Logix Designer application As many as 25 bus sharing groups are possible When Standalone is configured as the Bus Configuration Standalone dimmed is also configured as the Bus Sharing Group I...

Page 136: ...g Group Example Kinetix 5500 Servo Drive System Group 1 shared AC DC hybrid Kinetix 5500 Servo Drive System Group 2 shared DC commmon bus Kinetix 5500 ServoDrive Standalone 2198 H040 ERSx Common bus Leader Drive 2198 H003 ERSx Common bus Follower Drives 2198 H040 ERSx Common bus converter Leader Drives 2198 H003 ERSx Common bus inverter Follower Drives Three phase and 24V Input Power Three phasean...

Page 137: ...Chapter 6 Configure Bus sharing Groups Group 1 is a shared AC DC hybrid configuration The Bus Configuration for the first two converter drives is Shared AC DC The Bus Configuration for the inverter drives is Shared DC Figure 60 Group 1 Converter Drives Configuration Figure 61 Group 1 Inverter Drives Configuration ...

Page 138: ...rive System Group 2 is a shared DC common bus configuration The Bus Configuration for the leader drive is Shared AC DC The Bus Configuration for the follower drives is Shared DC Figure 62 Group 2 Leader Drive Configuration Figure 63 Group 2 Follower Drives Configuration Figure 64 Standalone Drive Configuration ...

Page 139: ...nput power has been removed Before working on the drive measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the front of the drive Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION Do not attempt to defeat or override the drive fault circuits You mustdeterminethecauseofafaulta...

Page 140: ...e the source of the fault or exception When a fault condition is detected the drive performs the appropriate fault action the fault is displayed and the fault is added to a persistent fault log along with diagnostics data The earlier faults have priority to be displayed The drive removes the fault text from the display when a Fault Reset service is sent from the controller and the fault is no long...

Page 141: ...mal capacity limit of 110 Modify the command profile to reduce speed or increase time FLT S08 MTR OVERLOAD UL Motor Thermal Overload User Limit Fault The motor thermal model has exceeded the thermal capacity limit given by Motor Thermal Overload User Limit Modify the command profile Increase the Motor Thermal Overload UL attribute value FLT S09 MTR PHASE LOSS Motor Phase Loss The motor has failed ...

Page 142: ...r Limit Fault The shunt thermal model has exceeded the thermal capacity limit given by Bus Regulator Thermal Overload User Limit Modify the duty cycle of the application Add external shunt for additional capacity Increase the Bus Regulator Thermal Overload UL attribute value Add capacitor module if needed FLT S31 BUS REG FAILURE Bus Regulator Failure The shunt driver IC has detected that the shunt...

Page 143: ...y loop tuning Reduce acceleration Verify sizing of the drive and motor Check motor power wiring Increase Velocity Error Tolerance and or Velocity Error Tolerance Time attribute values FLT S56 OVERTORQUE LIMIT Overtorque Limit Fault Motor torque has risen above user defined maximum torque level given by Overtorque Limit for a time period given by Overtorque Limit Time Verify Torque Trim value Verif...

Page 144: ...ck state of safety devices Table 60 NODE FLT Fault Codes Exception Code on Display Exception Text Problem Possible Solutions NODE FLT 01 LATE CTRL UPDATE Control Connection Update Fault Several consecutive updates from the controller have been lost Remove unnecessary network devices from the motion network Change network topology so that fewer devices share common paths Use high performance networ...

Page 145: ...M Fault Codes Exception Code on Display Exception Text Problem Possible Solutions NODE ALARM 01 LATE CTRL UPDATE ControlConnectionUpdate Alarm Updates from the controller have been late Remove unnecessary network devices from the motion network Change network topology so that fewer devices share common paths Use high performance network equipment Use shielded cables Separate signal wiring from pow...

Page 146: ...fault The drive detected a recoverable fault for example an incorrect or inconsistent configuration Steady Red Major fault The drive detected a non recoverable fault Flashing Green Red Self test The drive performs self test during powerup Condition Status Steady Off No power applied to the drive or IP address is not configured Flashing Green Drive connection is not established but has obtained an ...

Page 147: ... is incorrect or open Check wiring Unintentionally in Torque mode Check to see what primary operation mode was programmed Motor tuning limits are set too high Run Tune in the Logix Designer application Position loop gain or position controller accel decel rate is improperly set Run Tune in the Logix Designer application Improper grounding or shielding techniques are causing noise to be transmitted...

Page 148: ... motor power transmission components or ballscrew speeds resulting in velocity disturbance Decouple the motor for verification Check and improve mechanical performance for example the gearbox or ballscrew mechanism No rotation The motor connections are loose or open Check motor wiring and connections Foreign matter is lodged in the motor Remove foreign matter The motor load is excessive Verify the...

Page 149: ...option When an exception action is set to Alarm the Alarm goes away by itself when the exceptional condition has cleared Fault Status Only Like Alarm Fault Status Only instructs the controller to set the associated bit in the Motion Fault Status word but does not otherwise affect axis behavior However unlike Alarm an explicit Fault Reset is required to clear the fault once the exceptional conditio...

Page 150: ...tory Limit Fault X X Disable Coast FLT S04 MTR OVERSPEED UL Motor Overspeed User Limit Fault X X X X X Decel Hold FLT S05 MTR OVERTEMP FL Motor Overtemperature Factory Limit Fault X X Disable Coast FLT S07 MTR OVERLOAD FL Motor Thermal Overload Factory Limit Fault X X X Decel Disable FLT S08 MTR OVERLOAD UL Motor Thermal OverLoad User Limit Fault X X X X X X Decel Hold FLT S10 INV OVERCURRENT Inve...

Page 151: ... X X Disable Coast FLT S45 MTR FDBK COMM FL Motor Feedback Data Loss Factory Limit Fault X X Disable Coast FLT S47 FDBK DEVICE FAILURE Feedback Device Failure X X Disable Coast FLT S49 BRAKE SLIP FLT Brake Slip Exception X X X X X Decel Hold FLT S54 POSN ERROR Excessive Position Error Fault X X X X X Disable Coast FLT S55 VEL ERROR Excessive Velocity Error Fault X X X X X Disable Coast FLT S56 OVE...

Page 152: ...rm Minor Fault Major Fault NODE FLT 01 LATE CTRL UPDATE Control Connection Update Fault X X X Decel Disable NODE FLT 02 PROC WATCHDOG Processor Watchdog Fault X X X Disable Coast NODE FLT 03 HARDWARE Hardware Fault X X X Disable Coast NODE FLT 05 CLOCK SKEW FLT Clock Skew Fault X X X Disable Coast NODE FLT 06 LOST CTRL CONN Lost Controller Connection Fault X X X Decel Disable NODE FLT 07 CLOCK SYN...

Page 153: ...o voltage exists on drive connectors Non conductive probe for removing DC bus T connectors Topic Page Before You Begin 153 Remove and Replace Kinetix 5500 Servo Drives 154 Start and Configure the Drive 156 ATTENTION This drive contains electrostatic discharge ESD sensitive parts and assemblies You are required to follow static control precautions when you install test service or repair this assemb...

Page 154: ...ble shield clamp 7 Remove the ground screw and braided ground strap Refer to Ground the System Subpanel on page 73 ATTENTION To avoid shock hazard or personal injury assure that all power has been removed before proceeding This system can have multiple sources of power More than one disconnect switch can be required to de energize the system SHOCKHAZARD Thisproductcontainsstoredenergydevices Toavo...

Page 155: ...e two top and bottom screws 2 Grasp the top and bottom of the drive with both hands and pull the drive straight out and away from the panel clearing the zero stack mounting tabs and cutouts Replace the Servo Drive To replace the servo drive reverse the steps shown above or refer to Mount Your Kinetix 5500 Drive on page 56 Torque mounting shield clamp and ground screws to 2 0 N m 17 7 lb in max Rec...

Page 156: ...ntical to the old drive Refer to Configure the Drive on page 104 to access those settings b If you replaced a 2198 Hxxx ERS2 servo drive in an integrated safety application review Understanding Integrated Safety Drive Replacement on page 174 and follow the appropriate procedure in Replacing an Integrated Safety Drive in a GuardLogix System on page 175 to properly set the safety network number for ...

Page 157: ... 13849 and SIL CL2 according to IEC 61508 EN 61800 5 2 and EN 62061 in which removing the motion producing power is considered to be the safe state Refer to Appendix E on page 229 for these certification documents EC Type Examination Certificate EC Declaration of Conformity European Union Directives Important Safety Considerations The system user is responsible for the following Validation of any ...

Page 158: ...eved levels Refer to the EN ISO 13849 EN 61508 and EN 62061 standards for complete information on requirements for PL and SIL determination Description of Operation The safe torque off feature provides a method with sufficiently low probability of failure to force the power transistor control signals to a disabled state When disabled or any time power is removed from the safety enable inputs all o...

Page 159: ...ys occur prior to Event 3 to prevent GuardStopInputFault 3 First input is switched on 4 Second input is switched on within 1 second of event 3 5 Both inputs are in OFF state simultaneously within 1 second As a result GuardStopInputFault is not posted 6 GuardStopRequestStatusbitsetsbackto0ifevent4occurredwithin100msintervalafterevent3 Ifevent4 is outside of the 100 ms interval and within the 1 seco...

Page 160: ...tem Operation in the Event that the Safety Enable Inputs Mismatch Momentarily ATTENTION The safe torque off fault is detected upon demand of the safe torque off function After troubleshooting a safety function must be executed to verify correct operation IMPORTANT The SafeTorque Off faultcanberesetonlyifboth inputs areintheOff statefor more than 1 second After the fault reset requirement is satisf...

Page 161: ...ted system is directly related to the probability of a dangerous failure occurring per hour PFH PFH Data These PFH calculation is based on the equations from EN 61508 and show worst case values This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data Table 74 PFH for 20 year Proof Test Interval IMPORTANT Determin...

Page 162: ...nal 1 Safety bypass plus signal Connect to both safety inputs to disable the STO function SB 2 Safety bypass minus signal Connect to safety common to disable the STO function SB 3 STO input 1 SS_IN_CH0 S1 4 STO input common SCOM SC 5 STO input 2 SS_IN_CH1 S2 IMPORTANT TheNationalElectricalCodeandlocalelectricalcodestakeprecedence overthe values and methods provided IMPORTANT To improve system perf...

Page 163: ...orque off STO Terminal Plug Wiring IMPORTANT TheNationalElectricalCodeandlocalelectricalcodestakeprecedence overthe values and methods provided IMPORTANT Strandedwiresmustterminatewithferrulestopreventshortcircuits pertable D 7 of EN ISO 13849 2 1 2 3 4 5 SB SB S1 SC S2 R e m o ve Fo r D C B u s O n ly Kinetix 5500 Drive Top View Safe Torque off STO Connector Recommended Wire Size mm2 AWG Strip Le...

Page 164: ...8 Hxxx ERS drives do not operate without a safety circuit or safety bypass wiring For applications that do not require the safe torque off feature you must install jumper wires to bypass the safe torque off circuitry Safe Torque off Feature Bypass Each Kinetix 5500 drive ships with one 10 pin wiring plug for wiring to safety devices To bypass the safety function wire these signals as shown in Figu...

Page 165: ...ontrol panels or cabinets appropriate for the environmental conditions of the industrial location The protection class of the panel or cabinet must be IP54 or higher Table 77 Safe Torque off Signal Specifications Pin 1 SB SB S1 SC S2 Pin 1 24V DC First Drive Middle Drive Last Drive Dual channel Equivalent Safety Device Attribute Value Safety inputs per channel Input current 10 mA Input ON voltage ...

Page 166: ...166 Rockwell Automation Publication 2198 UM001D EN P May 2014 Chapter 9 Kinetix 5500 Safe Torque off Hardwired Safety Notes ...

Page 167: ...rives with integrated safe torque off for use in safety related applications up to PLe Category 3 according to EN ISO 13849 and SIL CL3 according to IEC 61508 EN 61800 5 2 and EN 62061 in which removing the motion producing power is considered to be the safe state Refer to Appendix E on page 229 for these certification documents EC Type Examination Certificate EC Declaration of Conformity European...

Page 168: ... by the safety controller The safety signature consists of an identification number date and time that uniquely identifies the safety portion of a project This includes all safety logic data and safety I O configuration For safety system requirements including information on the safety network number SNN verifying the safety signature and functional verification tests refer to the GuardLogix 5570 ...

Page 169: ...bled state When the command to allow torque ceases from the GuardLogix controller all of the drive output power transistors are released from the On state This results in a condition where the motor is coasting Disabling the power transistor output does not provide mechanical isolation of the electrical output that is required for some applications The 2198 Hxxx ERS2 drive STO function response ti...

Page 170: ...orqueDisabled Axis SafeTorqueOffActiveStatus Axis SafeTorqueOffActiveInhibit Axis SafeTorqueDisabledStatus Safe Torque off Request Axis SafetyResetRequestStatus Axis SafetyResetRequiredStatus Reset Request Exception Code on Drive Display Fault Message Logix Designer Problem Possible Solutions SAFE FLT S01 Safety Core Internal CPUWatchdogFault 1 Drive safety diagnostic detected internal STO design ...

Page 171: ...lculation is based on the equations from EN 61508 and show worst case values This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data Determination of safety parameters is based on the assumption that the system operates in high demand mode and that the safety function is requested at least once a year This table...

Page 172: ...dLogix 5570 safety controller for a non safety application With a GuardLogix 5570 safety controller when the safe torque off STO function is not required Out of Box State Support After the integrated safety connection configuration is applied to the 2198 Hxxx ERS2 servo drive at least once you can restore the drive to the out of box state ATTENTION This option is designed to restrict motion produc...

Page 173: ...apter 10 Follow these steps to restore your 2198 Hxxx ERS2 servo drive to the out of box state 1 Right click the 2198 Hxxx ERS2 servo drive you created and choose Properties 2 Click the Connection tab The Connection tab appears 3 Check Inhibit Module 4 Click Apply and click the Safety tab The Safety tab appears ...

Page 174: ...ect safety devices The SNN is also used to provide integrity on the initial download to the 2198 Hxxx ERS2 servo drive When the Logix Designer application is online the Safety tab of the Module Properties dialog box displays the current configuration ownership When the opened project owns the configuration Local is displayed Communication error is displayed if the module read fails Refer to Replac...

Page 175: ...and the DeviceID of the new drive matches the original you can download the configuration from the safety controller The DeviceID is a combination of the node IP address and the safety network number SNN and is updated whenever the SNN is set If the project is configured as Configure Only When No Safety Signature Exists follow the appropriate instructions in Table 80 to replace a 2198 Hxxx ERS2 dr...

Page 176: ...entIntegratedSafetyDriveIsOut of boxandSafetySignatureExists 1 Remove and replace the existing integrated safety drive 2 Right click the replacement drive and choose Properties The General tab appears in Module Properties dialog box 3 Click to the right of the safety network number The Safety Network Number dialog box appears 4 Click Set ...

Page 177: ...the correct drive 6 Click Yes to set the SNN and accept the replacement drive Scenario2 ReplacementIntegratedSafetyDriveSNNIsDifferentfromOriginalandSafety SignatureExists 1 Remove and replace the existing integrated safety drive 2 Right click the replacement drive and choose Properties 3 Click the Safety tab 4 Click Reset Ownership 5 Click OK 6 Right click the replacement drive and choose Propert...

Page 178: ...erties dialog box 7 Click to the right of the safety network number The Safety Network Number dialog box appears 8 Click Set 9 Verify that the Network Status NET status indicator is alternating red green on the correct drive 10 Follow your company prescribed procedures to functionally test the replacement drive and system and to authorize the system for use ...

Page 179: ...ed the controller automatically checks for and connects to a replacement drive that meets all of the following requirements The controller has configuration data for a compatible drive at that network address The drive is in out of box condition or has an SNN that matches the configuration If the project is configured for Configure Always follow the appropriate steps to replace a 2198 Hxxx ERS2 se...

Page 180: ...replacement drive and choose Properties 3 Click the Safety tab 4 Click Reset Ownership 5 Click OK 6 Follow your company prescribed procedures to functionally test the replacement drive and system and to authorize the system for use If Then The drive is in out of box condition Go to step 6 No action is needed for the GuardLogix controller to take ownership of the drive An SNN mismatch error occurs ...

Page 181: ...y drive has a Motion connection to a standard controller and a separate Safety connection to a dual safety controller the standard controller can transition to Program mode while the safety controller stays in Run mode and continues to execute the safety task However 2198 Hxxx ERS2 drive systems are designed with a bypass feature for the STO function in single safety controller configurations You ...

Page 182: ...that it receives from the safety controller Safety state Running Axis state Stopped Running as shown in Figure 75 Figure 75 Safety State Indications When Controller is in Run Mode safety task executing When the controller transitions to Program mode the integrated safety drive is in the safe state torque not permitted Safety state Not Running Axis state Start Inhibited as shown in Figure 76 Figure...

Page 183: ...n the Safety Controller is in Program Mode The warning in Figure 77 is displayed the first time a motion direct command is issued After you acknowledge the warning message by clicking Yes torque is permitted by the drive and a warning message is indicated in the software as shown in Figure 78 Safety state Not Running torque permitted Axis state Stopped Running Persistent Warning Safe Torque Off By...

Page 184: ...ning Icon and Text in Axis Properties In addition to the other warnings that require your acknowledgement the Logix Designer application also provides warning icons and persistent warning messages in other Axis Properties dialog boxes when the integrated safety drive is in STO Bypass mode Figure 80 Axis and Safe State Indications on the Hookup Services Dialog Box IMPORTANT The persistent warning m...

Page 185: ... UM001D EN P May 2014 185 Kinetix 5500 Safe Torque off Integrated Safety Chapter 10 Figure 81 Axis and Safe State Indications on Motion Direct Commands Dialog Box Figure 82 Axis and Safe State Indications on the Motion Console Dialog Box ...

Page 186: ...fety operating procedures ATTENTION Motion is allowed when motion direct commands are used in Program mode and STO function is not available MotiondirectcommandsissuedwhenthecontrollerisinProgrammodecauses the drive to bypass the STO Active condition It is your responsibility to implement additional preventive measures to maintain safety integrity of the machinery during execution of motion direct...

Page 187: ...ted safety open request support Type 1 and Type 2 requests N A Axis safety status Bit 0 Safety fault Axis SafetyFaultStatus Bit 1 Safety reset request Axis SafetyResetRequestStatus Bit 2 Safety Reset Required Axis SafetyResetRequiredStatus Bit 3 Safe torque off active Axis SafeTorqueOffActiveStatus Bit 4 Safe torque disabled Axis SafeTorqueDisabledStatus Bit 5 31 Undefined 0 N A Axis safety faults...

Page 188: ...188 Rockwell Automation Publication 2198 UM001D EN P May 2014 Chapter 10 Kinetix 5500 Safe Torque off Integrated Safety Notes ...

Page 189: ...equirements 7 DC connector covered with protective knockout is default configuration Remove knockout to insert DC bus T connector andbus bars Do not attach discrete wiring to the DC bus terminals is 8 Internal shunt wired to the RC connector is default configuration Remove internal shunt wires to attach external shunt wires 9 Default configuration for ground screws isfor grounded power at user sit...

Page 190: ... Input Notes 1 2 Bonded Cabinet Ground Bus Control Power CP Connector PE Ground Note 6 Mains AC Input IPD Connector Input Fusing Note 2 Indicates User Supplied Component 2198 Hxxx ERSx Kinetix 5500 Drives Chassis Note 4 Ground Screws Note 9 Customer Supplied 24V DC Power Supply Motor Brake BC Connector Three phase Motor Power Connections Note 11 Motor Power MP Connector Cable Shield Clamp Note 5 R...

Page 191: ...e operation Shunt RC Connector Motor Feedback MF Connector Digital Input IOD Connector Motor Brake Connections Motor Feedback Connections refer to Figure 91 Registrationand Home Input Connections Input Fusing Note 2 2198 DBxx F Three phase AC Line Filter Note 3 Internal Shunt Note 8 PE Ground Note 6 Note 5 24V_COM 24V RELAY RELAY 2 1 L3 L2 L1 4 3 2 1 24V_COM 24V 2 1 DC DC DC DC Control Power CP Co...

Page 192: ... Hxxx ERSx Kinetix 5500 Drive 2198 Hxxx ERSx Kinetix 5500 Drive PE Ground Note 6 PE Ground Note 6 PE Ground Note 6 Input Fusing Note 2 2198 H0x0 ADP IN Bus Bar Connectors 2198 H0x0 AP T Bus Bar Connectors 2198 H0x0 AP T Bus Bar Connectors Three phase Input IPD Connectors L3 L2 L1 4 3 2 1 L3 L2 L1 L3 L2 L1 24V_COM 24V 2 1 24V_COM 24V 24V_COM 24V DC DC DC DC DC DC 195 264V AC rms or 324 528V AC rms ...

Page 193: ... Hxxx ERSx Kinetix 5500 Drive PE Ground Note 6 PE Ground Note 6 PE Ground Note 6 Input Fusing Note 2 2198 H0x0 ADP IN Bus Bar Connectors 2198 H0x0 DP T Bus Bar Connectors 2198 H0x0 DP T Bus Bar Connectors L3 L2 L1 4 3 2 1 L3 L2 L1 L3 L2 L1 24V_COM 24V 2 1 24V_COM 24V 24V_COM 24V DC DC DC DC DC DC 195 264V AC rms or 324 528V AC rms Three phase Input Notes 1 2 Bonded Cabinet Ground Bus Control Power...

Page 194: ... 5500 servo drives Figure 90 Shunt Resistor Wiring Example Refer to the Kinetix 300 Shunt Resistor Installation Instructions publication 2097 IN002 for shunt resistor installation instructions IMPORTANT BeforewiringtheBulletin2097externalshunttotheRCconnector removethe wiresfrom the servodriveinternal shunt Do notconnect internal andexternal shunt resistors to the drive DC SH 2198 Hxxx ERSx Kineti...

Page 195: ...Brake BC Connector Motor Power MP Connector Cable Shield Clamp Note 5 2198 Hxxx ERSx Kinetix 5500 Servo Drives Motor Feedback MF Connector 2090 CSBM1DF xxAAxx or 2090 CSBM1DF xxAFxx Single Motor Cable Note 11 Three phase Motor Power Motor Feedback Refer to table on page 189for note information 2198 KITCON DSL Connector Kit VPL A Bxxxx C P Motors VPF A Bxxxx C P Motors or VPS BxxxD P Motors with Hi...

Page 196: ...PL B6xx MPM A Bxxx MPF A Bxxx and MPS A BxxxServo Motors with High Resolution Feedback Motor Feedback MF Connector Three phase Motor Power Motor Feedback Thermostat Refer to DSL feedback converter kit illustration lower left for proper grounding technique Grounding Technique for Feedback Cable Shield Cable Clamp Exposed shield secured under clamp Clamp Screws 2 Refer to table on page 189 for note ...

Page 197: ...eedback Thermostat Grounding Technique for Feedback Cable Shield Cable Clamp Exposed shield secured under clamp Clamp Screws 2 Refer to table on page 189 for note information 2198 H2DCK Feedback Converter Kit Cable Shield Clamp Note 5 2198 Hxxx ERSx Kinetix 5500 Servo Drives Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions publication 2198 IN006 for converter kit specific...

Page 198: ... phase Motor Power Motor Feedback Thermostat Grounding Technique for Feedback Cable Shield Cable Clamp Exposed shield secured under clamp Clamp Screws 2 Refer to table on page 189 for note information 2198 H2DCK Feedback Converter Kit Cable Shield Clamp Note 5 2198 Hxxx ERSx Kinetix 5500 Servo Drives Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions publication 2198 IN006 ...

Page 199: ...98 Hxxx ERSx Kinetix 5500 Servo Drives Refer to Hiperface to DSL Feedback Converter Kit Installation Instructions publication 2198 IN006 for converter kit specifications Refer to Table 83 for flying lead motor feedback cable Notes 11 12 13 Refer to Table 83 for motor power cable Notes 11 Power Connector Feedback Connector SpeedTec DIN Motor Connectors Refer to DSL feedback converter kit illustrati...

Page 200: ...phase Input Power Connector DC Bus Connector Internal or External Shunt Resitor Shunt Connector 24V Control Power Connector AC Ground Jumper DC Ground Jumper Switched Mode Power Supply Control Power Encoder Power Control Board Chassis Three phase Motor Poewr Connector Motor Cable Clamp Safe Torque off Connector Digital Inputs Connector Ethernet PORT1 Ethernet PORT2 Motor Feedback Connector Motor B...

Page 201: ... Diagrams Appendix A Figure 98 Kinetix 5500 Capacitor Module Block Diagram RELAY RELAY 24V 24V DC DC 1360 μF DC Bus Connector 24V Control Power Module Status Connector NO relay output Status Indicator SMPS Protection Precharge Capacitor Bank Relay K1 Relay K2 Fuse F2 Chassis ...

Page 202: ...202 Rockwell Automation Publication 2198 UM001D EN P May 2014 Appendix A Interconnect Diagrams Notes ...

Page 203: ... your Logix5000 controller communication selecting the drive to upgrade and upgrading the firmware Topic Page Before You Begin 204 Upgrade Firmware 207 Verify the Firmware Upgrade 211 IMPORTANT If the drive firmware contains updated safety firmware you must de energize the safety inputs first or the upgrade fails To update the drive firmware in Feedback Only mode you must inhibit the axis first Re...

Page 204: ... 5800 for assistance For more ControlFLASH information not drive specific refer to the ControlFLASH Firmware Upgrade Kit Quick Start publication 1756 QS105 11 00 or later Catalog numbers of the targeted Kinetix 5500 drive module you want to upgrade Network path to the targeted Kinetix 5500 drive module you want to upgrade IMPORTANT Control power must be present at CP 1 24V and CP 2 24V prior to up...

Page 205: ...as already been configured For more controller information refer to Additional Resources on page 12 Follow these steps to configure Logix5000 controller communication 1 Open your RSLinx Classic software 2 From the Communications menu choose Configure Drivers The Configure Drivers dialog box appears 3 From the Available Driver Types pull down menu choose Ethernet devices 4 Click Add New The Add New...

Page 206: ...g box Inhibit Feedback Only Axis If an axis is configured as Feedback Only you must inhibit the axis prior to performing the firmware upgrade Follow these steps to inhibit an axis 1 Open your Logix Designer application 2 Right click the 2198 Hxxx ERSx servo drive you configured as Feedback Only and choose Properties The Module Properties dialog box appears 3 Click the Connection tab 4 Check Inhibi...

Page 207: ...se steps to select the drive module to upgrade 1 In the Logix Designer application from the Tools menu choose ControlFLASH The Welcome to ControlFLASH dialog box appears 2 Click Next The Catalog Number dialog box appears TIP You can also open ControlFLASH software by choosing Start Programs FLASH Programming Tools ControlFLASH ...

Page 208: ...this example the 2198 H003 ERS servo drive is selected 4 Click Next The Select Device to Update dialog box appears 5 Expand your Ethernet node Logix backplane and EtherNet IP network module 6 Select the servo drive to upgrade 7 Click OK The Firmware Revision dialog box appears 8 Select the firmware revision to upgrade 9 Click Next ...

Page 209: ...ware Appendix B The Summary dialog box appears 10 Confirm the drive catalog number and firmware revision 11 Click Finish This ControlFLASH warning dialog box appears 12 Click Yes only if you are ready This ControlFLASH warning dialog box appears 13 Acknowledge the warning and click OK ...

Page 210: ... 15 Verify that the Update Status dialog box appears and indicates success or failure as described below 16 Click OK IMPORTANT Do not cycle power to the drive during this process or the firmware upgrade does not complete successfully Upgrading Status If Success Update complete appears in a GREEN Status dialog box then go to step 16 Failure Update failure appears in a RED Status dialog box then ref...

Page 211: ...upgrade was successful 1 Open your RSLinx software 2 From the Communications menu choose RSWho 3 Expand your Ethernet node Logix backplane and EtherNet IP network module 4 Right click the drive module and choose Device Properties The Device Properties dialog box appears 5 Verify the new firmware revision level 6 Click Close TIP Verifying the firmware upgrade is optional ...

Page 212: ...212 Rockwell Automation Publication 2198 UM001D EN P May 2014 Appendix B Upgrade the Drive Firmware Notes ...

Page 213: ...converter power available The zero stack tabs and cutouts must be engaged from drive to drive Systems cannot start in one cabinet and end in another Program drives for the same converter AC input voltage Shared bus Configurations Shared AC configurations are configured as Standalone in the project file and do not share these restrictions that apply to multi axis shared bus configurations All drive...

Page 214: ...n a Shared DC DC common bus configuration the first leftmost drive is the leader drive and is the only drive that receives the AC input voltage All drives to the right of the leader drives are follower drives They receive the DC bus voltage extended from the leader drive through the shared bus connection system For DC common bus installations the power rating of the leader drive must be greater th...

Page 215: ... 2198 H015 ERSx 2 and 1 2198 H025 ERSx 6 2198 H003 ERSx 3 2198 H008 ERSx 2 2198 H015 ERSx 2198 H025 ERSx 2 and 1 2198 H040 ERSx 6 2198 H003 ERSx 3 2198 H008 ERSx 2 2198 H015 ERSx 2198 H025 ERSx 2198 H040 ERSx 3 and 1 2198 H070 ERSx 7 2198 H003 ERSx 4 2198 H008 ERSx 3 and 2 2198 H015 ERSx 2198 H025 ERSx 2198 H040 ERSx 3 2198 H070 ERSx 1 ForBulletin 2198 capacitor module maximum values refer to the ...

Page 216: ...ves configured as Shared AC DC is described in Table 87 Table 87 Shared AC DC Panel Layout Figure 101 Typical Shared AC DC Configuration For an example shared AC DC installation with additional details refer to Typical Shared AC DC Installations on page 17 Drive Cat No Frame Size Drives Configured as Shared AC DC max 1 1 For Bulletin 2198 capacitormodule maximum values refer to the Kinetix 5500 Ca...

Page 217: ...must be sized for the motor load connected to it Total available converter power is derated by 30 The maximum number of drives configured in the project file as Shared AC DC is restricted according to Table 87 on page 216 The maximum number of drives configured in the project file as Shared DC is restricted according to Table 86 on page 215 Shared AC DC hybrid configurations support Bulletin 2198 ...

Page 218: ...ure 103 DC Common Bus Configuration Each 2198 H040 ERS drive is rated at 8 4 kW continuous output power to bus However only the leader drive acts as the converter so the available converter power to the system is 8 4 kW In this example total motoring load must not exceed 8 4 kW Configuration Available Converter Capacity Available Regenerative Capacity Shared AC Converter power rating of each drive...

Page 219: ...drives are used however two are connected as parallel converter leader drives and the other two as common bus follower drives The total converter power is derated by 30 Figure 104 Shared AC DC Hybrid Configuration The available converter power to the system is 8 4 2 0 7 11 76 kW In this example total motoring load must not exceed 11 76 kW The available converter power was increased by 40 over the ...

Page 220: ...er power to the system is 8 4 4 0 7 23 52 kW In this example total motoring load must not exceed 23 52 kW The available converter power was increased by 180 over the same drives in shared DC configuration Control Power Current Calculations Kinetix 5500 servo drives and the Bulletin 2198 capacitor module have different 24V DC power consumption Factors to consider when calculating the combined curre...

Page 221: ...uration is less than 30 ms 2198 H003 ERSx 0 4 2 4 2 0 2198 H008 ERSx 2198 H015 ERSx 0 8 2 8 3 0 2198 H025 ERSx 2198 H040 ERSx 2198 H070 ERSx 1 3 3 3 2198 CAPMOD 1300 0 3 N A 2 0 Bonded Cabinet Ground Three phase Input Power 24V Input Control Power 3 5 A min non brake motors 15 2 A min brake motors 2198 H040 ERS Servo Drives 2198 H008 ERS Servo Drives 2198 CAPMOD 1300 Capacitor Module DC Bus Connec...

Page 222: ...r module or external shunt resistor is needed Table 91 Energy Absorbing Potential Refer to Motion Analyzer software version 7 0 or later for custom shunt sizing Kinetix 5500 Drive Cat No Internal Shunt 1 J External Shunt kJ Capacitor Module 1 J Capacitor Module max 2 J 2198 H003 ERSx 427 09 12 51 N A N A 2198 H008 ERSx 554 4 554 4 2198 H015 ERSx 549 01 12 521 676 32 676 32 2198 H025 ERSx 575 223 1...

Page 223: ...g acceleration and running torque To configure your induction motor in the Logix Designer application refer to Configure Induction Motor Axis Properties on page 127 Open loop frequency control is suitable in applications such as conveyors pumps and fans These are the features Start Boost Run Boost and Auto Boost Electronic motor thermal overload protection per NEC NEMA Class 10 requirements Single...

Page 224: ...urve Start Boost Used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds Run Boost Used to create additional running torque at low speeds The value is typically less than the required acceleration torque The drive lowers the boost voltage to this level when running at low speeds not accelerating This reduces excess motor heating that could res...

Page 225: ...e to identify the motor resistance value see Tune the Axes on page 133 This is done so that the drive can accurately estimate the required boost voltage This method offers better torque production and speed regulation over a wider speed range than basic volts hertz However it is not appropriate when more than one motor is connected to the same drive The auto boost feature is applied internally to ...

Page 226: ...equency around the center point is determined by the SkipSpeedBand parameter The range is split half above and half below the SkipSpeed1 parameter If the commanded frequency is greater than or equal to the skip center frequency and less than or equal to the high value of the band skip plus 1 2 band the drive sets the output frequency to the high value of the band See A in Figure 110 If the command...

Page 227: ...ugh the band Skip Band Description Graphic Illustration The skip frequency has hysteresis so the output does not toggle between high and low values You can program three distinctbands If none ofthe skipbands touch or overlap each band has its own high low limit If the band is outside of the limits the skip band is inactive 0 Hz Frequency max Skip Frequency Skip Band 0 Hz 400 Hz Skip Frequency 60 H...

Page 228: ...228 Rockwell Automation Publication 2198 UM001D EN P May 2014 Appendix D Induction Motor Support Notes ...

Page 229: ...ix 5500 servo drive certification information EC Type Examination Certificate For product certifications currently available from Rockwell Automation go to http www rockwellautomation com products certification Topic Page EC Type Examination Certificate 229 EC Declaration of Conformity 230 European Union Directives 233 ...

Page 230: ...formity is declared EN 61800 5 1 2007 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional EN 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods EN 60204 1 2006 A1 2009 Safety of m...

Page 231: ...r 5 0Amp Network Safe Torque Off Yes Yes Yes 2198 H025 ERS2 Kinetix 5500 Frame 2 195 528Vrms 5 2 kW Inverter 8 0Amp Network Safe Torque Off Yes Yes Yes 2198 H040 ERS2 Kinetix 5500 Frame 2 195 528Vrms 8 4 kW Inverter 13 0Amp Network Safe Torque Off Yes Yes Yes 2198 H070 ERS2 Kinetix 5500 Frame 3 195 528Vrms 14 9 kW Inverter 23 0Amp Network Safe Torque Off Yes Yes Yes AC Line Filters 2198 DB08 F 460...

Page 232: ... N R N R 1585J M8CBJM x Shielded Ethernet cable N R N R N R 1606 XLxxx 24V DC Power Supply N R N R N R 2198 KITCON DSL Replacement feedback connector kit for Kinetix 5500 N R N R N R 2198 KITCON IOSP Replacement I O connector kit spring clamp for IOD connector N R N R N R 2198 KITCON IOSC Replacement I O connector kit screw terminal for IOD connector N R N R N R 2198 KITCON PWR40 Replacement conne...

Page 233: ...3 Adjustable Speed Electrical Power Drive Systems Part 3 EMC Product Standard including specific test methods EN 61326 3 1 EMC Immunity requirements for safety related systems The product described in this manual is intended for use in an industrial environment CE Declarations of Conformity are available online at http www rockwellautomation com rockwellautomation certification overview page and i...

Page 234: ...234 Rockwell Automation Publication 2198 UM001D EN P May 2014 Appendix E EC Certifications Notes ...

Page 235: ...s to the system overview table and throughout the manual Added Hiperface to DSL feedback converter kit and compatible MP Series motors and actuators to configuration diagrams Added Hiperface to DSL converter kit and footnote to noise zone diagram Added Hiperface to DSL converter kit and footnoteto motor feedback in table Added paragraph describing motor feedback types accepted by the Hiperface to ...

Page 236: ...cted dimension values Updated Motor Brake Circuit text and diagram Updated Wire the Motor Power Brake and Feedback Connectors with continuos flex cable catalog numbers and IMPORTANT advisory regarding single cable technology Updated NODE FLT 03 HARDWARE 01 and added sub codes HARDWARE 02 and HARDWARE 03 Added non conductive probe tobulleted list of tools Added IMPORTANT advisory regarding DC bus T...

Page 237: ...91 status indicator 147 support 49 wiring 95 catalog numbers capacitor module 26 motor cables 80 87 91 servo drives hardwired 26 integrated 26 shared bus connection system 26 category 3 requirements 158 168 stop category definitions 158 169 CE compliance 27 comply with CE 233 conformity 233 meet requirements 233 certification application requirements 168 EC Declaration of Conformity 230 EC Type Ex...

Page 238: ...description 14 Kinetix 5500 AOP 86 CP connector pinouts 59 wiring 77 D date time tab 109 DC bus connector pinouts 59 delay times 123 digital inputs 62 pinouts 60 wiring 80 display 100 download program 129 drilling hole patterns 49 drive replacement integrated safety 174 E earth ground 73 EC Declaration of Conformity 230 EC Type Examination Certificate 229 EMC directive 233 motor ground termination...

Page 239: ...ents 30 transformer 31 integrated safety configure always 179 configureonlywhennosafetysignatureexists 175 connections 112 drive replacement 174 out of box state 172 protocol 180 STO state reset 169 interconnect diagrams 2198 drive with LDAT 197 2198 drive with MPAR MPAI 199 2198 drive with MPAS 198 2198 drive with MPL MPM MPF MPS 196 2198 drive with VPL VPF VPS 195 bus sharing drives shared AC 19...

Page 240: ...ion buttons 100 network parameters 104 status indicator 146 new tag data type 116 noise abnormal 148 feedback 148 reduction 41 O open loop frequency control 223 out of box state 172 P panel requirements 30 parameter list category 123 129 PFH definition 161 171 pinouts 24V input power connector 59 DC bus connector 59 digital inputs connector 60 Ethernet connector 60 mains input power connector 59 m...

Page 241: ... inputs 62 EtherNet IP connections 63 motor feedback absolute position 65 Stegmann DSL 65 safe torque off 66 165 187 startup sequence 103 status indicators capacitor module 147 link speed status 146 link activity status 146 module status 146 network status 146 STO bypass 181 connector pinouts 162 connector wiring 163 state reset 169 stop drive 149 planner 149 Studio 5000 Environment 11 system bloc...

Page 242: ...68 V verify upgrade 211 W wiring BC connector 82 87 capacitor module 95 converter kit shield clamp 93 CP connector 77 earth ground 73 Ethernet cables 97 external shunt resistor 96 grounded power configuration 69 grounding screws 71 guidelines 76 input power type 69 IOD connector 80 IPD connector 78 MF connector 83 91 motor cable shield clamp 84 90 MP connector 81 87 RC connector 96 remove groundin...

Page 243: ......

Page 244: ...allation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these ...

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