Mastering Motion with Kinetix 7000 High-Performance Drives

Kinetix 7000 (Bulletin 2099) are high-power, single-axis servo drives designed and manufactured by Rockwell Automation to deliver a Kinetix Integrated Motion solution for machine control applications with high output power demands – in the scope of 22…149 kW continuous output power (40…248A rms continuous output current). Such applications include robotics, machine tools, printing machines, packaging machines, and injection molding machines.

As part of Rockwell’s Kinetix Integrated Motion platform, the Kinetix 7000 drives offer the following:

• A high level of commonality with other Allen-Bradley Kinetix servo drives, including the well-proven Kinetix 6000 (Bulletin 2094) multi-axis servo drives
• A single, comprehensive RSLogix 5000 software suite for simplified drive programming and configuration
• Tag-based addressing of parameter values, leading to reduced design time
• Easy and intuitive access to drive data (e.g., parameter settings) for process optimization
• Plug-and-play drive reconfigurability, allowing faster integration and start-up of the Kinetix 7000 drives
• Reduced wiring requirements, resulting in time savings and lower installation costs
• Cutting-edge diagnostic capabilities that minimize unplanned downtimes

Generally, Kinetix Integrated Motion technologies support Integrated Motion on SERCOS (Serial Real-time Communications System) and EtherNet/IP networks. Integrated Motion is simply the control of multiple axes of motion using the Integrated Architecture control platform from Rockwell Automation that brings together an exceptional range of Allen-Bradley motion control solutions including ControlLogix controllers, SERCOS-connected servo drives, I/O modules, rotary servo motors, smart actuators, EtherNet/IP-enabled servo and AC drives, NetLinx-based networks (ControlNet, DeviceNet, and EtherNet/IP), and HMI visualization platforms.

Kinetix 7000 Drive Features

The Allen-Bradley Kinetix 7000 drives are available with innovative features to help satisfy the demanding needs of high-performance motion control applications across a wide variety of industries. These features include:

• An extensive range of power ratings:
  • 22 kW, 30 kW, 37 kW, 56 kW, 75 kW, 112 Kw, and 149 kW (40, 52, 65, 96, 125, and 180 A rms) with 380…480V three-phase AC input, or  450…750V DC input
• Ability to operate with a common/shared DC bus using the  450…750V DC input
• One drive solution for induction (asynchronous) servo motors and permanent magnet (synchronous) servo motors
• An in-built Safe-off (SO) capability that provides maximum machine availability and enhanced safety, leading to increased machine productivity
• Supports a wide array of SERCOS interface modules, which enable SERCOS servo drive connectivity as well as control for the connected ControlLogix controllers
• Advanced axis control functionalities:
  • Single-axis drive control using an auxiliary encoder input channel
  • Point-to-point configurable positioning
  • Auto-tuning
  • Electronic gearing
  • Contouring or coordinated positioning
  • Position-lock mechanical camming
  • Time-lock mechanical camming
• Field-programmable drive firmware that’s stored in a flash memory, enabling easy firmware upgrades
• Includes intelligent feedback devices that offer automatic motor recognition capability
• Comprehensive I/O control via:
  • SERCOS interface using fiber-optic cables to connect:
    • 1768-M04SE CompactLogix SERCOS interface module
    • 1756-MxxSE ControlLogix SERCOS interface modules
    • 1784-PM16SE SoftLogix PCI (Peripheral Component Interconnect ) card
  • Dedicated local inputs
  • Relay Outputs
  • Dedicated local outputs
  • Innovative remote drive diagnostic capabilities
• Compliance with cULus and CE safety standards

Components of a Kinetix 7000 Drive System

Kinetix 7000 drive systems combine vector motor control and high-performance servo control, enabling machine builders and manufacturers to implement simple machine control solutions. This results in reduced time and labor costs for drive integration. This section will examine the drive modules and accessories required to build a typical Kinetix 7000 drive system.

A Kinetix 7000 Servo Drive

To build a standard Kinetix 7000 drive system, you’ll require at least one Kinetix 7000 high-power servo drive – drive Catalog No. 2099-BMxx-.

Kinetix 7000 drives are available in the following models:

• 2099-BM06-S: Continuous output power: 22 kW (30 Hp), Continuous output current: 56 A (0-pk)

• 2099-BM07-S: 30 kW (40 Hp), 73 A (0-pk)

• 2099-BM08-S: 37 kW 50 Hp), 92 A (0-pk)

• 2099-BM09-S: 56 kW (75 Hp), 135 A (0-pk)

• 2099-BM10-S: 75 kW (100 Hp), 176 A (0-pk)

• 2099-BM11-S: 112 kW (150 Hp), 254 A (0-pk)

• 2099-BM12-S: 149 kW (200 Hp), 351 A (0-pk)

Note: All of the Kinetix 7000 servo drives, as mentioned above, require a three-phase AC input voltage in the range of 342…528V AC rms at a supply frequency of 47…63 Hertz (Hz) or a 450 – 750V DC input.

SERCOS Fiber-Optic Communication Cables

The SERCOS interface modules discussed above use plastic, glass, or nylon2090-Series Sercos fiber-optic communication cables with connectors at both ends to establish a SERCOS communication link between the Kinetix 7000 servo drives and a compatible Allen-Bradley Logix controller platform. Some of the commonly used SERCOS fiber-optic cables in Kinetix 7000 servo drive systems include:

• Plastic SERCOS fiber-optic cables
  • 2090-SCEPxx-x Chlorinated Polyethylene (CPE), non-jacketed cables for in-cabinet tasks
  • 2090-SCVPxx-x Polyvinyl Chloride (PVC), standard jacketed cables for conduit and outdoor applications
  • 2090-SCNPxx-x nylon jacketed cables for on-machine duty
• Glass SERCOS fiber-optic cables
  • 2090-SCVGxx-x Polyvinyl Chloride (PVC), standard jacketed glass fiber-optic cables suitable for conduit and outdoor duty

Note: A typical Kinetix 7000 drive system requires two Kinetix 2090-SCxxx-x SERCOS fiber-optic cables. The 1756-MxxSE ControlLogixSERCOS interface modules use 2090-SCxxx-x fiber-optic cables rated Class 1 for IEC LED (Light-Emitting Diode) safety classification.

A Compatible Kinetix Servo Motor

Kinetix 7000 servo drives are compatible with the following Allen-Bradley rotary servo motors:

Kinetix  MPL Servo Motors

Kinetix MPL is a high-output, low-inertia brushless servo motor specially designed to deliver a significantly higher torque output in small motor sizes. These compact and highly dynamic rotary servo motors are available in nine frame sizes to address a wide scope of high-performance motion applications. They feature the following:

• 460V AC or 230V AC motor windings
• Peak torque in the range of 6.8…2460 lb-in. (0.77…278 Nm)
• Continuous stall torque in the range of 2.3…1440 lb-in. (0.26…163 Nm)
• A built-in 24V DC brake option
• Absolute single-turn (-E, -S) or multi-turn (-V, -M) high resolution (to 2 million counts per revolution), incremental resolver, and encoder feedback options. High-resolution feedback allows for smooth performance.

Note: Kinetix 7000 (400V class) is matched with Kinetix MPL (400V class) rotary servo motors.

Kinetix  MPM Servo Motors

Kinetix MPM are medium-inertia rotary servo motors that provide a compact, power-dense, full-featured solution for precisely controlling motion profiles that generate greater inertia or applications with heavier loads. These motors feature the following:

• 460V AC or 230V AC motor windings
• Several winding speed options
• Absolute multi-turn (-M) high-resolution encoder feedback
• Single-turn (-S) high-resolution encoder feedback
• Rotatable DIN connectors that simplify cable routing and motor mounting
• IEC metric motor mounting dimensions

Note: Kinetix 7000 (400V class) is matched with Kinetix MPM (400V class) rotary servo motors.

Kinetix MMA Servo Motors

Kinetix MMA is a three-phase AC induction (asynchronous) motor optimized with a range of special options and configurable features for use with the Kinetix 7000 drives. They are an excellent choice for heavy-duty motion applications requiring high torque and power output, with multiple speed ranges and six distinct shaft heights.

They are available with the following features:

• An extensive output power range: 0.6…205 kW
• Nine encoder feedback options, including SIL 2 safety-rated encoders
• Configurable with improved roller, ball, and high-speed bearing offerings
• Enhanced maximum speed and rated speed capabilities
• Improved temperature monitoring with cutting-edge thermal sensors
• A wide scope of mounting options, with flange and foot mounts for all Kinetix MMA motor sizes
• Advanced motor protection options for both harsh and humid industrial environments

Kinetix  HPK Servo Motors

Kinetix HPK is a high-power AC induction servo motor that employs well-established asynchronous motor technologies optimized for high-performance systems requiring rapid deceleration and acceleration.  When combined with Kinetix 7000 servo drives, these motors extend the power range of Rockwell’s Kinetix Integrated Motion solutions up to 201 HP (150 kW).

The Kinetix HPK motors feature the following:

• Optimized motor windings that provide constant torque output over an extended speed range
• 849 … 4266 lb-in. (96 … 482 Nm) continuous torque range
• 1699 …. 8531 lb-in. (192 … 964 Nm) peak torque range with 1500 and 3000 RPM base speeds
• Smart motor technology that offers automatic motor recognition capability
• Absolute multi-turn (-M) or single-turn (-S) high-resolution (up to 2 million CPR) encoder feedback, providing smooth and precise control
• Inbuilt blower cooling
• Standard junction boxes and DIN feedback connectors that simplify power connections during motor installation
• Standard IEC mounting options, with flange and foot mounts

Kinetix  RDB Servo Motors

Kinetix RDB, formerly the RDD-Series, are direct-drive rotary servo motors designed to provide direct coupling to the motor load. This helps improve system efficiency and performance by eliminating the need for pulleys, timing belts, chain drives, gearboxes, and other inefficient mechanical power transmission elements. The result is faster settling times, reduced energy consumption, and improved control of the connected motor load.

Key features of the Kinetix RDB servo motors include:

• Optimized motor windings for use with the Kinetix 7000 servo drives
• Ability to deliver high torque at low RPM speeds
• Bearingless motor housing configuration designed for servo systems in which the load has its bearings supporting it
• 289…3770 lb-in. (32.7…426 Nm) continuous torque range
• A choice of multi-turn (-7) or single-turn (-3) high-resolution (up to 4 million CPR) absolute position encoder feedback
• IP65 environmental protection

Note: A single-drive Kinetix 7000 servo system will require one MP-Series(Bulletin MPM, Bulletin MPL), RDD-Series (Bulletin RDB), Kinetix MMA, or HPK-Series rotary servo motor. The RDD-Series motors make use of the 2090-K7CK-KENDAT Low-profile EnDat Feedback module, while the other motor series require the 2094-K6CK-D15M Low-profile Connector Kit to be used with flying-lead feedback cables for motor feedback connections.

Motor Power/Brake and Feedback Cables

A single-drive Kinetix 7000 servo system featuring one Kinetix rotary servo motor will require one 2090-Series feedback cable and motor power/brake cable. For every Kinetix 7000 drive system configuration, the user should know the catalog numbers of the included Kinetix 7000 drive module and Kinetix servo motor to determine the catalog numbers of the feedback and power/brake cables to be used.

Various 2090-Series feedback and motor power/brake cables are available with rugged,  threaded, or SpeedTEC DIN connectors for connecting the Kinetix 7000 servo drive modules and compatible Kinetix servo motors. The motor brake/power cables include drive-end flying leads to connect to Kinetix 7000 servo drives and motor-end straight connectors to connect to compatible Kinetix servo motors. The high-power Kinetix servo motors used with Kinetix 7000 drives may require customer-supplied motor power/brake cables to handle their large current requirements.

The 2090-Series feedback cables include drive-end flying leads that link to 2094-K6CK-Dxxx low-profile connector kits for auxiliary feedback, motor feedback, I/O connections, and motor-end straight connectors to connect to compatible Kinetix servo motors. All flying-lead 2090-Series feedback cables should be used with connector kits or breakout components for drive-end terminations.

Available 2090-Series motor power/brake cables for use in a Kinetix 7000 servo drive system include:

• Standard (non-flex) 2090-Series Power/Brake Cables
  • 2090-CPBM7DF-xxAAxx: They include power/brake wires (PB) and drive-end flying leads (DF)
  • 2090-CPWM7DF-xxAAxx: They comprise power wires only (PW) and drive-end flying leads (DF)

• Continuous-flex 2090-Series Power/Brake Cables
  • 2090-CPBM7DF-xxAFxx Cables: They feature power/brake wires (PB) and drive-end flying leads (DF).
  • 2090-CPWM7DF-xxAFxx Cables: They include power wires only (PW) and drive-end flying leads (DF).
  • 2090-CPBM7E7-xxAFxx Cables: They contain a SpeedTEC DIN cable plug (M7) on the motor end and a male connector extension (E7) on the drive end for extending a threaded or SpeedTEC DIN cable.

Available 2090-Series feedback cables for use in a Kinetix 7000 servo drive system include:

• Standard (non-flex) 2090-Series Feedback Cables
  • 2090-CFBM7DF-CEAAxx Cables: They feature drive-end flying leads (DF) and are well-suited for high-resolution resolver or encoder applications (CE).
  • 2090-CFBM7DD-CEAAxx Cables: They contain a drive-end 15-pin connector (DD). They are ideal forhigh-resolution resolver or encoder applications (CE).

• Continuous-flex 2090-Series Feedback Cables
  • 2090-CFBM7DF-CDAFxx Cables: They consist of drive-end flying leads (DF) and are designed for incremental or high-resolution applications (CD).
  • 2090-CFBM7DF-CEAFxx Cables: They include drive-end flying leads (DF) and are appropriate for high-resolution resolver or encoder applications (CE).
  • 2090-CFBM7DD-CEAFxx Cables: They incorporate a drive-end 15-pin connector (DD). They are suitable forhigh-resolution resolver or encoder applications.
  • 2090-CFBM7E7-CDAFxx Cables: These cablescontain a SpeedTEC DIN cable plug (M7) on the motor end and a male connector extension (E7) on the drive end for extending a threaded or SpeedTEC DIN cable. They are ideal for incremental or high-resolution applications (CD).
  • 2090-CFBM7E7-CEAFxx: They also featurea SpeedTEC DIN cable plug (M7) on the motor end and a male connector extension (E7) on the drive end for extending a threaded or SpeedTEC DIN cable. They are appropriate for high-resolution resolver or encoder applications (CE).

Note: The 2090-Series Standard, non-flex feedback, and power/brake cables (represented by AA in Catalog No.) are designed for static applications, while the Continuous-flex feedback and power/brake cables (represented by AF in Catalog No.) are designed for reverse bending and rolling applications.

Required Accessories

Kinetix 7000 servo drive systems require the following accessories to function as intended.

• 24V DC Power Module (Catalog No. 1606-XLxxx): It is required to provide a 24V DC voltage for control power and the integral 24V DC motor brakes in some Kinetix rotary servo motors.
• 2094-K6CK-D26M Low-profile Connector Module: Required for use with flying-lead 2090-Series feedback cables to support I/O connections
• 2094-K6CK-D15F Connector Kit: Used 2090-Series feedback cables with flying leads to support auxiliary feedback connections.
• 2094-K7CK-KENDAT Module: Required for flying-lead 2090-Series feedback cables with Kinetix RDBdirect-drive servo motors featuring EnDat encoders. The module helps enhance motor feedback connections.
• 2094-K6CK-D15M Connector Kit: Also used with2090-Series feedback cables with flying leads to support motor feedback connections.

Optional Drive Accessories

You can include the following optional drive accessories to enhance the performance, safety, and feedback capabilities of your Kinetix 7000 servo drive system.

• 8720MC Regenerative Power Supply (RPS)
• 2094 Line Interface Modules
• 8720MC Line Reactors
• 1336 External Active Shunt
• 1202-Cxx Safety Interface Cables
• 2090-XNSM-x Safety Headers
• 2090 AC Line Conditioners/Filters for Electromagnetic compatibility (EMC)
• 2099-K7KCP-1 DC-DC Converter Kit
• External Auxiliary Encoders
• 2099-K7KCK-1 Connector Kit
• 2099-K7KCB-1 Control Board Kit