Kinetix 5500 vs Kinetix 5700

Overview

In the realm of modern motion control, the Allen-Bradley Kinetix family from Rockwell Automation is a dominant standard. For engineers designing systems within the Logix environment using Group 1 or Group 2 ControlLogix or CompactLogix controllers, the choice often narrows down to the Kinetix 5500 and the Kinetix 5700. While both drives are optimized for EtherNet/IP connectivity and single-cable motor technology, they are built to fulfill fundamentally different layout topologies and power requirements.

The Kinetix 5500 is a compact, standalone servo drive designed for small to mid-sized machine applications. It employs an innovative system that allows multiple standalone units to share a common DC bus via side-by-side terminal bus bars, reducing mains wiring but keeping each axis structurally independent.

The Kinetix 5700, on the other hand, is a highly modular, multi-axis system. It decouples the power supply from the drive modules entirely, utilizing a central DC-bus power supply (or regenerative power supply) to distribute power to individual single-axis or space-saving dual-axis servo modules. This system is engineered for large, complex machines with high axis counts where panel space, wiring efficiency, and absolute power density are critical priorities.

Key Differences at a Glance

The architectural difference between these two platforms changes how controls engineers approach cabinet layout, system scaling, and thermal management.

Specifications Comparison

The table below provides direct technical specifications for comparing power, voltage, control capability, and lifecycle state.

Performance & Capabilities

When assessing purely mechanical performance, the Kinetix 5700 scales parameters far beyond the limits of the Kinetix 5500.

Power and Current Capacity

The Kinetix 5500 operates comfortably in the low to mid-range power spectrum, delivering continuous output currents from 1.6 A to 32.5 A (peak currents up to 43.1 A). This meets the needs of most standard packaging, assembly, and materials handling applications.

The Kinetix 5700 scales up to 192 A continuous output current (with peak output exceeding 300 A in high-output frames). Additionally, rather than letting decelerating energy dissipate as heat across external shunt resistors, the Kinetix 5700 family supports Regenerative Power Supplies (typically catalog series 2198-RP). These units feed excess energy back onto the AC main power grid, significantly lowering utility demands for large-scale operations like printing presses, continuous web handling, and large gantries.

Feedback Configuration

While the Kinetix 5500 keeps things lean by standardizing on Hiperface DSL digital feedback (allowing a single, unified cable for power and feedback), it struggles when tasked with integrating legacy motors or high-resolution encoders requiring dual-loop control.

The Kinetix 5700 bypasses this limitation. By leveraging auxiliary feedback cards (like the 2198-AUXKIT), it supports EnDat absolute encoders, legacy Stegmann Hiperface/SinCos encoders, resolvers, and secondary feedback devices for physical load-side positioning. This makes the 5700 highly adaptable to systems requiring sub-micron scaling precision or extreme load-side backlash compensation.

Programming & Software

Both Kinetix platforms integrate seamlessly with Rockwell Automation’s software ecosystem, meaning system commissioning is handled natively inside Studio 5000 Logix Designer using standard Motion Instructions (such as MAM, MAJ, MCG, and MAG).

However, the hardware configuration steps within the I/O Tree vary significantly:

• Kinetix 5500 AOP (Add-On Profile): Configuration is straightforward. The user adds the specific drive catalog number directly to the Ethernet branch. Tuning relies on the integrated Load Observer engine inside ControlLogix to dynamically adjust gains, compensating for real-time load mechanics.
• Kinetix 5700 AOP: Setting up the I/O tree requires creating a power system profile (defining the DC Bus power supply) and then mounting the physical single or dual-axis modules onto that power rail virtual equivalent. Tuning capabilities also include Adaptive Tuning with tracking notch filters that adjust dynamically to structural resonances, minimizing machine wear and high-frequency acoustic noise.

Communication & Networking

Both families utilize EtherNet/IP with CIP Sync (part of the ODVA Common Industrial Protocol standard) as their core communication protocol, meaning they can perform precision multi-axis synchronized motion over standard Ethernet.

However, physical implementation varies:

• Kinetix 5500: Uses dual-port Ethernet connections to support Device Level Ring (DLR) topologies. This provides high network resiliency without needing external managed switches for basic ring layouts.
• Kinetix 5700: Also features dual active ports, facilitating DLR configurations. Because of the sheer mass of data generated by multi-axis modules (which might pack up to 30 synchronized axes on a single DC-bus link), 5700 networks require high-performance network designs. These often leverage Stratix managed switches configured with Quality of Service (QoS) priorities to prevent timing jitter and motion packet drops.

Pricing & Lifecycle

Both the Kinetix 5500 and 5700 are actively supported, flagship products in Rockwell Automation’s current portfolio, meaning they are not facing obsolescence phase-outs or end-of-life cycles in the foreseeable future.

Total Cost of Ownership (TCO) Calculations

• Low-Axis Applications (1–3 Axes): The Kinetix 5500 is highly cost-effective here. Because it features an integrated AC main input rectifier, you do not need to buy a separate central power supply module. You buy only the drives you need.
• High-Axis Applications (4+ Axes): The financial scale tips toward the Kinetix 5700. In high-axis setups, purchasing one central DC-bus power supply and multiple space-saving dual-axis drive modules is far cheaper per axis than buying multiple standalone AC-input Kinetix 5500 drives. It also drastically reduces the physical footprint, slicing cabinet cooling costs and DIN rail length requirements by up to 50%.

When to Choose Each

Select the Kinetix 5500 if:

1. Low Axis Counts: Your mechanical design requires only 1 to 4 axes of synchronized motion.
2. Standard Power Demands: Your continuous power requirements do not exceed 15 kW per motor, and you are using VP-Series low-inertia or food-grade motors.
3. Budget Focus: You want a low entry-point cost per drive without investing in modular power grids or common-bus rail infrastructures.
4. Primary Drive Needs: Basic Safe Torque Off (STO) is sufficient for your plant-floor safety requirements.

Select the Kinetix 5700 if:

1. High Axis Densities: You are building large, multi-station machines (e.g., fillers, cartoners, complex assembly lines) with 6 to 30+ axes per control enclosure.
2. Advanced Safety Needs: You need SIL3/PLe safety functions over the network, such as Safe Stop, Safe Speed, Safe Direction, or Guarded SLimits, implemented via CIP Safety.
3. High Power/Heavy Duty Cycles: Your application demands huge mechanical torque requiring motors rated above 15 kW (such as high-inertia HPK-Series or massive VPH Hygienic motors).
4. Feedback Diversity: Your process requires dual-loop feedback, auxiliary encoders, or legacy resolver integrations.
5. Cabinet Optimization: You must squeeze maximum control density into a minimal cabinet footprint using dual-axis profile modules.

Migration & Upgrade Path

For facilities running legacy motion systems, modernizing to either platform yields major gains in throughput and safety.

Upgrading Legacy Drives (Kinetix 6000 or Ultra3000)

• To Kinetix 5500: Best suited for replacing standalone legacy drives like the Ultra3000 or older single-phase systems. If you are upgrading older machinery with low axis counts to EtherNet/IP, replacing the legacy hardware with Kinetix 5500 modules alongside high-performance VPL-Series motors is a direct path to higher machine speeds and simplified cabling.
• To Kinetix 5700: This is the natural upgrade path for legacy modular multi-axis platforms, such as the Kinetix 6000 or Kinetix 6500. Transitioning to the 5700 allows you to eliminate external breakout panels, consolidate power wiring via the shared DC bus architecture, and implement integrated CIP Safety over the physical communication network, replacing bulky hardwired safety relays.

Frequently Asked Questions

Can I mix Kinetix 5500 and Kinetix 5700 drives on the same Logix network?

Yes. Because both drive platforms communicate over standard EtherNet/IP using standard CIP Sync motion profiles, a single ControlLogix or CompactLogix processor can easily coordinate motion profiles across a mixed network containing both Kinetix 5500 and Kinetix 5700 drives.

Does the Kinetix 5500 support dual-axis drive modules?

No. The Kinetix 5500 hardware architecture is strictly a standalone, single-axis design per frame module. If you require dual-axis modules within a single housing to conserve panel space, you must use the Kinetix 5700 platform.

What is the maximum physical cable distance supported?

Both drive families support standard motor power and feedback cabling up to 50 meters (164 feet) for standard VP-Series single-cable designs. However, the Kinetix 5700 can be configured with specialized feedback extenders and long-distance filters to manage high-capacitance current leakage in very large installations.

Can both drives run induction motors?

Yes. Both the Kinetix 5500 and Kinetix 5700 are capable of running standard induction (AC third-party) motors utilizing open-loop frequency control (V/Hz) or closed-loop vector control in addition to high-performance PM servo motors.

Related Articles

• Troubleshooting EtherNet/IP Motion Jitter on Kinetix Drives
• Sizing DC Bus Capacitance in Shared Bus Kinetix 5500 Systems
• Understanding CIP Safety on Kinetix 5700 Modular Systems