Page 1 This manual links to Kinetix 5500 Servo Drive Fault Codes Reference Data, publication 2198-RD005, for fault codes. Download the spreadsheet now for offline access. Kinetix 5500 Servo Drives Catalog Numbers 2198-H003-ERS, 2198-H008-ERS, 2198-H015-ERS, 2198-H025-ERS, 2198-H040-ERS, 2198-H070-ERS, 2198-H003-ERS2, 2198-H008-ERS2, 2198-H015-ERS2, 2198-H025-ERS2, 2198-H040-ERS2, 2198-H070-ERS2, 2198-CAPMOD-1300 User Manual Original Instructions...
Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
Page 3: Table Of Contents
Zero-stack Tab and Cutout ........46 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 4 Motor Power Connections ........81 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 5 Interpret Status Indicators........144 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 6 Understand Integrated Safety Drive Replacement....171 Replace an Integrated Safety Drive in a GuardLogix System..171 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 7 The Effects of Current Limiting ......216 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 8 Index ............251 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 9: Preface
EtherNet/IP™ communication module or controller. If you do not have a basic understanding of Kinetix 5500 servo drives, contact your local Rockwell Automation sales representative for information on available training courses. Download Firmware, and Use the Product Compatibility and Download Center at rok.auto/pcdc...
Page 10: Additional Resources
Product specifications for Kinetix 2090 motor and interface cables. publication KNX-TD004 Kinetix Servo Drive Performance Specifications per Ecodesign Regulation Provides energy efficiency performance data for Rockwell Automation Kinetix Servo drives. (EU) 2019/1781 Technical Data, publication KNX-TD006 This data supports IE2 compliance of Kinetix Servo drives per EU 2019/1781.
Page 11 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at rok.auto/literature.
Page 12 Preface Notes: Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 13: About The Kinetix 5500
Controller Platform 1756-EN2T module EtherNet/IP network communication modules for use with ControlLogix® 5570, ControlLogix 5580, and GuardLogix 5570 1756-EN2TR module controllers. Linear, Device Level Ring (DLR), and star topology is supported. 1756-EN3TR module Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 14 Bulletin 1606 24V DC power supply for control circuitry, digital inputs, safety, and motor brake. Supply External Shunt 2097-R6 and 2097-R7 Bulletin 2097 external passive shunt resistors for when the internal shunt capability of the drive is exceeded. Resistors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 15: Drive Hardware And Input Power Configurations
Powe r S u p p l y (customer-supplied) Input AC Input Power 2198-H0x0-x-x shared-bus connection system for bus- sharing configurations. 2198-Hxxx-ERSx Drive (front view) 2097-Rx Digital Inputs Shunt Resistor to Sensors and Control String (optional component) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 16 Shunt Resistor Digital Inputs (optional component) to Sensors and Control String IMPORTANT In shared AC configurations, all drives must have the same power rating. Shared AC configurations do not support Bulletin 2198 capacitor modules. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 17: Shared Ac/Dc Configurations
Shared-bus connection system for bus-sharing configurations. 2097-Rx Digital Inputs Shunt Resistor to Sensors and Control String (optional component) IMPORTANT In shared AC/DC configurations, all drives must have the same power rating (catalog number). Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 18: Shared Dc Common-Bus Configurations
Common-bus Common-bus Leader Drive (optional component) Follower Drives IMPORTANT In shared DC common-bus configurations, the leader drive power rating must be greater than or equal to the power rating of the follower drives. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 19: Shared Ac/Dc Hybrid Configuration
Follower Drives Leader Drives IMPORTANT In shared AC/DC hybrid configuration, the converter drives must have the same power rating and must be greater than or equal to the power ratings of the inverter drives. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 20: Motor Feedback And Feedback-Only Configurations
2090-CSxM1DF/DG single motor cable, and reuse the 2090-CFBM7DF feedback cable. This increases the maximum cable length for 18 AWG and 14 AWG single cables to 50 m (164 ft). 2090-CSBM1DF-10AFxx and 2090-CSBM1DG-10xxxx (10 AWG) cables do not support this 50 m (164 ft) option. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 21: Typical Communication Configurations
Motion Encoder PanelView™ Plus EtherNet/IP Adapter Display Terminal 1734-AENTR POINT I O Module Status Network Activity Network Status Point Bus Link 1 Status Activity/ Status System Power Field Power Link 2 Activity/ Status Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 22: Ring Topology
Field EtherNet/IP Adapter Power Kinetix 5500 Servo Drive System Link 2 Activity/ Status 842E-CM Integrated Motion Encoder 2198-ABQE Encoder Output Module OUTPUT-A OUTPUT-B 1585J-M8CBJM-OM15 0.15 m (6 in.) Ethernet cable for drive-to-drive connections. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 23: Star Topology
842E-CM encoder helps eliminate the need for point-to-point wiring while letting customers use the encoder in a variety of network topologies. For more information, see the 842E-CM Integrated Motion on EtherNet/IP Product Profile, publication 842ECM-PP001. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 24: Safe Torque Off Configurations
GuardLogix 5570 Safety Controllers ControlLogix 5580 Controllers or GuardLogix 5580 Safety Controllers CompactLogix 5370 Controllers or Compact GuardLogix 5370 Safety Controllers CompactLogix 5380 or 5480 Controllers or Compact GuardLogix 5380 Safety Controllers Kinetix VP Servo Motors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 25: Integrated Safety Configurations
Powe r S u p p l y and Motor Brake Power (customer-supplied) Input AC Input Power Motion and Safety Connections to the Drive Digital Inputs to Sensors and Control String Kinetix VP Servo Motors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 26 2198-Hxxx-ERS2 Servo Drives and Motor Brake Power Ethernet (shielded) Cable (front view) (customer-supplied) Input AC Input Power Motion and Safety Connections to the Drive Digital Inputs to Sensors and Control String Kinetix VP Servo Motors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 27: Catalog Number Explanation
AC and control power sharing AC and control power T-connectors 2198-H070-DP-T DC and control power sharing DC and control power T-connectors 2198-H070-ADP-T AC, DC, and control power sharing AC, DC, and control power T-connectors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 28: Agency Compliance
(grounded to the enclosure) outside of the enclosure. Separate signal and power cables. • Separate input power wiring from control wiring and motor cables. Appendix A on page 179 for input power wiring and drive/motor interconnect diagrams. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 29: System Design Guidelines
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 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 30: Ac Line Filter Selection
3 Axes 4 Axes 5 Axes 6 Axes 7 Axes 8 Axes 2198-H003-ERSx 240/480V 2198-DBR20-F 2198-H008-ERSx 240/480V 2198-DBR20-F 2198-H015-ERSx 240/480V 2198-DBR20-F — 2198-H025-ERSx 240/480V 2198-DBR40-F — 2198-H040-ERSx 240/480V 2198-DBR40-F 2198-DBR90-F — 2198-H070-ERSx 240/480V 2198-DBR90-F — Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 31: Transformer Selection
KTK-R-15 140U-D6D3-C12 and 140UT-D7D3-C12 140U-D6D3-C12 and 140UT-D7D3-C12 2198-H025-ERSx 240/480V Three-phase KTK-R-20 140U-D6D3-C20 and 140UT-D7D3-C20 140U-D6D3-C20 and 140UT-D7D3-C20 2198-H040-ERSx 240/480V Three-phase KTK-R-25 140U-D6D3-C25 and 140UT-D7D3-C25 140U-D6D3-C25 and 140UT-D7D3-C25 2198-H070-ERSx 240/480V Three-phase LPJ-35SP 140G-G6C3-C40 140G-G6C3-C40 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 32 140U-D6D3-C15 and 140UT-D7D3-C15 140U-D6D3-C15 and 140U-D6D3-C20 and 2198-H015-ERSx 240/480V — — 140UT-D7D3-C15 140UT-D7D3-C20 140U-D6D3-C25 and 140U-D6D3-C30 and 2198-H025-ERSx 240/480V — — 140UT-D7D3-C25 140UT-D7D3-C30 2198-H040-ERSx 240/480V 140G-G6C3-C40 140G-G6C3-C50 — 2198-H070-ERSx 240/480V — 140G-G6C3-C60 — Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 33 140U-D6D3-C15 and 140UT-D7D3-C15 2198-H008-ERSx 140UT-D7D3- 140U-D6D3-C20 140U-D6D3-C15 240/480V – – 2198-H015-ERSx 140UT-D7D3- 140UT-D7D3-C15 140U-D6D3-C20 140U-D6D3-C30 240/480V — — 2198-H025-ERSx 140UT-D7D3- 140UT-D7D3- 140U-D6D3-C30 240/480V — 140G-G6C3-C50 — 2198-H040-ERSx 140UT-D7D3- 240/480V — 140G-G6C3-C50 — 2198-H070-ERSx Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 34: 24V Control Power Evaluation
Select a contactor with a voltage rating and SCCR rating appropriate for your drive installation • Do not cycle power to the contactor more than once per minute to help prevent damage to the Kinetix 5500 drive Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 35: Passive Shunt Considerations
How the Bulletin 2097-Rx shunts connect to Kinetix 5500 drives is explained in External Passive-shunt Resistor Connections on page 97 and illustrated with interconnect diagrams in Shunt Resistor Wiring Example on page 184. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 36: Enclosure Selection
Contact your cabinet manufacturer for options available to cool your cabinet. Table 17 - Power Dissipation Specifications Usage as Percentage of Rated Power Output Kinetix 5500 Drive Frame (watts) Cat. No. Size 100% 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 37: Minimum Clearance Requirements
In multi-axis shared-bus configurations, drives must be spaced by aligning the zero-stack tab and cutout. Figure 15 - Multi-axis Shared-bus Clearance Requirements Shared-bus connection system for bus-sharing configurations is not shown for clarity. Zero-stack Tab and Cutout Aligned Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 38: Electrical Noise Reduction
Excessive high- frequency energy can affect the operation of other microprocessor-controlled equipment. Figure 16 on page 39 shows recommended bonding practices for painted panels, enclosures, and mounting brackets. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 39 Flat Washer Star Washer Flat Washer If the mounting bracket is coated with a non-conductive material (anodized or Star Washer painted), scrape the material around the mounting hole. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 40: Bonding Multiple Subpanels
25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) Cabinet ground bus that is bonded to the subpanel. Wire Braid 25.4 mm (1.0 in.) by Paint removed 6.35 mm (0.25 in.) from cabinet. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 41: Establishing Noise Zones
(1) When space to the right of the drive does not permit 150 mm (6.0 in.) separation, 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 the 2198-H2DCK converter kit is used, feedback cable routes in the clean wireway. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 42: Cable Categories For Kinetix 5500 Systems
IMPORTANT CE and UK test certification applies to only the AC line filter used with a single drive or the line filter used in multi-axis drive configurations. Sharing a line filter with more than one multi-axis drive configuration can perform satisfactorily, but the customer takes legal responsibility. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 43 AC Line Filter (can be required for Ethernet and I/O Cables CE and UK) Module Status Single Motor Cable Route single motor cables Route registration and communication in shielded cable. signals in shielded cables. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 44 AC Line Filter (can be required for Ethernet and I/O Cables CE and UK) Module Status Single Motor Cable Route single motor cables Route registration and communication in shielded cable. signals in shielded cables. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 45 Because the system is of the open type construction, be careful to keep metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry and result in damage to the components. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 46: Determine Mounting Order
Figure 22 - Shared-bus Connection System Example Shared-bus Connection System 2198-Hxxx-ERSx Drive System (required in shared-bus (front view) 2198-CAPMOD-1300 Capacitor Module Frame 1 Drives Frame 2 Drives Frame 3 Drive Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 47: Shared-Bus Connection System
The three components assemble from left to right across the drive system. 1. Attach wiring to input wiring connectors. 2. Insert input wiring connectors and T-connectors into the appropriate drive connectors. 3. Insert busbars to connect between wiring connectors and T-connectors. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 48: Single-Axis Configurations
The maximum number of drives in Shared AC bus power-sharing groups cannot exceed 5. • The maximum number of drives in any other bus power-sharing group cannot exceed 8. For a multi-axis example configuration, refer to Shared AC/DC Hybrid Configuration on page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 49: Drill-Hole Patterns
Number of Capacitor Modules Connected, Max 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx — 2198-H070-ERSx (1) Catalog number 2198-H003-ERS and any drive in standalone single-phase operation is not compatible with the Kinetix 5500 capacitor module. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 50 Frame 2 Standalone Drive Standalone Drive Standalone Drive ØM4 (#8-32) 243.84 273.70 193.68 34.00 4.51 5.00 Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding. 52.50 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 51 This hole pattern applies when transitioning 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 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 52 Axis 1 Axis 2 (frame 2) (frame 1) ØM4 (#8-32) 243.83 243.84 5.00 57.00 Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding. 50.15 52.50 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 53 This hole pattern applies when transitioning 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 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 54 Axis 1 Axis 2 (frame 3) (frame 1) ØM4 (#8-32) 273.70 272.23 34.00 97.20 Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding. 78.55 52.50 92.70 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 55 Axis 1 Axis 2 (frame 3) (frame 2) ØM4 (#8-32) 273.70 272.24 34.00 100.00 Hole spacing is measured in millimeters and not converted to inches to avoid errors due to rounding. 28.40 52.50 95.00 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 56: Mount Your Kinetix 5500 Drive
Zero-stack mounting is required based on configuration, refer to the Zero-stack Tab and Cutout Example page 6. Tighten all mounting fasteners. Apply 2.0 N•m (17.7 lb•in) maximum torque to each fastener. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 57 This chapter illustrates drive connectors and indicators, including connector pinouts, and provides descriptions for Kinetix® 5500 drive features. Topic Page Kinetix 5500 Connector Data Understand Control Signal Specifications Feedback Specifications Safe Torque Off Safety Features Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 58: Connector Data And Feature Descriptions
(1) Protective knock-out covers the 2198-H2DCK Hiperface-to-DSL feedback converter kit mounting hole. Remove knock-out for use with the converter kit. (2) DC bus connector ships with protective knock-out cover that can be removed for use in shared-bus configurations. (3) Protective knock-out cover is removed on 2198-Hxxx-ERS (hardwired STO) drives. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 59: Module Status Connector Pinout
For the hardwired Safe Torque Off (STO) connector pinouts, feature descriptions, and wiring information, see Chapter 9 beginning on page 157. Input Power Connector Pinouts Table 22 - Mains Input Power Connector IPD Pin Description Signal Chassis ground Three-phase input power Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 60: Dc Bus And Shunt Resistor Connector Pinouts
Negative overtravel Home/Registration 1 (1) Studio 5000 Logix Designer,® version 27 or later, is required to change from the default configuration. Figure 32 - Pin Orientation for Digital Inputs (IOD) Connector Pin 1 SHLD Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 61: Ethernet Communication Connector Pinout
Cable shield and grounding plate (internal to 2198-KITCON-DSL connector kit) termination point SHIELD SHIELD Cable shield and shield clamp (internal to 2198-H2DCK converter kit) termination point Figure 33 - Pin Orientation for Motor Feedback (MF) Connector Pin 1 Pin 2 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 62: Understand Control Signal Specifications
0 (delay compensated) Registration accuracy ±3 µs Registration repeatability 700 ns Windowed registration invalid-to-valid event delay 125 µs, min Figure 34 - Digital Input Circuitry IOD-1 or IOD-3 INPUT 24V DC Kinetix 5500 Drive IOD-2 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 63: Ethernet Communication Specifications
Logix Designer application (refer to Configure SPM Motor Closed-loop Control Axis Properties beginning on page 127). An active signal releases the motor brake. Turn-on and turn-off delays are specified by the MechanicalBrakeEngageDelay and MechanicalBrakeReleaseDelay settings. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 64: Control Power
Input voltage 21.6…26.4V DC Control power AC input current 400 mA 800 mA 1.3 A Nom @ 24V DC 2.0 A 3.0 A 3.0 A Inrush, max (1) Plus BC connector (MBRK+) current. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 65: Feedback Specifications
LDAT-Sxxxxxx-xDx — 960 (37.8) Figure 36 - Absolute Position Limits (measured in turns) 4096 Turns 2048 Turns 512 Turns -2048 -1024 +128 +512 +1024 +2048 -512 -256 -128 +256 Position at Power Down Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 66: Safe Torque Off Safety Features
EtherNet/IP™ network and the 2198-Hxxx-ERS2 servo drives execute the command. Chapter 10 beginning on page 165. for integrated safety drive specifications, configuring motion and safety connections, motion direct commands, and the STO bypass feature. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 67: Connect The Kinetix 5500 Drive System
Wiring Requirements Wiring Guidelines Wire the Power Connectors Wire the Digital Input Connectors Wire Kinetix VP Motors and Actuators Wire Other Motors and Actuators Capacitor Module Connections External Passive-shunt Resistor Connections Ethernet Cable Connections Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 68: Basic Wiring Requirements
Electrical Noise Reduction on page 38 for examples of routing high and low voltage cables in wireways. Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001, for more information. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 69: Determine The Input Power Configuration
2198-DBRxx-F line filter, the AC ground jumper is installed and the DC ground jumper is installed. The Kinetix 5500 drive has factory-installed ground screws for grounded (wye) power distribution. Power Wiring Examples beginning on page 180 for input power interconnect diagrams. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 70 (1) The AC ground jumper is removed and the DC ground jumper is removed. See Figure 42 page 73 for access to ground screws. Power Wiring Examples beginning on page 180 for input power interconnect diagrams. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 71: Ungrounded Power Configurations
Remove the Ground Screws in Select Power Configurations page 73 for more information. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 72: Ground Screw Settings
(1) Removing the AC ground screw to minimize leakage current in single-phase operation can affect EMC performance. ATTENTION: To help prevent damage to the servo drive, you must set the ground screws according to the example diagrams that are summarized in Table Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 73: Remove The Ground Screws In Select Power Configurations
ATTENTION: Risk of equipment damage exists. The drive ground configuration must be accurately determined. Leave the ground screws installed for grounded power configurations (default). Remove the screws for ungrounded, corner-grounded, and impedance-grounded power configurations. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 74: Ground The Drive System
Braided ground strap (customer supplied) Ground grid or power distribution ground Bonded cabinet ground bus (customer supplied) See the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001, for more information. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 75: Ground Multiple Subpanels
Figure 44 - Subpanels Connected to a Single Ground Point Follow NEC and applicable local codes. Bonded Ground Bus Ground Grid or Power Distribution Ground High-frequency (HF) bonding is not illustrated. For HF bonding information, Bonding Multiple Subpanels on page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 76: Wiring Requirements
(5) These signals and the Safe Torque Off (STO) connector apply to only the 2198-Hxxx-ERS drives. (6) This connector uses spring tension to hold wires in place. (7) This signal has dual-functionality. You can use IN1 (IOD-1) as registration or Home input. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 77: Wiring Guidelines
4. Tighten the connector screws. 5. Gently pull on each wire to make sure it does not come out of its terminal; reinsert and tighten any loose wires. 6. Insert the connector plug into the drive connector. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 78: Wire The Power Connectors
Recommended Wire Size Input Current, Max Strip Length Torque Value Drive Cat. No. CP Pin Signal A rms mm (in.) N•m (lb•in) (AWG) CP-1 24V+ 2198-Hxxx-ERSx 1.7…1.8 10 (6) 11.0 (0.43) 2198-CAPMOD-1300 (15.0…15.9) CP-2 24V- Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 79: Wire The Input Power Connector
Kinetix 5500 Drive Input Current, Max Strip Length Torque Value Signal Cat. No. A rms mm (in.) N•m (lb•in) (AWG) 2198-H003-ERSx 2198-H008-ERSx 13.3…3.3 2198-H015-ERSx 1.7…1.8 (6…12) 11.0 (0.43) 2198-H025-ERSx (15.0…15.9) 2198-H040-ERSx 2198-H070-ERSx 13.3 (6) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 80: Wire The Digital Input Connectors
Kinetix 5500 drives and Kinetix VP motors, you cannot build your own cables or use third-party cables. See the Kinetix Rotary and Linear Motion Cable Specifications Technical Data, publication KNX-TD004, for cable specifications. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 81: Maximum Cable Lengths
WARNING: Make sure that 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 equipment. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 82: Motor Brake Connections
Drive Cat. No. Wire Size Wire Color mm (in.) N•m (lb•in) (AWG) BC-1 MBRK+/Black 0.22…0.25 2198-Hxxx-ERSx — 7.0 (0.28) (1.9…2.2) BC-2 MBRK-/White (1) Motor brake wires are part of the 2090-CSBM1DF/DG motor cable. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 83: Motor Feedback Connections
1 drives) route around the shield clamp (as shown in Figure 52). The feedback bundle in2090-CSxM1DG-18, 2090-CSxM1xx-14, and 2090-CSBM1xx-10 motor cables (typically used with frame 2 and 3 drives) route with the power and brake wires inside the cable shield. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 84: Apply The Single Motor-Cable Shield Clamp
(loosen, do not remove) Feedback cable routed 2090-CSxM1DF-18Axxx Single around the shield clamp. Motor Cable When the drive/motor combination calls for 18 AWG cable, the feedback cable routes around the motor cable shield clamp. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 85 3. Tighten each screw a few turns at a time until the maximum torque value of 2.0 N•m (17.7 lb•in) is achieved. 4. Repeat step 1 through step 3 for each drive in multi-axis configurations. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 86: Wire Other Motors And Actuators
4. Click the Add-On Profile icon and follow the download instructions. 5. Extract the AOP zip file and run Setup. To access AOP downloads by using the Product Compatibility Download Center (PCDC), see Install the Kinetix 5500 Add-On Profile on page 106. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 87: Motor Power And Brake Connections
Power-only, bayonet 2090-XXTPMP-xxSxx Table 49 - Induction Motor Power Cable Specifications Cable Manufacturer Cable Series Voltage Rating Temperature Rating Belden 29500…29507 Lapp Group ÖLFEX VFD XL 600V 90 °C (194 °F) VFD XLPE TR Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 88: Motor Power/Brake Cable Series Change
Dimensions are in mm (in.) 234 (9.20) 15.0 (0.59) 71 (2.80) 12.7 (0.50) Power Conductors 5.0 (0.20) Kinetix MP Motors and Actuators Brake Overall Cable Shield Conductors Heat Shrink 8.0 (0.31) 5.0 (0.20) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 89: Maximum Cable Lengths
For frame 3 drives, 2090-CPBM7DF (14 AWG) cables, and 12 AWG and 10 AWG (series A) cables, the overall length of the cable preparation area must be increased for the motor power conductors to reach the MP connector and also provide a proper service loop. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 90 (1) The overall shield braid covering the brake conductors can be removed. Figure 56 and on page 92 for a typical installation example. For strip lengths and torque values, refer to Table 43 page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 91: Apply The Motor Power/Brake Shield Clamp
When the clamp screws are tight, 2.0 N•m (17.7 lb•in), the result must be a high-frequency bond between the cable shield and the drive chassis. Figure 56 page 92 for a cable-clamp attachment illustration. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 92: Motor Feedback Connections
All current and legacy feedback cables that are listed below are compatible with the 2198-H2DCK (series B or later) converter kit. IMPORTANT Only Allen-Bradley motors and actuators with single-turn or multi-turn high-resolution absolute encoders are compatible. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 93 (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. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 94: Motor Feedback Cable Preparation
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 relief. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 95 3. Tighten screws, torque (catalog number 2198-H070-ERSx) 0.3 N•m (2.6 lb•in). Exposed Shield Aligned See Hiperface to DSL Feedback Converter Kit Installation Instructions, in the Cable Channel Shield Clamp publication 2198-IN006, for converter kit specifications. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 96: Capacitor Module Connections
(20…14) (1.9…2.2) DC-bus power Busbar — — — (1) DC bus connections are always made from one drive module to another over the shared-bus connection system. These terminals do not receive discrete wires. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 97: External Passive-Shunt Resistor Connections
RC-2 0.5…4.0 0.5…0.6 2198-H015-ERSx 8.0 (0.31) (20…12) (4.4…5.3) 2198-H025-ERSx RC-1 2198-H040-ERSx RC-2 2198-H070-ERSx IMPORTANT You must disconnect the internal shunt wires at the RC connector before connecting the Bulletin 2097 shunt resistor wires. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 98: Ethernet Cable Connections
IMPORTANT When using an external Ethernet switch for routing traffic between the controller and the drive, switches with IEEE-1588 time synchronization capabilities (boundary or transparent clock) must be used to make sure that switch delays are compensated. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 99: Configure And Start The Kinetix 5500 Drive System
Test and Tune the Axes 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 your motion control application. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 100: Understand The Kinetix 5500 Display
Press to return to the Home screen. Press to display the fault help (possible solutions in troubleshooting tables). (1) For Kinetix 5500 fault code descriptions and possible solutions, see Kinetix 5500 Servo Drive Fault Codes Reference Data, publication 2198-RD005. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 101: Menu Screens
The possible solution as reported in the Kinetix 5500 Fault Codes.xlsx file. • Reduce duty-cycle of commanded motion (1) For Kinetix 5500 fault code descriptions and possible solutions, see Kinetix 5500 Servo Drive Fault Codes Reference Data, publication 2198-RD005. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 102: Setup Screens
IMPORTANT You must cycle control power to make network configuration changes persistent. In this example, the IP address was changed. The change takes effect and the asterisk disappears after control power is cycled. Display configuration changes take effect immediately. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 103 (2) The DC bus voltage is one of several cyclic data attributes. You can select any of the Cyclic Data Select attributes to be displayed on the Home screen. (3) The Safety menu applies to only 2198-Hxxx-ERS2 drives. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 104: Startup Sequence
The drive is faulted due to an existing or past fault condition. START INHIBITED The drive has an active condition that inhibits it from being enabled. SHUTDOWN The drive has been shut down. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 105: Configure The Drive
IMPORTANT To configure these additional drive features with your Kinetix 5500 servo drive, you must have drive firmware 4.001 or later. See Table 58 to determine if you must install the Kinetix 5500/5700 Add-on Profile. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 106: Install The Kinetix 5500 Add-On Profile
The Compatibility & Downloads webpage appears. 2. Click Download. 3. Enter Kinetix 5500 in the Search PCDC window. 4. Click the appropriate firmware revision and follow prompts to download. 5. Extract the AOP zip file and run Setup. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 107: Configure The Logix 5000 Controller
2. From the Create menu, choose New Project. The New Project dialog box appears. IMPORTANT If you are configuring a 2198-Hxxx-ERS2 (integrated) servo drive in a safety application, you must use a GuardLogix safety controller. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 108 The new controller appears in the Controller Organizer under the I/O Configuration folder. Controller Organizer with CompactLogix 5380 controller. Controller Organizer with GuardLogix 5580 controller. 6. In this example, a GuardLogix 5580 controller with 1756-EN2T communication module is used. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 109 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. 10. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 110: Configure The Kinetix 5500 Drive
Enter 2198 here to further limit your search. 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. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 111 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 Configuration page 116 to continue with your drive configuration. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 112 In this example, the Private Network address is selected. c. Enter the address of your 2198-Hxxx-ERS2 servo drive. In this example, the last octet of the address is 2. d. Under Module Definition click Change. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 113 Controller Organizer and choose Properties. The Module Properties dialog box appears. 8. Click the Drive Safety tab. 9. From the Restart Type pull-down menu, choose Manual or Automatic depending on your specific application. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 114 If any differences are detected, the connection between the GuardLogix controller and the 2198-Hxxx-ERS2 drive is lost, and the yellow yield icon appears in the controller project tree after you download the program. 12. Click Advanced. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 115 13. Click OK. For more information about the Advanced Connection Reaction Time Limit Configuration, refer to the GuardLogix 5570 Controllers User Manual, publication 1756-UM022. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 116 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. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 117 Table 30 on page 62 Table 31 on page 10. Click Apply. 11. Click the Power tab. IMPORTANT Single-phase operation is possible only when Module Properties > Power tab > Bus Configuration is configured as Standalone. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 118 (5) See the Kinetix 5700, 5500, 5300, and 5100 Servo Drives Specifications Technical Data, publication KNX-TD003, for more information on the Bulletin 2097 external shunt resistors. 13. Click OK. 14. Repeat step 1 through step 13 for each 2198-Hxxx-ERSx servo drive. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 119: Configure The Motion Group
5. Click the Axis Assignment tab and move your axes (created earlier) from Unassigned to Assigned. 6. Click the Attribute tab and edit the default values as appropriate for your application. 7. Click OK. Your axis moves to the new motion group. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 120: Configure Feedback-Only Axis Properties
The Master Feedback Device Specification appears. 8. From the Type pull-down menu, choose a feedback device type. 9. Review other categories in the Controller Organizer and make changes as needed for your application. 10. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 121: Configure Induction-Motor Frequency-Control Axis Properties
5. From the Module pull-down menu, choose the drive to associate with your Frequency Control (induction motor) axis. The Module Type and Power Structure fields populate with the chosen drive catalog number. 6. Click Apply. 7. Select the Motor category. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 122: Basic Volts/Hertz Method
3. From the Frequency Control Method pull-down menu, select Basic Volts/ Hertz. 4. Enter the Basic Volts/Hertz attribute values appropriate for your application. Default values are shown. 5. Click Apply. 6. Select the Parameter List category. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 123 8. Set the FluxUp, SkipSpeed, VelocityDroop, and CurrentVectorLimit attributes appropriate for your application. See the corresponding section in Appendix D for information and configuration examples regarding all of these topics. 9. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 124: Sensorless Vector Method
9. Set the FluxUp, SkipSpeed, VelocityDroop, MaximumFrequency, MaximumVoltage, and CurrentVectorLimit attributes appropriate for your application. See the corresponding section in Appendix D for information and configuration examples regarding all of these topics. 10. Click Apply. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 125 In this example, Calculate Model is chosen. See Motor Tests and Autotune Procedure on page 228 for information about each of the tests. 15. Click Start. 16. Click Accept Test Results. 17. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 126: Fan/Pump Volts/Hertz Method
8. Set the FluxUp, SkipSpeed, VelocityDroop, RunBoost, MaximumFrequency, MaximumVoltage, and CurrentVectorLimit attributes appropriate for your application. See the corresponding section in Appendix D for information and configuration examples regarding all of these topics. 9. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 127: Configure Spm Motor Closed-Loop Control Axis Properties
IMPORTANT Unprogrammed Smart feedback devices (Hiperface Sin/Cos and Hiperface DSL) are not supported. Unprogrammed as load or feedback- only feedback types are supported. Contact your local distributor or Rockwell Automation sales representative for support options. Follow these steps to configure surface permanent-magnet (SPM) motor closed-loop axis properties.
Page 128 To verify the motor catalog number, refer to the motor nameplate. 10. To close the Change Catalog Number dialog box, click OK. 11. Click Apply. Motor data specific to your motor appears in the Nameplate / Datasheet - Phase to Phase parameters field. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 129 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. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 130 From this dialog box, you can change the action for exceptions (faults). Logix 5000 Controller and Drive Behavior on page 149 for more information. In the Logix Designer application, version 32.00 and later, Disable replaced StopDrive as the default Action. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 131: Download The Program
1 through step 19 for each servo motor axis. Download the Program After completing the Logix Designer application and saving the file, you must download your program to the Logix 5000 processor. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 132: Apply Power To The Kinetix 5500 Drive
230V AC to 460V AC or from 460V AC to 230V AC, the bus voltage must bleed down below 50V DC before the new configured input voltage is applied. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 133: Understand Bus-Sharing Group Configuration
Figure 64 - Standalone Bus Configuration Bus-sharing Group Example In this example, 12 axes are needed to support the motion application. All 12 axes are configured in the same Motion group in the Logix Designer application. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 134: Configure Bus-Sharing Groups
Shared DC. ATTENTION: To avoid damage to equipment, all modules that are physically connected to the same shared-bus connection system must be part of the same Bus Sharing Group in the Logix Designer application. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 135 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 68 - Group 2 Leader Drive Configuration Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 136: Test And Tune The Axes
2. In your Motion Group folder, right-click an axis and choose Properties. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 137 6. Click Start. The Logix Designer - Motor and Feedback Test dialog box appears. The Test State is Executing. TESTING appears on the drive LCD display. Drive LCD Display TESTING 192.168.1.1 DC BUS: 218.3V Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 138: Tune The Axes
2. Click the Autotune tab in the Axis Properties dialog box. a. From the pull-down menus for Application Type, Loop Response, and Load Coupling, choose Custom, Medium, and Rigid settings, respectively. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 139 Choose Load Observer Only if the axis is configured for Velocity Loop control. Load Observer is not available for Torque Loop control. b. Click Apply and click Yes to update all dependent attributes. The Load Observer Bandwidth and other gains are set automatically. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 140 ATTENTION: To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then reattach the load and perform the tuning procedure again to provide an accurate operational response. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 141 Test State changes from Executing to Success. Tuned values populate the Loop and Load parameter tables. Actual bandwidth values (Hz) depend on your application and can require adjustment once motor and load are connected. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 142 Adjust motor velocity. c. See the controller user manual for more information. d. Return to step 6 and run the test again. 11. Repeat Test and Tune the Axes for each axis. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 143: Troubleshoot The Kinetix 5500 Drive System
ATTENTION: Provide an earth ground for test equipment (oscilloscope) used in troubleshooting. Failure to ground the test equipment could result in personal injury. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 144: Interpret Status Indicators
If the fault persists after attempting to troubleshoot the system, contact your Rockwell Automation sales representative for further assistance. Display Interface The LCD display provides fault messages and troubleshooting...
Page 145: Fault Codes
FLT S08 – MTR OVERLOAD UL. Fault Codes This manual links to Kinetix 5500 Servo Drive Fault Codes Reference Data, publication 2198-RD005, for fault codes. Download the spreadsheet now for offline access. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 146: Kinetix 5500 Drive Status Indicators
10 Mbit Steady On 100 Mbit Link Speed Status Indicators Table 64 - Ethernet Link/Activity Status Indicator Condition Status Link/Activity Steady Off No link Status Indicators Steady On Link established Blinking Network activity Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 147: Kinetix 5500 Capacitor Module Status Indicators
Verify limit settings and correct them, as necessary. Velocity Limit limits are incorrect. Verify limit settings and correct them, as necessary. The motor is operating in the field-weakening range of operation. Reduce the commanded acceleration or deceleration. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 148 Erratic operation - Motor locks into position, runs without Motor power phases U and V, U and W, or V and W reversed. Check and correct motor power wiring. control or with reduced torque. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 149: Logix 5000 Controller And Drive Behavior
Shutdown Reset is required to restore the drive to operation. For Kinetix 5500 drives, only selected exceptions are configurable. In the drive behavior tables, the controlling attribute is given for programmable fault actions. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 150 In the Logix Designer application, version 32.00 and later, Disable replaced StopDrive as the default Action. Figure 71 - Logix Designer Axis Properties - Actions Category This dialog box applies to Kinetix 5500 (EtherNet/IP network) servo drives. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 151 FLT S55 – VEL ERROR Overtorque Limit Fault — Decel/Hold FLT S56 – OVERTORQUE LIMIT Undertorque Limit Fault — Decel/Hold FLT S57 – UNDERTORQUE LIMIT (1) Does not apply to induction motors in frequency control mode. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 152 — — — Decel/Disable Fault NODE FLT 07 – CLOCK SYNC Clock Sync Fault — — — Disable/Coast NODE FLT 09 – DUPLICATE IP Duplicate IP Address Fault — — — Disable/Coast ADDRESS Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 153: Before You Begin
You also need these tools available before you begin removal and replacement procedures: • Screwdrivers (to loosen/remove screws) • Voltmeter (to make sure that no voltage exists on drive connectors) • Non-conductive probe for removing DC bus T-connectors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 154: Remove And Replace Kinetix 5500 Servo Drives
Retention Screw (loosen, do not remove) Motor Cable 6. Remove the single motor cable from the cable shield clamp. 7. Remove the ground screw and braided ground strap. Ground the System Subpanel on page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 155: Remove The Servo Drive
Mount Your Kinetix 5500 Drive on page • Torque mounting, shield clamp, and ground screws to 2.0 N•m (17.7 lb•in), max • Reconnect the feedback connector kit and torque the mounting screws to 0.4 N•m (3.5 lb•in), max Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 156: Start And Configure The Drive
Integrated Safety Drive in a GuardLogix System on page 171 properly set the safety network number for the new drive. 3. Download the Logix Designer application to the controller. 4. Verify the drive/system is working properly. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 157: Certification
ISO 13849-1, Performance Level d (PLd) and Category 3, SIL CL 2 per IEC 61508, IEC 61800-5-2, and IEC 62061, in which removing the motion producing power is considered to be the safe state. For product certifications currently available from Rockwell Automation, go to website rok.auto/certifications. Important Safety Considerations You, the system user, are responsible for the following: •...
Page 158: Category 3 Requirements According To Iso 13849-1
See the ISO 13849-1, IEC 61508, and IEC 62061 standards for complete information on requirements for PL and SIL determination. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 159: Description Of Operation
If event 4 is outside of the 100 ms interval, but within the 1 second interval after event 3, then the GuardStop RequestStatus bit sets back to 0 after the 1 second interval following event 3 (not immediately following event 4). Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 160: Fault Codes
IMPORTANT The GuardStopInputFault can be reset only if both inputs are in the OFF- state for more than 1 second. After the fault reset requirement is satisfied, an MAFR command in the Logix Designer application must be issued to reset the GuardStopInputFault. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 161: Probability Of Dangerous Failure Per Hour
Safety bypass plus signal. Connect to both safety inputs to disable the STO function. Safety bypass minus signal. Connect to safety common to disable the STO function. STO input 1 (SS_IN_CH0). STO input common (SCOM). STO input 2 (SS_IN_CH1). Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 162: Wire The Safe Torque Off Circuit
Recommended Wire Size Strip Length Torque Value mm (in.) N•m (lb•in) (AWG) Signal STO-1 STO-2 0.2…1.5 STO-3 10 (0.39) — (24…16) STO-4 STO-5 (1) This connector uses spring tension to hold the wires in place. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 163: Safe Torque Off Feature
To bypass the safety function, wire these signals as shown in Figure With the jumper wires installed, the Safe Torque Off feature is not used. Figure 77 - Safe Torque Off Bypass Wiring Pin 1 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 164: Cascade The Safe Torque-Off Signal
(1) The maximum number of drives cascaded with Safe Torque Off wiring is 50. For additional information regarding Allen-Bradley® safety products, including safety relays, light curtain, and gate interlock applications, refer to https://www.rockwellautomation.com/en-us/products/hardware/allen- bradley/safety-products.html. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 165: Certification
ISO 13849-1, Performance Level e (PLe) and Category 3, SIL CL 3 per IEC 61508, IEC 61800-5-2, and IEC 62061, in which removing the motion producing power is considered to be the safe state. For product certifications currently available from Rockwell Automation, go to website rok.auto/certifications. Important Safety Considerations You, the system user, are responsible for the following: •...
Page 166: Safety Application Requirements
IMPORTANT If there is a malfunction, the most likely stop category is Stop Category 0. When designing the machine application, timing and distance must be considered for a coast-to-stop. For more information regarding stop categories, refer to IEC 60204-1. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 167: Performance Level (Pl) And Safety Integrity Level (Sil)
IMPORTANT 2198-Hxxx-ERS2 servo drives enter the STO state if any STO function fault is detected. Figure 79 for an understanding of the 2198-Hxxx-ERS2 STO-state manual restart functionality. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 168: Fault Codes
High-demand mode and that the safety function is requested at least once every three months. Table 76 - PFH for 20-year Proof Test Interval Attribute Value PFH (1e-9) 1.54 Proof test (years) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 169: Safe Torque Off Feature
2198-Hxxx-ERS2 servo drive at least once, you can restore the drive to the out- of-box state. 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 that you created and choose Properties. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 170 IMPORTANT If power to the drive is not cycled after step 5, the drive does not transition to the out-of-box state and maintains STO function. IMPORTANT When the drive returns to the out-of-box state, STO safety integrity is lost. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 171: Understand Integrated Safety Drive Replacement
Two options for safety drive replacement are available on the Safety tab of the Controller Properties dialog box in the Logix Designer application: • Configure Only When No Safety Signature Exists • Configure Always Figure 80 - Safety Drive Replacement Options Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 172: Configure Only When No Safety Signature Exists
GuardLogix user manual appropriate for your Logix 5000® controller: • GuardLogix 5570 Controllers User Manual, publication 1756-UM022 • Compact GuardLogix 5370 Controllers User Manual, publication 1769-UM022. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 173: Motion Direct Commands In Motion Control Systems
ATTENTION: It is your responsibility to maintain machine safety integrity while executing motion direct commands. One alternative is to provide ladder logic for Machine Maintenance mode that leaves the controller in Run mode with safety functions executing. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 174: Logix Designer Application Warning Messages
(torque not permitted). Safety state = Not Running, Axis state = Start Inhibited, as shown in Figure 82). Figure 82 - Safety State Indications After Controller Transitions to Program Mode Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 175 Stopped/Running, Persistent Warning = Safe Torque Off Bypassed. IMPORTANT Switch the controller to Run mode to exit Motion Direct Command mode with STO function bypassed. Figure 84 - Safety State Indications After Controller Transitions to Program Mode (MDC executing) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 176: Torque Permitted In A Multi-Workstation Environment
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 86 - Axis and Safe State Indications on the Hookup Services Dialog Box Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 177 Kinetix 5500 Safe Torque Off - Integrated Safety Figure 87 - Axis and Safe State Indications on Motion Direct Commands Dialog Box Figure 88 - Axis and Safe State Indications on the Motion Console Dialog Box Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 178: Functional Safety Considerations
Bit 0: Torque disabled Drv:SI.TorqueDisabled Safety input 0X1A0 Bit 6: Safety fault Drv:SI.SafetyFault assembly Bit 7: Reset required Drv:SI.ResetRequired Bit 0: Safe Torque Off output Drv:SO.SafeTorqueOff Safety output 0X180 assembly Bit 7: Reset request Drv:SO.Reset Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 179: Interconnect Diagrams
Brake connector pins are labeled plus (+) and minus (-) or F and G respectively. Power connector pins are labeled U, V, W, and (GND) or A, B, C, and respectively. Kinetix LDAT linear thrusters do not have a brake option, so only the 2090-CPWM7DF-xxAAxx or 2090-CPWM7DF-xxAFxx motor power cables apply. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 180: Power Wiring Examples
(MF) Connector Shunt (refer to Figure DATA -/EPWR- (RC) Connector Internal Shunt Note 8 Registration and Digital Input Home Input (IOD) Connector Connections * Indicates User Supplied Component SHLD Ground Screws Note 9 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 181 RELAY+ Three-phase Input Note 3 Notes 1, 2 Circuit Protection * Note 2 DC Bus (DC) Connectors 2198-H0x0-ADP-IN 2198-H0x0-DP-T * Indicates User Supplied Component Busbar Connectors Busbar Connectors Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 182: Bus-Sharing Wiring Examples
AC Line Filter Three-phase Input Note 3 Notes 1, 2 Circuit Protection * Note 2 DC Bus (DC) Connectors 2198-H0x0-ADP-IN 2198-H0x0-ADP-T 2198-H0x0-ADP-T Busbar Connectors Busbar Connectors Busbar Connectors * Indicates User Supplied Component Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 183 AC Line Filter Three-phase Input Note 3 Notes 1, 2 Circuit Protection * Note 2 DC Bus (DC) Connectors 2198-H0x0-ADP-IN 2198-H0x0-ADP-T 2198-H0x0-DP-T Busbar Connectors Busbar Connectors Busbar Connectors * Indicates User Supplied Component Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 184: Shunt Resistor Wiring Example
Figure 96 - Shunt Resistor Wiring Example 2198-Hxxx-ERSx 2097-Rx Kinetix 5500 Drive Shunt Resistor Shunt (RC) Connector Internal Shunt See the Kinetix 300 Shunt Resistor Installation Instructions, publication 2097- IN002, for shunt resistor installation instructions. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 185: Kinetix 5500 Servo Drive And Rotary Motor Wiring Examples
Mounting Screws (2) Cover 2198-KITCON-DSL Feedback Connector Kit Clamp Screws (2) Exposed Shield Connector Plug See Kinetix 5500 Feedback Connector Kit Installation Instructions, publication Grounding Plate Feedback Cable 2198-IN002, for connector kit (EPWR+, EPWR-) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 186 Feedback Connector Power Connector Hiperface-to-DSL Feedback Converter Kit Clamp Screws (2) See Hiperface to DSL Feedback Converter Kit Installation Instructions, Exposed shield secured Cable Clamp publication 2198-IN006, for converter kit specifications. under clamp. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 187: Kinetix 5500 Drive And Linear Actuator Wiring Examples
Kinetix 5500 servo drives. 2090-CSxM1DG cables have flying leads that are longer than 2090-CSxM1DF cables to accommodate Kinetix 5700 servo drives. See the cable-shield grounding technique for single cables on page 185. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 188 Hiperface-to-DSL Feedback Connector Power Connector Feedback Converter Kit Clamp Screws (2) See Hiperface to DSL Feedback Converter Kit Installation Instructions, Exposed shield secured Cable Clamp publication 2198-IN006, for converter kit specifications. under clamp. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 189 Feedback Cable Shield 2198-H2DCK Hiperface-to-DSL Feedback Connector Power Connector Feedback Converter Kit Clamp Screws (2) See Hiperface to DSL Feedback Converter Kit Installation Instructions, Exposed shield secured Cable Clamp publication 2198-IN006, for converter kit specifications. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 190 MPAR-A/B1xxx (series B and C) MPAR-A/B2xxx (series B and C) MPAR-A/B3xxx 2090-CPxM7DF-16AAxx (standard) or 2090-CFBM7DF-CEAAxx (standard) or MPAI-A/B2xxxx 2090-CPxM7DF-16AFxx (continuous-flex) 2090-CFBM7DF-CEAFxx (continuous-flex) MPAI-A/B3xxxx MPAI-A/B4xxxx MPAI-B5xxxx 2090-CPxM7DF-14AAxx (standard) or 2090-CFBM7DF-CEAAxx (standard) or MPAI-A5xxxx 2090-CPxM7DF-14AFxx (continuous-flex) 2090-CFBM7DF-CEAFxx (continuous-flex) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 191: System Block Diagrams
Appendix A Interconnect Diagrams System Block Diagrams This section provides block diagrams of the Kinetix 5500 drive modules. Figure 104 - Kinetix 5500 Drive Block Diagram Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 192 Figure 105 - Kinetix 5500 Capacitor Module Block Diagram Precharge Protection Relay K2 Fuse F2 Relay K1 Capacitor Bank DC Bus Connector 1360 µF 24V+ 24V Control Power SMPS 24V- Module Status RELAY+ Connector (N.O. relay output) RELAY- Status Indicator Chassis Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 193: Update The Drive Firmware
IMPORTANT The axis state on the LCD display must be STANDBY, CONFIGURING, or PRECHARGE before beginning this procedure. IMPORTANT The axis state on the LCD display must be STANDBY, when Protected mode is enabled. See Table 57 on page 104 for more information. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 194: Configure Logix 5000 Controller Communication
The Add New RSLinx Classic Driver dialog box appears. 5. Type the new driver name. 6. Click OK. The Configure driver dialog box appears. 7. Type the IP address of your Kinetix 5500 servo drive. 8. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 195: Inhibit Feedback Only Axis
Only and choose Properties. The Module Properties dialog box appears. 3. Click the Connection tab. 4. Check Inhibit Module. 5. Click OK. 6. Save your file and download the program to the controller. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 196: Update Firmware
2. Click Next. The Catalog Number dialog box appears. 3. Select your drive module. In this example, the 2198-H003-ERS servo drive is selected. 4. Click Next. The Select Device to Update dialog box appears. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 197 8. Select the firmware revision to update. 9. Click Next. The Summary dialog box appears. 10. Confirm the drive catalog number and firmware revision. 11. Click Finish. This ControlFLASH warning dialog box appears. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 198 16. Click OK. IMPORTANT If you are updating a feedback-only axis and you checked Inhibit Module on the Connection tab in Module Properties, you must clear the Inhibit Module checkbox before resuming normal operation. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 199: Verify The Firmware Update
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. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 200 Appendix B Update the Drive Firmware Notes: Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 201: Size Multi-Axis Shared-Bus Configurations
In shared AC configurations, the first (leftmost) drive receives AC input voltage. The shared-bus connection system extends the AC bus to all downstream drives: • All drives are configured in the project file as Standalone drives. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 202: Shared Dc Configurations
Frame Size Combination Leader Drive Cat. No. Follower Cat. No. Follower Drives, Max Modules, Max 2198-H003-ERSx 2198-H003-ERSx 2198-H003-ERSx 2198-H008-ERSx 2198-H008-ERSx 2198-H003-ERSx 2 and 1 2198-H015-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H003-ERSx 2 and 1 2198-H008-ERSx 2198-H025-ERSx 2198-H015-ERSx 2198-H025-ERSx Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 203 Common-bus Follower Drives IMPORTANT The total number of drives in a Kinetix 5500 drive system must not exceed eight. For an example shared DC installation with additional details, see Figure 4 on page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 204: Shared Ac/Dc Configurations
DC Bus Connections Input Power 24V Input Control Power 2198-CAPMOD-1300 Capacitor Module (optional component) Kinetix 5500 Servo Drives (top view) For an example shared AC/DC installation with additional details, see Figure 3 on page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 205: Shared Ac/Dc Hybrid Configurations
(1) For Bulletin 2198 capacitor module maximum values, refer to the Kinetix 5500 Capacitor Module Installation Instructions, publication 2198-IN004. For an example shared AC/DC hybrid installation with additional details, see Figure 5 on page Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 206: Power-Sharing Sizing Examples
Each 2198-H040-ERS drive is rated at 8.4 kW continuous output power to the 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. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 207: Shared Ac/Dc Hybrid Example
The available converter power to the system is (8.4 • 2) • 0.7 = 11.76 kW. In this example, the total motoring load must not exceed 11.76 kW. The available converter power was increased by 40% over the same drives in shared DC configuration. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 208: Shared Ac/Dc Example
Table 86 - Control Power Current Demand 24V Current 24V Current 24V Inrush Current (non-brake motor) (2 A brake motor) Cat. No. 2198-H003-ERSx 2198-H008-ERSx 2198-H015-ERSx 2198-H025-ERSx 2198-H040-ERSx 2198-H070-ERSx 2198-CAPMOD-1300 — (1) Inrush current duration is less than 30 ms. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 209: Kinetix 5500 System Current Demand Example
(1) Value assumes the use of one servo drive and one capacitor module. (2) Value assumes the use of one servo drive and the maximum number of capacitor modules allowed. See Motion Analyzer Online, version 7.0 or later, for custom shunt sizing. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 210 Appendix C Size Multi-axis Shared-bus Configurations Notes: Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 211: Motor Control Feature Support
Stability Control for Frequency Control Skip Speeds Flux Up Current Regulator Loop Settings Motor Category Selection of Motor Thermal Models Speed Limited Adjustable Torque (SLAT) Motor Overload Retention Phase Loss Detection Velocity Droop Commutation Test Adaptive Tuning Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 212: Frequency Control Methods
50 m (164 ft) (1) Applies to all Kinetix 5500 (frame 2 and 3) drives. For Kinetix 5500 (frame 1) drives in continuous-flex applications, 30 m (98 ft) is the maximum cable length. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 213: Basic Volts/Hertz
Slopes the portion of the curve that is used above base speed. Figure 114 - Basic Volts/Hertz Method Voltage, max Base Voltage (nameplate) Break Voltage Start/Accel Boost Run Boost Break Base Frequency Frequency, Frequency (nameplate) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 214: Basic Volts/Hertz For Fan/Pump Applications
Figure 116 - Basic Volts/Hertz Fan/Pump Method Voltage, max Base Voltage (nameplate) Run Boost Frequency (Hz) Base Frequency Frequency, (nameplate) The Fan/Pump control method supports the run-boost attribute, but does not support break-voltage, break-frequency, or start-boost. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 215: Sensorless Vector
Dynamic boost is applied internally to compensate voltage drop and improve starting torque. Figure 118 - Approximate Load Curve Voltage, max Base Voltage (nameplate) Ideal, volts/hertz Dynamic Boost Applied Frequency, Base Frequency (nameplate) Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 216: Current Limiting For Frequency Control
Aggressive Acceleration, Current Limiting Active 1000 1200 1600 1000 1200 1400 1600 1800 2000 1400 1800 2000 Time (ms) Time (ms) Output Current Operative Current Limit Output Frequency Output Frequency Output Current Operative Current Limit Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 217 Control and when executing an MDS command. Units of feedback counts / Amp, inst. IMPORTANT For induction motors greater than 5 Hp, we recommend that you enable the Stability Control feature when Current Limiting is enabled. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 218: Enable The Current Limiting Feature
IMPORTANT The CurrentVectorLimit attribute appears in the Parameter List of the Logix Designer application, version 29.00 and later. If you are using a previous version, the CurrentVectorLimit attribute must be set via a Message Configuration (MSG) instruction. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 219: Stability Control For Frequency Control
Stability Angle Gain frequency control. Units of radians/Amp (inst). IMPORTANT Because the stability control feature works by manipulating the OutputVoltage and OutputFrequency signals, these signals may appear 'noisy' when the feature is enabled. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 220: Enable The Stability Control Feature
Enable the Stability Control Feature In this example, a Message Configuration (MSG) instruction is configured to enable the StabilityControl attribute for axis 1. The Instance field is used to direct the message to the proper axis. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 221: Skip Speeds
IMPORTANT Acceleration and deceleration are affected by the skip-speed feature. Too large of a SkipSpeedBand value can result in an overcurrent drive fault. IMPORTANT The MaximumFrequency attribute is always enforced. Skip-speed band boundary values beyond the MaximumFrequency value do not apply. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 222: Multiple Skip Speeds
(point B), or the command is changed outside of the skip band. Figure 125 - Zero-speed Skip Frequency SkipSpeed1 = 0 Hz SkipSpeed2 = 15 Hz Skip Band = 10 Hz 5000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 Output Frequency Command Frequency Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 223: Flux Up
Flux Up Current = Maximum DC Current Rated Flux Rated Motor Flux Current Motor Flux Flux Up Time Once rated flux is reached in the motor, normal operation can begin and the desired acceleration profile achieved. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 224: Flux Up Attributes
FluxUpTime Attribute When FluxUpControl is configured for Manual Delay, this attribute sets the length of delay time to fully flux the motor before transitioning to the Running state. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 225: Configure The Flux Up Attributes
IMPORTANT The Logix Designer application does not perform calculations when the Torque/Current Loop Bandwidth attribute is updated. This bandwidth affects many other gains and limits. Changing (lowering) the torque loop bandwidth without updating all dependent attributes can result in drive/motor instability. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 226: Motor Category
E QU I V A L E NT W Y E C K T .PA R A M E T E R S (OHM S PE R PHA SE ) 8.378 5.6232 10.7068 9.9116 278.036 ZR E F T D0 11132.8 0.0071 0.136 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 227 In this example, the Calculate Model test was run. If the Motor > Analyzer test executes successfully, and you accept the test values, they populate the Model Parameter attributes. Figure 132 - Motor Analyzer Category Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 228: Motor Tests And Autotune Procedure
Nameplate data was entered on page 226. The nameplate data must be entered before running the Calculate test. 3. To run the test, click Start. 4. To save the values, click Accept Test Results. 5. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 229: Motor Analyzer Category Troubleshooting
For the Logix Designer application, version 28.00 or earlier, initial estimates can be entered by running and accepting the results of a Calculate test, or by entering the values directly into the Logix Designer application. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 230 If using the Dynamic test in Frequency Control mode, uncouple the motor from any load or results may not be valid. In closed-loop control, either a coupled or uncoupled load produces valid results. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 231: Selection Of Motor Thermal Models
The purpose of this algorithm is to limit the time that a motor is operating with excessive levels of current. This thermal model uses the first- order time constant that is determined from the MotorWindingToAmbientResistance and Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 232: Speed Limited Adjustable Torque (Slat)
VelocityError > 0 and switches back to Torque regulation if VelocityError < SLATSetPoint for SLATTimeDelay. Direction of the applied torque and direction of the material movement determine whether SLAT minimum or SLAT maximum mode should be used. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 233: Motion Polarity Setting
(speed control is ON) (speed control is OFF) Velocity Error > SLAT Setpoint for SLAT Time See the Integrated Motion on the EtherNet/IP™ Network Reference Manual, publication MOTION-RM003, for more information on SLAT attributes. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 234: Slat Max Speed/Torque
1 = SLAT Min Speed/Torque 2 = SLAT Max Speed/Torque SLAT Set Point Velocity Units SLAT Time Delay Seconds (1) SLAT Disable, when viewed in version 28.00 (and earlier) of the Logix Designer application, reads Torque Only. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 235: Configure The Axis For Slat
3. From the Axis Configuration pull-down menu, choose Velocity Loop. The Velocity Loop dialog box appears. 4. Enter values for the Velocity Loop attributes appropriate for your application. 5. Click Apply. 6. Select the Parameters List category. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 236 General category, Axis Configuration pull-down menu. 8. Click Apply. 9. Enter values for SLATSetPoint and SLATTimeDelay attributes appropriate for your application. 10. Click OK. 11. Select the Drive Parameters category. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 237 To stop the axis, use an MAS instruction. • The axis accelerates and decelerates at the MAJ instruction programmed Acceleration and Deceleration rates. • You can also change the rates using the MCD instruction. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 238: Motor Overload Retention
You cannot write to the InitialMotorCapacity attribute after the first time the axis is enabled following a power cycle. Use a message instruction to write to the InitialMotorCapacity value. In this example, the source element tag motorcapacity is a REAL data type. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 239: Phase Loss Detection
Phase-loss Detection Attributes Access Attribute Conditional Implementation 0 = Disabled ProvingConfiguration 1 = Enabled % Motor Rated Units: Amps TorqueProveCurrent Default: 0.000 Min/Max: 0/10,000 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 240: Phase-Loss Detection Configuration
INHIBIT M04 torque proving configuration fault code. The minimum amount of torque proving current depends on the catalog number of the drive. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 241: Phase Loss Detection Current Example
IMPORTANT When configured for closed-loop control, the units of the VelocityDroop attribute are Velocity Control Units / Sec / % Rated Torque. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 242: Frequency Control
1. In the Controller Organizer, right-click an axis and choose Properties. 2. Select the Parameter List category and scroll to VelocityDroop. 3. Enter a value in the Velocity Droop attribute appropriate for your application. 4. Click OK. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 243: Commutation Test
Automatically adjust torque-loop notch and low-pass filter parameters to suppress resonances • Automatically adjust control-loop gains to avoid instability when detected See Motion System Tuning Application Techniques, publication MOTION- AT005, for more information on the AdaptiveTuningConfiguration attribute. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 244 Appendix D Motor Control Feature Support Notes: Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 245: History Of Changes
Added 140UT- catalog numbers to the various Drive Systems tables, and to the two Shared AC/DC and Hybrid Systems tables. 2198-UM001J-EN-P 2198-UM001J-EN-P, November 2019 Change Added reference to Knowledgebase article for fault codes and descriptions. Added Kinetix 5700 drive compatibility with 2090-CSxM1xx-xxVAxx (PVC) and 2090-CSBM1xx-xxLFxx (Halogen-free PUR) single motor-cables. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 246: 2198-Um001I-En-P
Updated Current Limiting for Frequency Control with changes in drive firmware 7.001. Updated Motor > Model Category text with changes in drive firmware 7.001. Updated Motor Tests and Autotune Matrix table with changes in drive firmware 7.001. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 247: 2198-Um001G-En-P
Updated Circuit Breaker/Fuse Selection tables with replacement circuit breaker catalog numbers. Updated Digital Inputs Connector Pinouts with configurable I/O content. Added ATTENTION statement to Motor Power connector pinouts. Updated Digital Input tables with new configurable features. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 248: 2198-Um001D-En-P
Added INIT FLT-M14 - SAFETY FIRMWARE fault code. Updated NODE FLT fault codes. Added NODE FLT 03 – HARDWARE 04 fault code. Added NODE ALARM 04 – CLOCK SKEW ALARM. Updated the configurable stopping action definitions. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 249: 2198-Um001C-En-P
IMPORTANT advisory regarding single-cable technology. Updated NODE FLT 03 HARDWARE 01 and added sub-codes HARDWARE 02 and HARDWARE 03. Added IMPORTANT advisory regarding DC bus T-connector removal. Updated Energy Absorbing Potential table with External Shunt values. Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 250 Appendix E History of Changes Notes: Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 251: Index
EMI (electromagnetic interference) 38 examples 39 high frequency energy 40 subpanels 40 brake relay 63 Bulletin MPAI electric cylinders 20 MPAR electric cylinders 20 MPAS linear stages 20 configuration 118 regulator 118 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 252 209 system calculations 208 erratic operation 148 wiring 78 Ethernet connector ControlFLASH pinouts 61 firmware update 193 EtherNet/IP firmware upgrade 193 troubleshooting 198 connecting cables 98 connections 63 PORT1 and PORT2 connectors 98 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 253 87 pinouts 60 configure flux up 225 wiring 80 control methods IP address 105 basic volts/hertz 213 IPD connector fan/pump 214 sensorless vector 215 pinouts 59 flux up 223 wiring 79 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 254 105 status indicator 146 Motion Analyzer website 10 new tag motion direct commands data type 116 STO bypas 173 noise warning messages 174 abnormal 148 motion group 119 feedback 148 reduction 42 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 255 65 PFH 161 Stegmann DSL 65 pinouts 161 safe torque-off 66 specifications 66 speed limited adjustable torque 232 safety SPM motor closed-loop axis properties 127 tab 114 stability control 219 scaling category 129 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 256 Motion Analyzer 10 status only 149 product selection 10 general system problems 147 abnormal noise 148 axis unstable 147 erratic operation 148 feedback noise 148 motor accel/decel 147 motor overheating 148 motor velocity 148 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 257 RC connector 97 remove grounding screws 73 requirements 68 routing power and signal wiring 68 safe torque-off bypass 163 safe torque-off cascaded 164 STO connector 162 ungrounded power configuration 71 zero-stack tab and cutout 46 Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 258 Index Notes: Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 259 Kinetix 5500 Servo Drives User Manual Rockwell Automation Publication 2198-UM001M-EN-P - November 2022...
Page 260 Allen-Bradley, CompactGuardLogix, CompactLogix, ControlFLASH, ControlLogix, expanding human possibility, GuardLogix, Kinetix, Logix 5000, PanelView Plus, POINT Guard I/O, POINT I/O, Rockwell Automation, RSLinx, Stratix, Studio 5000, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. CIP Safety, CIP Sync, and EtherNet/IP are trademarks of ODVA, Inc.

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