High-Power Motion Control: Key Features of the Kinetix 7000 Servo Drives

The Allen-Bradley Kinetix 7000 (Bulletin 2099) Series features high-power servo drives that are designed to extend the benefits and simplicity of Kinetix Integrated Motion to servo systems with demanding power requirements – in the range of 30 to 200 HP/22 to 149 kW (40.0 to 248.0 A rms). With output power ratings of up to 200 HP, this drive series supports a wide variety of high-power motion applications, including web handling, injection molding machines, robotics, material handling, printing, packaging, converting, and machine tools. Kinetix 7000 servo drives are essentially designed to control both induction (asynchronous) motors and synchronous permanent magnet motors. They support 3-phase AC input power (in the range of 380 to 480 Volts AC) and DC input power for common DC bus applications.

Power specifications of the Kinetix 7000 drive series:

• AC input voltage: three-phase, 342 to 528V AC rms (380 to 480V nom)
• Control power input voltage: 24V DC, nom (18 to 30V DC)
• AC input frequency: 47 to 63 Hz
• Continuous output current: 40.0 to 248.0 A rms (56.0 to 351.0 A 0-pk)
• Continuous power output: 30 to 200 HP (22 to 149 kW, nom)
• DC input current: 42.9 to  281.0 A
• DC input voltage: 450 to 750V DC

In addition, Kinetix 7000 drives are part of the Allen-Bradley Integrated Architecture platform – a real-time control & information system – providing Integrated Motion capability via SERCOS (Serial Real-time Communications System) interface. The drives also include built-in Safe Torque-Off (STO) safety functionality, allowing machine builders and manufacturers to implement motion control solutions that provide maximum machine availability, enhanced operator & machine safety, and increased productivity.

Available Kinetix 7000 servo drives:

• 2099-BM06-S: 30 Hp/22 kW/40.0 A rms
• 2099-BM07-S: 40 Hp/30 kW/52.0 A rms
• 2099-BM08-S: 50 Hp/37 kW/65.0 A rms
• 2099-BM09-S: 75 Hp/56 kW/96.0 A rms
• 2099-BM10-S: 100 Hp/75 kW/125.0 A rms
• 2099-BM11-S: 150 Hp/112 kW/180.0 A rms
• 2099-BM12-S: 200 Hp/149 kW/248.0 A rms

Key Features of Kinetix 7000 Servo Drives

The Allen-Bradley Kinetix 7000 drive series provides a variety of innovative key features that allow for high-power motor control. The features include:

Integrated Motion on SERCOS

Kinetix Integrated Motion solutions are part of the Rockwell Automation high-performance Integrated Architecture system. The Integrated Architecture system is a unified real-time control and information platform that provides a standard design framework, single control solution, secure connectivity, integrated safety, visualization tools, interoperability, common network, and enhanced productivity.

Integrated Motion on SERCOS is a drive/ controller interface that makes use of noise-immune, SERCOS fiber-optic cables. Kinetix 7000 servo drive systems utilize Kinetix 2090 fiber-optic cables to provide process reports and advanced diagnostics via the SERCOS interface. A fiber-optic ring acts as the sole interface between the Kinetix 7000 drive and an Allen-Bradley Logix controller, such as GuardLogix, CompactLogix, or ControlLogix controller. This eliminates the need for costly feedback and command wiring, consequently reducing installation time and wiring costs.

A Kinetix 7000 Integrated Motion system on SERCOS supports up to sixteen (16) motion axes per motion module — ControlLogix, GuardLogix, or CompactLogix motion module option. The system can be scaled up to support a maximum of 100 motion axes per connected controller. If there’s a need for additional axes, multiple Logix controllers can be integrated into the system.  You can use a dedicated motion network to support the Kinetix 7000 SERCOS interface drives.

Advanced Motor Overload Protection

Kinetix 7000 servo drives utilize a solid-state motor overload protection system that operates in conformity with UL functional safety requirements. The system includes highly developed electronic relays that transcend basic motor current monitoring to real-time detection and responding to potential motor issues, such as abnormal load conditions, phase imbalances, and motor overheating. This provides more precise motor protection using real-time system data for preventative and predictive maintenance, often through features like versatile communication capabilities, comprehensive motor health monitoring functions, and user-customizable trip settings.

In essence, solid-state motor overload protection is provided by algorithms that are stored in thermal memory. These algorithms predict the actual temperature of the connected motor based on real-time operating conditions, provided that control power is continuously applied to the Kinetix 7000 drive operating the motor. The thermal memory feature allows the Kinetix 7000 drive to simulate the thermal behavior of the connected motor by tracking immediate current fluctuations, even with them being short-lived, and integrating the resulting heating effect over time. This provides effective motor protection against repeated overload conditions that are likely to lead to motor overheating.

In addition to the thermal memory, Kinetix 7000 servo drives also include an input provision for an external thermistor/temperature sensor, embedded in the connected motor, for compliance with UL safety requirements for solid-state motor overload protection. Kinetix 7000 drives that use digital servo link (DSL) encoder technology require the connected DSL encoder to execute motor temperature monitoring and transmit the collected data over a single motor cable. If the drives are paired with Kinetix VP (Bulletin VPS, VPH, VPC-Bxxxxx-Q, VPF, and VPL) servo motors using DSL technology to perform the same function, then no additional wiring is needed.

Benefits of solid-state motor overload protection:

• Enhanced safety: Prevents potential electrical hazards due to the motor overheating
• Improved operational efficiency: Helps optimize motor performance through quick identification and prompt response to overload conditions
• Reduced motor downtime: Predictive maintenance algorithms provided by the solid-state overload protection system allow early detection of possible problems, minimizing the risk of motor damage and unplanned downtime
• Cost savings: Predictive maintenance helps prevent unnecessary motor replacements, significantly reducing maintenance costs

Integral Safe Torque-Off

Kinetix 7000 servo drives rated for 460 Volts AC input power or that can operate with a common DC bus are available with an integral Safe Torque Off (STO) feature. Such drives are TÜV Rheinland certified for use in safety-related motor control applications rated up to EN/ ISO 13849-1 Performance Level e (PLe) and SIL (Safety Integrity Level) 3, safety Category 3 per IEC 61508, EN 62061, and EN 61800-5-2, in which removing the motor’s motion-producing power is regarded to be a safe state.

The STO safety feature stops a motor from producing torque or restarting unexpectedly and is often used for emergency stops. It safely blocks the electrical power output from a Kinetix 7000 drive to the connected motor, causing the motor to coast to a stop due to friction and inertia. It is primarily the basis for drive-based functional safety, as it brings a Kinetix 7000 servo drive safely to a torque-free state. It is also considered a fail-safe drive feature because it is executed through hardware design and not software.

The Safe Torque Off feature finds application in a wide range of systems and machines with moving axes, including conveyor systems, robotics, and different material handling equipment. Note that the feature is activated by a dual-channel closed circuit within a Kinetix 7000 drive. Its response time is normally less than 25 milliseconds. The STO condition takes place through normal drive operation.

Extensive Motor Support

The Kinetix 7000 (400V class) servo drives are compatible with the following Allen-Bradley motors:

• Kinetix MPL-Series: High-output, low-inertia brushless rotary servo motors that are uniquely designed to deliver significantly higher torque in a compact, innovative design structure with a reduced footprint. They are primarily intended to meet the demanding power needs of high-performance motion systems. These highly dynamic servo motors are available with a choice of multi-turn or single-turn high-performance encoders that provide high-resolution feedback. Typical applications include electronic assembly, metal forming, material handling, packaging, and converting.
• Kinetix MPM-Series: Medium-inertia, brushless AC synchronous rotary servo motors that offer a compact, feature-rich, and power-dense solution for motion systems with heavier loads and higher inertia. They provide high-resolution multi-turn and single-turn absolute feedback, as well as a resolver feedback option. By leveraging smart motor technology, these servo motors are ideal for web handling, printing, automotive, converting, and other industrial applications with heavy payloads and high inertias.
• Kinetix MMA Asynchronous Main Motors: Three-phase AC induction Allen-Bradley motors that are designed for heavy-duty motion systems requiring maximum torque and power output across an extensive range of speeds. They are a highly configurable type of induction motors, providing optimized motion performance in a mechanical structure with a variety of special options and configurable features that allow users to customize their motor solutions. Typical applications include flying knife, converting, material handling, metal forming, sheeters, winding/unwinding/rewinding machines, and tire building.
• Kinetix HPK-Series: High-horsepower asynchronous servo motors that employ the well-established induction motor technology to optimize servo system performance. These motors provide exceptional system performance for rapid deceleration and acceleration. They pair with the Kinetix 7000 servo drives to expand the range of Kinetix Integrated Motion solutions on SERCOS up to 150 kW. They are ideal for use in converting, high-power packaging, winders/rewinders/unwinders, flying knife, sheeters, and material handling applications.
• Kinetix RDB-Series: Direct-drive rotary servo motors that connect directly to the applied load, eliminating the use of gearboxes, pulleys, timing belts, and other mechanical elements. This results in faster settling times, better overall control of the applied load, and reduced energy consumption. Reduced part count and simplified mechanics also help minimize maintenance requirements and system downtime.

In addition, Kinetix RDB motors enable modern manufacturers to simplify the design of their motion systems while integrating servo solutions that provide exceptional speed and control to various production processes. These motors deliver high torque at low speeds, with a continuous torque range of 289 to 3770 lb-in (32.7 to 426 Nm). They are used in direct drive applications featuring motion axes with high-performance and high-power requirements and tight space constraints. They are also used to replace mechanical gearboxes, belts, and pulleys in servo systems. Though if the 7000 is a bit too much drive, we have a breakdown of the 6500 here that might better suit your system.

If you are looking to pick one of these drives up yourself, or even have your own drive repaired, we at DO Supply have you covered! Our team of experts are ready to assist you in finding the perfect fit for your automation system. We specialize in Allen-Bradley drives just like these, all backed by our two-year DO Supply Warranty. Give us a call today and we can help take your automation solution to the next level!