Allen-Bradley Kinetix 6000M User manual

User Manual

Kinetix 6000M Integrated Drive-Motor System

Catalog Numbers 2094-SEPM-B24-S, MDF-SB1003P, MDF-SB1153H, MDF-SB1304F

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety

Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1

available from your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/ ) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

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.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Rockwell Software, Rockwell Automation, Kinetix, On-Machine, ControlLogix, CompactLogix, SoftLogix, RSLinx, RSLogix, DriveExplorer, ControlFLASH and TechConnect are trademarks of

Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Table of Contents

Preface

Start

About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1

About the Kinetix 6000M System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Typical Hardware Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Typical Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Catalog Number Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Component Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

CE Requirements (system without LIM module). . . . . . . . . . . . . . . . 19

CE Requirements (system with LIM module). . . . . . . . . . . . . . . . . . . 19

Planning the Kinetix 6000M System

Installation

Chapter 2

Cable Length Restrictions and System Sizing . . . . . . . . . . . . . . . . . . . . . . . 21

IPIM Module Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Circuit Breaker/Fuse Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

IDM Unit Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Electrical Noise Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Cable Categories for Kinetix 6000M System . . . . . . . . . . . . . . . . . . . . 28

Chapter 3

Mounting the Kinetix 6000M System

Mounting the IPIM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Using the 2094 Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installing the 2094 Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Determine Mounting Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Mount the IPIM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Installing the IDM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Aligning the IDM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Mount and Connect the IDM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Rockwell Automation Publication 2094-UM003A-EN-P - May 2012

3

Table of Contents

Kinetix 6000M System Connector

Data

Connecting the Kinetix 6000M

System

Chapter 4

IPIM Module Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 38

IPIM Module Connector and Signal Descriptions . . . . . . . . . . . . . . . . . . 39

Hybrid Cable DC Bus Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Hybrid Cable Communication Signals Connector . . . . . . . . . . . . . . 39

Safe Torque-off Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Sercos Fiber-optic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

EtherNet/IP Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

IPIM Module Network Connector Pinouts. . . . . . . . . . . . . . . . . . . . . 42

IDM Unit Connectors and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

IDM Unit Connector and Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . 44

Hybrid Cable Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

IDM Network Input and Output Connector Pinouts . . . . . . . . . . . 45

Digital Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Brake Override Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Peak Duty Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Absolute Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 5

Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Grounding the IDM System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Apply the Cable Shield Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

General IDM System Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Hybrid Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Network Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

How to Bypass an IDM Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

The Sercos Fiber-optic Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4



Configuring the Kinetix 6000M

System

Removing and Replacing the

Kinetix 6000M IPIM Module

Chapter 6

Configure the Kinetix 6000M Integrated Drive-motor System . . . . . . . 65

Understanding the IPIM Module Display . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Information Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Tools Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Configuring the IPIM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Setting the IPIM Module Network Address . . . . . . . . . . . . . . . . . . . . 69

Configuring the IDM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Setting the Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Add-on Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Configure the Logix Sercos Interface Module . . . . . . . . . . . . . . . . . . . . . . . 73

Configure the Logix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Configure the Logix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Configure the IDM Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Configure the Motion Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Apply Power to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Test the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Troubleshooting the Kinetix 6000M

System

Chapter 7

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

IDM System Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Reading the Fault Status of the IPIM Module . . . . . . . . . . . . . . . . . . . 88

Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

IPIM Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

IDM Unit Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

General System Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

IPIM Module Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

IPIM Module Fault Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

IDM Unit Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Logix Controller/IDM Unit Fault Behavior . . . . . . . . . . . . . . . . . . . . 95

Use a Web Browser to Monitor System Status . . . . . . . . . . . . . . . . . . . . . . 97

Chapter 8

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Remove the IPIM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Replace the IPIM Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


5


Using the Safe Torque-off Feature with the Kinetix 6000M System

Appendix A

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Category 3 Requirements According to EN ISO 13849-1 . . . . . . . 104

Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Performance Level (PL) and Safety Integrity Level (SIL) . . . . . . . . 104

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Troubleshooting the Safe Torque-off Function . . . . . . . . . . . . . . . . 105

PFD, PFH, and MTTFd Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

PFD, PFH, and MTTFd Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Wiring Your Safe Torque-off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

IDM Safe Torque-off Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Safe Torque-off Feature Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

IDM System Safe Torque-off Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Cascading the Safe Torque-off Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Safe Torque-off Signal Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Appendix B

Interconnect Diagram

Upgrading the Kinetix 6000M System

Firmware

Appendix C

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Configure Logix Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

IPIM Module Firmware Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

IDM Unit Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Kinetix 6000M System Sizing

Index

Appendix D

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Manually Sizing the Kinetix 6000M System . . . . . . . . . . . . . . . . . . . . . . . 128

6


Preface

About This Publication

This manual provides detailed installation instructions for mounting, wiring, and troubleshooting the Kinetix® 6000M Integrated Drive-Motor (IDM) system including the IDM Power Interface Module (IPIM).

For information on wiring and troubleshooting the safe-off feature on your integrated drive-motor system, refer to Appendix

A .

This manual is intended for engineers or technicians directly involved in the installation, wiring, and programming of the Kinetix 6000M integrated drivemotor system.

If you do not have a basic understanding of the Kinetix drives, contact your local

Rockwell Automation sales representative for information on available training courses.

Conventions Used in This

Manual

The conventions listed below are used throughout this manual.

• Bulleted lists such as this one provide information, not procedural steps.

• Numbered lists provide sequential steps or hierarchical information.

• Acronyms for the Kinetix 6000 and Kinetix 6200 system components and

Kinetix 6000M integrated drive-motor are shown in the table below and are used throughout this manual.

Acronym

IDM

IPIM

IAM

AM

LIM

Kinetix Modules

Integrated drive-motor

IDM power interface module

Integrated axis module

Axis module

Line interface module

Cat. No.

MDF-SBxxxxx-Qx8xA-S

2094-SEPM-B24-S

2094-BCxx-Mxx-x

2094-BMxx-x

2094-BLxx and 2094-BLxxS-xx

Additional Resources

These documents contain additional information concerning related

Rockwell Automation products.

Resource

Kinetix 6000M IPIM-to-IDM Hybrid Cable Installation Instructions, publication 2090-IN031

Kinetix 6000M IDM-to-IDM Hybrid Cable Installation Instructions, publication 2090-IN032

Description

Provides detailed cable information.

Kinetix 6000M IDM Network Cable Installation Instructions, publication 2090-IN034

Kinetix 6000M Manual Brake Release Cable Installation

Instructions, publication 2090-IN037


7

Preface

8

Resource

Kinetix 6000M IPIM Hybrid Terminator Installation Instructions, publication 2090-IN035

Kinetix 6000M Network Terminator Installation Instructions, publication 2090-IN036

Kinetix 6000M Hybrid Power Coupler Installation Instructions, publication 2090-IN038

Description

Provides detailed terminator information.

Kinetix 6000M Bulkhead Cable Adapter Kit Installation

Instructions, publication 2090-IN039

Kinetix 6000M Integrated Drive-Motor Installation Instructions, publication MDF-IN001

Kinetix 6000M Integrated Drive-Motor Power Interface Module

Installation Instructions, publication

2094-UM001

2094-IN016

Kinetix 6000 Multi-axis Servo Drives User Manual, publication

Kinetix 6200 and Kinetix 6500 Modular

Multi-axis Servo Drives User Manual, publication 2094-UM002

Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010

Provides installation information for the Hybrid

Power Coupler.

Provides installation information for the Bulkhead

Cable Adapter.

Provides installation information for the IDM unit.

Provides information on the installation of the IPIM module.

Provides detailed information about the Kinetix

6000 drives.

Provides detailed information about the Kinetix

6200 drives.

Provides information on proper handling, installing, testing, and troubleshooting fiber-optic cables.

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Provides information, examples, and techniques designed to minimize system malfunctions caused by electrical noise.

EMC Noise Management DVD, publication GMC-SP004

Kinetix Rotary Motion Specifications, publication GMC-TD001

Kinetix Safe-off Feature Safety Reference Manual, publication

GMC-RM002

Provides IPIM module and IDM unit specifications.

Kinetix Motion Accessories Specifications, publication GMC-TD004 Provides product specifications for Bulletin 2090 motor and interface cables, low-profile connector kits, drive power components, and other servo drive accessory items.

Provides information on wiring and troubleshooting your Kinetix 6000 servo drives with the safe-off feature.

Kinetix Motion Control Selection Guide, publication GMC-SG001 Provides specifications, motor/servo-drive system combinations, and accessories for Kinetix motion control products.

Sercos and Analog Motion Configuration User Manual, publication

MOTION-UM001

Provides information on configuring and troubleshooting your ControlLogix®,

CompactLogix™, and SoftLogix™ sercos interface modules.

Motion Coordinate System User Manual, publication

MOTION-UM002

SoftLogix Motion Card Setup and Configuration Manual, publication

AG-7.1

1784-UM003

Rockwell Automation Industrial Automation Glossary, publication

Rockwell Automation Configuration and Selection Tools website: http://www.rockwellautomation.com/en/e-tools

Provides information to create a motion coordinate system with sercos or analog motion modules.

Provides information on configuring and troubleshooting SoftLogix PCI cards.

A glossary of industrial automation terms and abbreviations.

Rockwell Automation Product Certification website: http://www.rockwellautomation.com/products/certification

Motion Analyzer application analysis software for drive/motor sizing.

Online product selection and system configuration tools, including AutoCAD (DXF) drawings.

For declarations of conformity (DoC) currently available from Rockwell Automation.

You can view or download publications at http:/www.rockwellautomation.com/literature/ . To order paper copies of technical documentation, contact your local Allen-Bradley® distributor or

Rockwell Automation sales representative.


Chapter

1

Start

Use this chapter to become familiar with the design and installation requirements for the Kinetix 6000M integrated drive-motor system.

Topic

About the Kinetix 6000M System

Typical Hardware Configurations

Typical Communication Configurations

Catalog Number Explanations

Component Compatibility

Agency Compliance

17

18

19

11

16

Page

9

About the Kinetix 6000M

System

The Kinetix 6000M integrated drive-motor system is designed to provide a

Kinetix Integrated Motion solution for your applications. Table 1 lists the

components that can be used to build an integrated solution.

System Component Cat. No.

IDM Unit MDF-SBxxxxx-Qx8xA-S

IDM Power Interface

Module (IPIM)

2094-SEPM-B24-S

Table 1 - System Component Overview

Description

Integrated drive-motor (IDM) unit with the safe-off feature. The unit contains a servo drive and motor.

460V AC integrated drive-motor power interface module that resides on the power rail and provides power and communications to the IDM units. The module also monitors power output and provides overload protection.

Hybrid cable provides power and inter-module communication to each IDM unit via daisy chain.

IDM Hybrid Cables

IDM Network Cables

From the IPIM module to the first IDM unit:

2090-CHBIFS8-12AAxx

From IDM unit to IDM unit:

2090-CHBP8S8-12AAxx

From the IPIM module to the first IDM unit:

2090-CNSSPRS-AAxx,

2090-CNSSPSS-AAxx

From IDM unit to IDM unit:

2090-CNSSPRS-AAxx,

2090-CNSSPSS-AAxx,

2090-CNSRPSS-AAxx,

2090-CNSRPRS-AAxx

Integrated Axis Module 2094-BCxx-Mxx-S (Kinetix 6000)

2094-BCxx-Mxx-M (Kinetix 6200)

Axis Module 2094-BMxx-S (Kinetix 6000)

2094-BMxx-M (Kinetix 6200)

Shunt Module 2094-BSP2

Required to daisy chain the Kinetix 6000M network.

460V Integrated Axis Modules (IAM) contains an inverter and converter section.

Axis Modules (AM) are a shared DC-bus inverter rated for 460V input power. The AM module must be used with an IAM module.

The Bulletin 2094 shunt module mounts to the power rail and provides additional shunting capability in regenerative applications.


9

Chapter 1

Start

System Component

Power Rail

Power Rail Slot-filler

Module

Cat. No.

2094-PRSx

2094-PRF

Logix Controller Platform 1756-Mxx SE CompactLogix module

1768-M04SE ControlLogix module

1784-PM16SE PCI option card

RSLogix 5000 Software 9324-RLD300ENE

Description

The Bulletin 2094 power rail consists of copper bus bars and a circuit board with connectors for each module. The power rail provides power and control signals from the converter section to adjacent inverters. The IPIM, IAM and AM power modules, shunt module, slot-filler modules mount to the power rail.

The Bulletin 2094 slot-filler module is used when one or more slots on the power rail are empty after all the other power rail modules are installed. One slot-filler module is required for each empty slot.

The network interface module/PCI card serves as a link between the ControlLogix/CompactLogix/

SoftLogix platform and the Kinetix 6000 drive system. The communication link uses the IEC 61491 Serial

Real-time Communication System (sercos) protocol over a fiber-optic cable.

RSLogix 5000 software provides support for programming, commissioning, and maintaining the Logix family of controllers. Version 20 or later is required when using the Kinetix 6000M integrated drivemotor system.

Line Interface Modules

IDM Unit Digital Input

Cables

Safe-Off Wiring

Headers

(1)

2094-BLxxS

2094-XL75S-Cx

889D DC Micro

For first drive in multiple safety drive configurations: 2090-XNSM-W

Middle header for drive-to-drive connections in multiple safety drive configurations with three or more drives:

2090-XNSM-M

Safe-off terminating header for the last drive in multiple safety drive configurations:

2090-XNSM-T

Line interface modules (LIM) include the circuit breakers, AC line filter (catalog number 2094-BL02 only), power supplies, and safety contactor required for Kinetix 6000 operation. The LIM module does not mount to the power rail. You can purchase individual components separately in place of the LIM module.

Allows use of sensors (see

Digital Input Connectors on page 45

). Also refer to the Connection Systems

Quick Selection Guide, publication CNSYS-BR001 , or the On-Machine™ Connectivity Catalog, publication

M117-CA001 .

Required for various installations of the IPIM module into the Kinetix 6000 servo drive systems.

Sercos Interface Cables Network fiber-optic plastic cables, regular duty:

2090-SCEPx-x

2090-SCVPx-x

2090-SCNPx-x (harsh duty)

Network fiber-optic glass cables:

2090-SCVGx-x

Network fiber optic cable bulkhead adapter:

2090-S-BLHD (2 per pack)

EtherNet/IP Interface

Cables

RJ45-to-RJ45:

1585J-M8CBJM-xx:

RJ45 Insulation Displacement Connector:

1585J-M8CC-H

Cable, shielded: 1585-C8CB-Sxxx

Required for various installations of the IPIM module into the Kinetix 6000 and Kinetix 6200 servo drive systems.

Required for various installations of the IPIM module into the Kinetix 6200 servo drive systems.

Cascaded Safety Cables

Bulkhead Adapter Kits

1202-Cxx (xx = length)

Network cable: 2090-CBUSPSS

Hybrid cable: 2090-KPB47-12CF

Required accessory to support cascaded safety wiring across multiple modules on the 2094 power rail.

Provides wall-mount connectors for hybrid and network cables. The connector kit allows signals to pass through a cabinet wall or other physical barrier.

(1) Refer to

Appendix A

for safety information.

10


Typical Hardware

Configurations

Start

Chapter 1

SHOCK HAZARD: To avoid personal injury due to electrical shock, place a

2094-PRF slot-filler module in all empty slots on the power rail.

Any power rail connector without a module installed will disable the 3-phase power; however, control power is still present.

Figure 1 - Typical Kinetix 6000M Integrated Drive-motor System

Catalog numbers are in parenthesis

IPIM-to-IDM Hybrid Cable

(2090-CHBIFS8-12AAxx)

IPIM Module

(2094-SEPM-B24-S)

IDM-to-IDM Hybrid Cable

(2090-CHBP8S8-12AAxx)

Terminator

Last IDM Unit

(2090-CTHP8)

Network Cable

(2090-CNSxPxS)

Network Terminator

Last IDM Unit

(2090-CTSRP)

PORT 1 PORT 2 NETWORK

IDM Unit

(MDF-SBxxxx)

IDM Unit

(MDF-SBxxxx)

Network Cable to

First IDM Unit

(2090-CNSSPxS)


11

Chapter 1

Start

Figure 2 - Typical 2094 Power Rail with Kinetix 6000M System (with LIM)

3-Phase

Input Power

2090-XXLF-xxxx

AC Line Filter

(required for CE)

2094-BLxxS

Line Interface Module

(optional component)

MAIN VAC

Control Power

2094 Drive System

(Kinetix 6000 shown)

2094-PRSx

Power Rail

2090-K6CK-Dxxxx

Low Profile Connector

Kits for I/O, Motor

Feedback, and Aux

Feedback

To Input Sensors and Control String

Bulletin 2090

Motor Feedback Cables

2094-SEPM-B24-S

IPIM Module

2094-BSP2

Shunt Module


2094-PRF

Slot-filler Module

(required for unused slots)

Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

Digital

Inputs

MDF-SBxxxxx

IDM Unit

Digital

Inputs

MDF-SBxxxxx

IDM Unit

Digital

Inputs

MDF-SBxxxxx

IDM Unit

Digital

Inputs

MDF-SBxxxxx

IDM Unit

2090-CTHP8, 2090-CTSRP terminators required on last IDM unit.

Bulletin 2090

Motor Power Cables

12


Start

Chapter 1

Magnetic

Contactor

3-Phase Input Power

Line

Disconnect

Device

Input

Fusing

Control

Power

Figure 3 - Typical 2094 Power Rail with Kinetix 6000M System (without LIM)

2090-XXLF-xxxx

Line Filter

(required for CE)

2094-SEPM-B24-S

IPIM Module

2094-BSP2

Shunt Module


2090-XXLF-xxxx

AC Line Filter

(required for CE)

2094 Drive System

(Kinetix 6000 shown)

2094-PRSx

Power Rail

2090-K6CK-Dxxxx

Low Profile Connector Kits for I/O,

Motor Feedback, and Aux Feedback


Digital

Inputs

2094-PRF

Slot-filler Module

(required for unused slots)

Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

MDF-SBxxxxx

IDM Unit

Digital

Inputs

MDF-SBxxxxx

IDM Unit

Digital

Inputs

MDF-SBxxxxx

IDM Unit

Bulletin 2090


Digital

Inputs

MDF-SBxxxxx

IDM Unit


Bulletin 2090

Motor Power Cables


13

Chapter 1

Start

In the following example, the leader IAM module is connected to the follower

IAM module via the DC common-bus. When planning your panel layout, you must calculate the total bus capacitance of your DC common-bus system to be sure that the leader IAM module is sized sufficiently to pre-charge the entire system.

Refer to the Kinetix 6000 Multi-axis Servo Drives User Manual, publication

2094-UM001, or the Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo

Drives User Manual, publication 2094-UM002 , for further information.

IMPORTANT

If total bus capacitance of your system exceeds the leader IAM module precharge rating and input power is applied, the IAM module status indicator will display an error code.

To correct this condition, you must replace the leader IAM module with a larger module or decrease the total bus capacitance by removing AM or IPIM modules.

14


Start

Chapter 1

Figure 4 - Typical Kinetix 6000 with Kinetix 6000M System Common Bus

2090-XXLF-xxxx

AC Line Filter (required for CE)

3-phase

Input Power

Control Power

MAIN VAC

2094-BLxxS



2094-BCxx-Mxx-S

IAM Module

Common Bus Leader

2094-PRSx Power Rail

DC Common Bus

2094-SEPM-B24-S

IPIM Module

2094-BSP2

Shunt Module


2094-PRF

Slot-filler Module

(required to fill unused slots)

2094-BCxx-Mxx-S

IAM Module

Common Bus Follower


Bulletin 2090


Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

Digital

Inputs

MDF-SBxxxxx

IDM Unit

Digital

Inputs

MDF-SBxxxxx

IDM Unit


Bulletin 2090

Motor Power Cables


15

Chapter 1

Start

Typical Communication

Configurations

TX

RX

The Kinetix 6000M IPIM module uses the EtherNet/IP network to report diagnostics to the controller and for firmware upgrades via ControlFLASH™ software. For more information on Ethernet cables, refer to the Industrial

Ethernet Media Brochure, publication 1585-BR001 .

Figure 5 - Typical Kinetix 6000M, Kinetix 6000 and Kinetix 6200 Network Configuration

Logix Controller Programming Network

Bulletin 1585

Ethernet (shielded) Cable

EtherNet/IP Module

Logix Sercos Interface Module

SERCOS interface

CP OK

Tx (rear)

Rx (front)

Logix Platform

(ControlLogix is shown)

Bulletin 2090

Sercos Fiber-optic Cable

RSLogix 5000

Software

Network Connectors (top view)

Kinetix 6000

Kinetix 6200 IPIM Module

➊ ➊

2094-SEPM-B24-S

IPIM Module

2094-BCxx-Mxx-S

IAM Module

RX TX

RX TX

Recommended Fiber-optic Cables

Number Cable Length Catalog Number

➊

0.1 m (5.1 in.) 2090-SCxx0-1

➋

0.2 m (7.1 in.) 2090-SCxx0-2

2094-PRSx

Power Rail

Digital

Inputs

Bulletin 2090

Network Cables

MDF-SBxxxxx

IDM Unit

Digital

Inputs

➊ ➋ ➋ ➊ ➋ ➊

MDF-SBxxxxx

IDM Unit

Single-wide

2094-BCxx-Mxx-S

IAM Module

2094-BMxx-M Single-wide

AM Power Modules with

2094-SE02F-M00-Sx

Control Modules

2094-BMxx-S

Single-wide AM

Module

Kinetix 6000 Double-wide

2094-BCxx-Mxx-S

IAM Module

2094-BMxx-S Double-wide

AM Module

16


Catalog Number

Explanations

Start

Chapter 1

Kinetix 6000M catalog numbers and descriptions are listed in the tables below.

Table 2 - Power Interface Module (IPIM)

Cat. No.

2094-SEPM-B24-S

Description

460V IDM Power Interface Module (IPIM) w/Safe-off

Table 3 - Integrated Drive-motor (IDM)

Cat. No. (No Brake)

MDF-SB1003P-QJ82A-S

Cat. No. (with Brake)

MDF-SB1003P-QJ84A-S

Description

460V, IEC 100 mm, 5000 rpm, Keyed

MDF-SB1003P-QK82A-S MDF-SB1003P-QK84A-S 460V, IEC 100 mm, 5000 rpm, Smooth

MDF-SB1153H-QJ82A-S MDF-SB1153H-QJ84A-S 460V, IEC 115 mm, 3500 rpm, Keyed

MDF-SB1153H-QK82A-S MDF-SB1153H-QK84A-S

MDF-SB1304F-QJ82A-S MDF-SB1304F-QJ84A-S

MDF-SB1304F-QK82A-S MDF-SB1304F-QK84A-S

460V, IEC 115 mm, 3500 rpm, Smooth

460V, IEC 130 mm, 3000 rpm, Keyed

460V, IEC 130 mm, 3000 rpm, Smooth

Table 4 - Replacement Parts

Cat. No.

MPF-SST-A3B3

MPF-SST-A4B4

MPF-SST-A45B45

2094-XNIPIM

2094-SEPM-FUSE

MDF-SB-NODECVR

1485-M12

2090-CTHP8

2090-CTSRP

Description

Shaft seal kit for:

MDF-SB1003

MDF-SB1153

MDF-SB1304

IPIM module connectors; includes hybrid DC bus, hybrid communication, safe-off, and enable.

Fuses for IPIM module, 6 each.

IDM unit node address switch covers.

IDM unit digital input connector covers.

Terminator:

Hybrid

Network

Table 5 - Accessories

Cat. No.

MPS-AIR-PURGE

Description

Positive air pressure kit.


17

Chapter 1

Start

Component Compatibility

The Kinetix 6000M integrated drive-motor system is compatible with:

• 400V-class Series B Kinetix 6000 drive systems

• 400V-class Kinetix 6200 drive systems

IMPORTANT

Kinetix 6500 EtherNet/IP control modules (catalog numbers 2094-EN02D-

M01-Sx) are not compatible with the Kinetix 6000M IPIM or Kinetix 6000/

Kinetix 6200 IAM and AM modules on the same Bulletin 2094 power rail.

IMPORTANT

The IDM system cannot be accessed with DriveExplorer™ or a human interface module (HIM). However, all IDM units will respond to a Stop command from a

HIM.

Table 6 - IDM System Compatibility

Component

RSLinx® software version

RSLogix™ 5000 software

IPIM AOP (Add-On Profile)

Kinetix 6000 drive firmware

Kinetix 6200 drive firmware

ControlLogix EtherNet/IP modules

Requires

RSLinx version 2.59 or greater will fully support the IPIM module after installation of an appropriate EDS file

20.01

(1)

or later

1.x

1.123 or later

1.045 or later

All 1756 Ethernet modules; 1756-ENBT, 1756-EN2T

(1) Version 20.00 may be used if the motion database is updated to version 8.12. For detailed information about updating the motion database, refer to RA Knowledgebase article 490160.

18


Agency Compliance

Start

Chapter 1

If this product is installed within the European Union and has the CE mark, the following regulations apply.

ATTENTION: Meeting CE requires a grounded system, and the method of grounding the AC line filter and IDM must match. Failure to do this renders the filter ineffective and may cause damage to the filter.

Refer to

Grounding the IDM System

on

page 54

.

For more information on electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 .

CE Requirements (system without LIM module)

To meet CE requirements when your system does not include the LIM module, these requirements apply:

• Install an AC line filter (catalog number 2090-XXLF-xxxx) as close to the

IAM module as possible.

• Use line filters for 3-phase input power and single-phase control power.

• Use 2090 series cables.

• Use 889 series sensor cables.

• Combined motor power cable length for all axes on the same power rail must not exceed 240 m (787 ft).

• Combined cable length for all IDM units connected to a single IPIM module is 100 m (328 ft).

• Install the Kinetix 6x00 system inside an enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure.

Separate signal and power cables.


2094-UM001 , or the Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo

Drives User Manual, publication 2094-UM002 , for interconnect diagrams, including input power wiring.

CE Requirements (system with LIM module)

To meet CE requirements when your system includes the LIM module, follow all

the requirements as stated in CE Requirements (system without LIM module)

and these additional requirements as they apply to the AC line filter.

• Install the LIM module (catalog numbers 2094-BL02) as close to the IAM module as possible.

• Install the LIM module (catalog numbers 2094-BLxxS, or 2094-XL75S-

C

x) with line filter (catalog number 2090-XXLF-xxxx) as close to the

IAM module as possible.

When the LIM module (catalog numbers 2094-BL

xxS, or 2094-XL75S-

C

x) supports two IAM modules, each IAM module requires an AC line filter installed as close to the IAM module as possible.


19

Chapter 1

Start

Notes:

20


Chapter

2

Planning the Kinetix 6000M System Installation

This chapter describes system installation guidelines used in preparation for mounting your Kinetix 6000M components.

Topic

Cable Length Restrictions and System Sizing

IPIM Module Design Guidelines

IDM Unit Design Guidelines

Electrical Noise Reduction

22

26

Page

21

27

ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

Cable Length Restrictions and System Sizing

This section provides guidelines for sizing an IDM system. For accurate, detailed sizing, use Motion Analyzer software version 6.000 or later. For additional information and a sizing estimation method, refer to

Kinetix 6000M System

Sizing on page 127

.

When sizing your system, please note the following:

• Motion Analyzer software (version 6.000 or later), should be used for sizing your system.

• Maximum cable length between IDM units is 25 m (82 ft).

• Combined cable length for all IDM units connected to a single IPIM module is 100 m (328 ft).

• Combined motor power and hybrid cable length for all axes on the same power rail must not exceed 240 m (787 ft).

• The number of IDM units also depends on the use of the safe-off function.

Refer to

Using the Safe Torque-off Feature with the Kinetix 6000M

System on page 103 for details.


21

Chapter 2

Planning the Kinetix 6000M System Installation

The following items limit the number of IDM units that can be used in a system.

1. The IDM unit control power load which consists of three load sources:

• internal load (constant)

• parking brake load

• digital input loading.

These items also affect the total control power load:

• The cable lengths between IDM units

• IDM units with brakes and their location in the daisy chain

• IDM units that use digital inputs.

2. The continuous and intermittent load on the DC bus of all AM modules and IDM units.

IMPORTANT

The Kinetix 6000 or Kinetix 6200 IAM module supplying DC bus power to the

IDM units should be sized to support all IDM units connected to the power rail.

Motion Analyzer software (version 6.000 or later) sizing analysis accounts for control power and DC bus power.

3. The total number of axes connected in the safe-off circuit.

IPIM Module Design

Guidelines

Use the information in this section when designing your enclosure and planning to mount your system components.

For on-line product selection and system configuration tools, including

AutoCAD (DXF) drawings of the product, refer to http://www.rockwellautomation.com/en/e-tools .

System Mounting Requirements

• To comply with UL and CE requirements, the Kinetix 6000M power interface module must be part of a Kinetix 6000 or Kinetix 6200 system that is enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP2X such that they are not accessible to an operator or unskilled person. A NEMA 4X enclosure exceeds these requirements providing protection to IP66.

• The panel you install inside the enclosure for mounting your system components must be on a flat, rigid, vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors.

• Size the enclosure so as not to exceed the maximum ambient temperature rating. Consider heat dissipation specifications for all components.

• Use high-frequency (HF) bonding techniques to connect the modules, enclosure, machine frame, and motor housing, and to provide a lowimpedance return path for high-frequency (HF) energy and reduce electrical noise.

22



Chapter 2

• Combined motor power cable lengths for all axes and hybrid cable lengths for all IDM units on the same DC bus must not exceed 240 m (787 ft) with 400V-class systems. Drive-to-motor power cables must not exceed

90 m (295.5 ft).

IMPORTANT

System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements.

Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 , to better understand the concept of electrical noise reduction.

Circuit Breaker/Fuse Options

The 2094-SEPM-B24-S IPIM module and the MDF-SBxxxxx IDM units use internal solid-state motor short-circuit protection and when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 200,000 A. Fuses or circuit breakers, with adequate withstand and interrupt ratings, as defined in NEC or applicable local codes, are permitted.

The 2094-BL02 LIM module contains supplementary protection devices and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 5000 A. When these modules are used, protection on the line side of the LIM module is required. Fuses must be class J or

CC only.

The 2094-BL

xxS, and 2094-XL75S-Cx LIM modules contain branch circuit rated devices suitable for use on a circuit capable of delivering up to 65,000 A

(400V-class).

Refer to the Line Interface Module Installation Instructions, publication 2094-

IN005 , for power specifications and more information on using the LIM module.

Fuse Location and Replacement

The IPIM module uses internal fuses (see

Figure 6

) for short-circuit protection of the DC bus. The recommended fuse is Bussmann FWP-50A14Fa. A fuse replacement kit (catalog number 2094-SEPM-FUSE) is also available.


23

Chapter 2


Figure 6 - IPIM Fuse Location

24

ATTENTION: Capacitors on the DC bus may retain hazardous voltages after input power has been removed. Before working on the IDM system, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the IPIM module. Failure to observe this precaution could result in severe bodily injury or loss of life.

To replace the fuses, follow these steps.

1. Ensure that all power to the power rail has been removed.

2. Measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the IPIM module.

3. Loosen the captive screws.

4. Grasp the top and bottom edges of the fuse holder and pull straight out.

5. Replace the fuses.

Enclosure Selection

Heat dissipation of the IPIM module is shown in

Table 7 and Table 8

. To size the enclosure you will need heat dissipation data from all equipment inside the enclosure (such as the Logix controller, LIM module, IAM). Once the total amount of heat dissipation (in watts) is known, you can calculate the minimum enclosure size.



Drives User Manual, publication 2094-UM002 , for further information.



Chapter 2

Table 7 - Power Dissipation Specifications - Percent of DC Bus Current

Power Dissipation as % of DC Bus Current Output Rating

Watts

20% 40% 60% 80% 100%

2 7 14 25 38

(1) x is percent of DC bus current output rating: any value between 0.0 and 1.0.

Heat Dissipation Formula

(1)

Y = 33.95x

2

+ 3.18x

Table 8 - Power Dissipation Specifications - Percent of IPIM Module Control Power

Power Dissipation as % of IPIM Module Control

Power Output Rating

Watts Control Power Input

Frequency

Hz

Voltage

AC

50

120V

240V

20%

22

34

40%

29

42

60%

38

52

80%

48

63

100%

61

76

60

120V

240V

23

38

27

49

32

62

39

76

46

92

(1) x is percent of IPIM module control power output rating: any value between 0.0 and 1.0.

Heat Dissipation Formulas

(1)

Y = 23.76x

2

+ 20.73x + 16.54

Y = 18.56x

2

+ 30.19x + 27.41

Y = 14.57x

2

+ 11.40x + 20.01

Y = 19.63x

2

+ 43.22x + 28.75

Minimum Clearance Requirements

This section provides information to assist you in sizing your cabinet and positioning your IDM unit.

Figure 7 illustrates minimum clearance requirements for proper airflow and

installation:

• Additional clearance is required for the cables and wires connected to the top and front of the module.

• Additional clearance left and right of the power rail is required when the module is mounted adjacent to noise sensitive equipment or clean wireways.

Table 9 - Minimum Cabinet Depth

Cat. No.

2094-SEPM-B24-S

Cabinet Depth, Min

272 mm (10.7 in.)


25

Chapter 2


Figure 7 - Minimum IPIM Module Clearance Requirements

50.8 mm (2.0 in.) clearance for airflow and installation

Clearance left of the module is not required

(1)

Power Rail

(2094-PRSx)

287 mm

(11.3 in.)

(2)

Clearance right of the module is not required

(1)

50.8 mm (2.0 in.) clearance for airflow and installation

(1) The power rail (slim), catalog number 2094-PRSx, extends left and right of the first and last module 5.0 mm (0.20 in.). The Bulletin 2094-PRx power rail extends approximately 25.4 mm (1.0 in.) left of the IAM module and right of the last module mounted on the rail.

(2) Dimension applies to the following modules:

IPIM module 2094-SEPM-B24-S

IAM module (Series B) 2094-BC01-Mxx-x and 2094-BC02-M02-x

AM module (Series B) 2094-BMP5-x, 2094-BM01-x, 2094-BM02-x

IDM Unit Design Guidelines

Minimum Clearance Requirements

Figure 8 illustrates minimum IDM unit clearance requirements for proper

airflow and installation.

BURN HAZARD: Outer surfaces of the motor can reach high temperatures,

125 °C (275 °F), during motor operation.

Take precautions to prevent accidental contact with hot surfaces. Consider IDM unit surface temperature when selecting motor mating connections and cables.

Failure to observe these safety procedures could result in personal injury or damage to equipment.

Additionally, consider the following items:

• Obtain the specified motor thermal rating by mounting the motor on a surface with heat dissipation equivalent to a 304.8 x 304.8 x 12.7 mm

(12 x 12 x 0.5 in.) aluminum heatsink.

• Do not install the motor in an area with restricted airflow, and keep other heat producing devices away from the motor.

26



Chapter 2

Figure 8 - Minimum IDM Unit Clearance Requirements

100.0 mm (3.9 in.)

100.0 mm (3.9 in.)

100.0 mm (3.9 in.)

Electrical Noise Reduction



Drives User Manual, publication 2094-UM002 , for information on best practices that minimize the possibility of noise-related failures as they apply specifically to

Kinetix 6000 system installations. For more information on the concept of highfrequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference

Manual, publication GMC-RM001 .

Observe these guidelines when your system includes the 2094-SEPM-B24-S

IPIM module. In this example, a 2094-BL02 LIM module is used in the Bulletin

2094 system and mounted left of the IAM module:

• Establish clean (C) and dirty zones (D) similar to other Bulletin 2094 drive systems.

• The sercos fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone.

• IPIM communication wires are noise sensitive and belong with the fiberoptic cables in the clean zone.

• Ethernet cables are noise sensitive and belong in the clean zone.

• IDM network cables, although noise sensitive by nature, are shielded and designed to be routed with the hybrid cable outside of the enclosure.

• The Bulletin 2090 hybrid cable is dirty and belongs in the dirty zone.

This layout is preferred due to the reduced size of the very dirty zone.


27

Chapter 2


D

Figure 9 - Noise Zones (Bulletin 2094 power rail with IPIM module)

Dirty Wireway

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Motor and Hybrid Cables

D

D

VD

Clean Wireway

Fiber-optic Cables and

IPIM Communication Wires

C

No sensitive

(2) equipment within

150 mm (6.0 in.).

2094-BL02 or 2094-BLxxS


C

Kinetix 6000

System

D

C

D

Route 24V DC I/O shielded cable.

I/O

(1)

, Feedback, and

Network Cables

Route encoder/analog/registration shielded cables.

(1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O cable in dirty wireway.

(2) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 .

Cable Categories for Kinetix 6000M System

Zoning requirements of cables connecting to the IDM system components are

shown in Table 10 .

Table 10 - IPIM Module Zoning Requirements

Wire/Cable

Hybrid DC bus power, control power, inter-module communication, and safeoff

(1)

Zone Method

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

X

X

X

X

X

Enable input

Fiber-optic No restrictions

Ethernet network

IDM network

(1)

(1) There is no option for making your own hybrid or IDM network cables.

X

X

X

X

X

X

28


Chapter

3

Mounting the Kinetix 6000M System

This chapter provides the system installation procedures for mounting your

Kinetix 6000M integrated drive-motor (IDM) unit and your power interface module (IPIM).

Topic

Mounting the IPIM Module

Installing the IDM Unit

Page

30

33

This procedure assumes you have prepared your panel, mounted your Bulletin

2094 power rail, and understand how to bond your system. For installation instructions regarding equipment and accessories not included here, refer to the instructions that came with those products.

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2094 power rail and modules prior to applying power.

Once power is applied, connector terminals may have voltage present even when not in use.



29

Chapter 3

Mounting the Kinetix 6000M System

Mounting the IPIM Module

Using the 2094 Mounting Brackets

You can use Bulletin 2094 mounting brackets to mount the power rail or LIM module over the AC line filter. Refer to the 2094 Mounting Brackets Installation

Instructions, publication 2094-IN008 , when using mounting brackets with your system.

Installing the 2094 Power Rail

The Bulletin 2094 power rail comes in lengths to support one IAM module and up to seven additional modules. A maximum of four IPIM modules can be mounted to a single power rail. The connector pins for each slot are covered by a protective cover. The cover is designed to protect the pins from damage and make sure that no foreign objects lodge between the pins during installation. Refer to the Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003 , when installing your power rail.

ATTENTION: To avoid damage to the power rail during installation, do not remove the protective covers until the module for each slot is ready for mounting.

Determine Mounting Order

Refer to the Module Mounting Order Example diagram on page 31

and mount the modules in the order (left to right) shown. Install modules according to power utilization (highest to lowest) from left to right starting with the highest power utilization. If power utilization is unknown, position modules (highest to lowest) from left to right based on the IPIM or AM continuous power rating

(kW).

Power utilization is the average power (kW) consumed by a servo axis. If the servo axis has been sized by using Motion Analyzer software, version 6.000 or later, the calculated axis power required can be used for power utilization. If the servo axis has not been sized in Motion Analyzer, use

Table 11

, showing the maximum continuous power for IPIM and AM modules, to determine the desired location on a power rail.

Table 11 - Module Type and Continuous Power Output

2094-BM05-S

Axis Module

22.0 kW

2094-SEPM-B24-S

IPIM Module

2094-BM03-S

Axis Module

15.0 kW 13.5 kW

2094-BM02-S

Axis Module

6.6 kW

2094-BM01-S

Axis Module

3.9 kW

2094-BMP5-S

Axis Module

1.8 kW

The IPIM module may be installed on a power rail with an IAM module configured as a common bus follower, but you will be responsible for configuring the leader for the appropriate additional capacitance in the follower power rail, including the IPIM module.

30



Chapter 3

Figure 10 - Module Mounting Order Example

Highest Power Utilization

Integrated Axis

Module

IPIM Module Axis Modules

Lowest Power Utilization

Shunt

Module

Slot Filler

Module

IMPORTANT

The IAM must be positioned in the leftmost slot of the power rail. Position your other modules to the right of the IAM module.

Mount modules according to power utilization (highest to lowest) from left to right starting with the highest power utilization. If power utilization is unknown, position modules (highest to lowest) from left to right based on continuous power rating (kW). Refer to

page 30

.

The shunt module must be installed to the right of the last module. Only slotfiller modules may be installed to the right of the shunt module.

Do not mount the shunt module on power rails with a follower IAM module.

Common bus follower IAM modules disable the internal, rail mounted, and external shunt modules.

SHOCK HAZARD: To avoid personal injury due to electrical shock, place a

2094-PRF slot-filler module in all empty slots on the power rail. Any power rail connector without a module installed will disable the drive system; however, control power will still be present.


31

Chapter 3


Mount the IPIM Module

All modules mount to the power rail using the same technique.

1. Determine the next available slot and module for mounting. Refer to

Determine Mounting Order on page 30 .

2. Remove the protective covers from the power rail connectors.

3. Inspect the module connector pins and power rail connectors and remove any foreign objects.

ATTENTION: To avoid damage to the pins located on the back of each module and to make sure that module pins mate properly with the power rail, hang modules as explained below.

The power rail must be mounted vertically on the panel before hanging modules on the power rail.

4. Hang the module mounting bracket from the slot on the power rail.

Mounting Bracket

32

Slots for Additional Modules

Power Rail Slot

Power Rail

5. Pivot module downward and align the guide pin on the power rail with the guide pin hole in the back of the module.

Power Rail

Guide Pin

Pivot module downward and align with pin

Guide Pin Hole

Fuse A ccess

See User Manual B efore Remo ving

Rear View

Side View

6. Gently push the module against the power rail connectors and into the final mounting position.


7. Tighten the mounting screws.

Bracket secured in slot


Chapter 3

Flat

2.26 N•m (20 lb•in)

Installing the IDM Unit

Power Rail

8. Repeat the above steps for each module being installed.

ATTENTION: Do not attempt to open or modify the IDM unit. This manual describes modifications that you can perform in the field. Do not attempt other changes. Only a qualified Allen-Bradley employee can service an IDM unit.


ATTENTION: Damage may occur to the bearings and the feedback device if a sharp impact is applied to the shaft during installation of couplings and pulleys, or to remove the shaft key. Damage to the feedback device also may result from applying leverage from the faceplate to remove devices mounted on the shaft.

Do not strike the shaft, key, couplings, or pulleys with tools during installation or removal. Use a wheel puller to apply pressure from the user end of the shaft to remove any friction fit or stuck device from the shaft.

Failure to observe these safety procedures could result in damage to the IDM unit.


33

Chapter 3


34

Aligning the IDM Unit

The IDM unit can be mounted in any position and has a mounting pilot that aids in aligning the unit on a machine. A shaft seal that helps protect the motor against fine dust and fluids is factory installed and should be replaced at regular intervals.

Preferred fasteners are stainless steel. The installation must comply with all local regulations. The installer also must use equipment and installation practices that promote electromagnetic compatibility and safety.

ATTENTION: Unmounted IDM units, disconnected mechanical couplings, loose shaft keys, and disconnected cables are dangerous, if power is applied.

Disassembled equipment should be appropriately identified (tagged-out) and access to electrical power restricted (locked-out).

Before applying power, remove the shaft key and other mechanical couplings that could be thrown from the shaft.


Mount and Connect the IDM Unit

To install the IDM unit, follow these procedures and recommendations.

ATTENTION: Arcing or unexpected motion can occur if cables are connected or disconnected while power is applied to the IDM system. Before working on the system, disconnect power and wait the full time interval indicated on the IPIM module warning label or verify the DC bus voltage at the IPIM module measures less than 50V DC.

Failure to observe this precaution could result in severe bodily injury or loss of life, and damage to the product will occur.

ATTENTION: Do not strike the shaft, couplings, or pulleys with tools during installation or removal.

Damage may occur to the motor bearings and the feedback device if you apply a sharp impact to the shaft during installation of couplings and pulleys, or a shaft key.

Failure to observe these safety procedures could result in damage to the motor and its components.

ATTENTION: The IDM unit is not for direct connection to an AC power line.

IDM units are designed for connection to an IPIM module that controls the application of power.

Failure to observe these safety precautions could result in damage to the motor and equipment.



Chapter 3

1. Allow sufficient clearances around the IDM unit for it to stay within its

specified operating temperature range. See page 27

for details.

BURN HAZARD: Outer surfaces of the IDM unit can reach high temperatures,

125 °C (275 °F), during motor operation.

Take precautions to prevent accidental contact with hot surfaces. Consider IDM unit surface temperature when selecting motor mating connections and cables.


2. Determine the radial and axial shaft load limitations of your motor. Refer to the Kinetix Rotary Motion Specifications Technical Data, publication

GMC-TD001 , for specifications.

3. Set the node address for the IDM unit. Refer to

Setting the Node Address

on

page 70 .

4. If sufficient mounting clearance is provided, rotate the hybrid cable connectors into position prior to installing. If the mounting clearance is restricted, rotate after installing.

ATTENTION: Connectors are designed to be rotated into a fixed position during motor installation, and remain in that position without further adjustment.

Strictly limit the applied forces and the number of times the connector is rotated to make sure that connectors meet the specified IP ratings.

Apply force only to the connector and cable plug. Do not apply force to the cable extending from the cable plug. No tools, for example pliers or vise-grips, should be used to assist with the rotation of the connector.

Failure to observe safety precautions could result in damage to the IDM unit and its components.

5. Position the IDM unit on the machine in any position.

TIP

IDM units with a brake may require use of the manual brake release cable to release the brake prior to rotating the shaft so the IDM unit will align with the machine mounts.

Refer to the Manual Brake Release Cable Installation Instructions, publication 2090-IN037 , for details on using this cable.

6. Properly mount and align the IDM unit using stainless steel bolts. Refer to the Kinetix Rotary Motion Specifications Technical Data, publication

GMC-TD001 , for dimensions.


35

Chapter 3


Notes:

36


Chapter

4

Kinetix 6000M System Connector Data

This chapter provides connector locations and signal descriptions for your

Kinetix 6000M integrated drive-motor system.

Topic

IPIM Module Connectors and Indicators

IPIM Module Connector and Signal Descriptions

IDM Unit Connectors and Indicators

IDM Unit Connector and Signal Descriptions

Power Specifications

Feedback Specifications

44

50

52

39

43

Page

38


37

Chapter 4

Kinetix 6000M System Connector Data

IPIM Module Connectors and

Indicators

Figure 11 - Module Connectors and Indicators

➍

SE2

SE-

SE1 SH3

RT

N

OUT

CN+

CNSH2

42-

42+ SH1

➎

➏

➐

➑

➊

➋

➌

➒

➓

ETHERNET 1

ETHERNET 2

NETWORK

Item Description

➊

Hybrid cable DC bus connector

➋

Hybrid cable communication signals connector

➌

Safe-off connector

➍

Enable connector

➎

Sercos fiber-optic connectors

➏

LCD display

➐

Navigation buttons

➑

Status indicators

DC Bus

Control Bus

Port 1 and Port 2

Module Status

Network Status

➒

EtherNet/IP ports

➓

IDM network cable connector

Termination point for +/- DC and PE

Connection point for IDM unit power and communication

Termination point for safety signals

Enable input to the IDM system

Transmit and receive fiber-optic connectors

41

Allows ethernet configuration and system status

66

Four buttons provide access and navigation when using the LCD display

40

41

66

90

See page

39

39

DC bus status

Control bus status (present, faulted)

Communication status of the EtherNet/IP ports

IPIM module status (operating, standby, faulted)

Indicates IDM system network status

Two Ethernet ports are provided

Connection point for network cable to first IDM unit

42

42

38



Chapter 4

IPIM Module Connector and

Signal Descriptions

Hybrid Cable DC Bus Connector

This connector supplies the DC bus voltage. Three wires from the hybrid power and communication cable (catalog number 2090-

CHBIFS8-12AA

xx) are used to extend this voltage to the first

IDM unit.

Terminal Description

1 DC bus supply (-)

2 Chassis ground

3 DC bus supply (+)

Signal

DC-

DC+

Strip

Length

mm (in.)

DC9.7 (0.38)

DC+

1

DC-

DC+

Torque

N•m (lb•in)

0.75 (6.6)

Hybrid Cable Communication Signals Connector

The hybrid communication connector extends control power, communication, and safety signals to the first

IDM unit. The 2090-CHBIFS8-12AA

xx cable interfaces with this connector.

1

SH1

42+

42-

SH2

CN-

CN+

OUT

RTN

SH3

SE1

SE-

SE2

10

11

8

9

12

6

7

4

5

2

3


1 Shield

Control Power +42V DC

Control Power -42V DC

CAN Bus Shield

IDM CAN Bus Lo

IDM CAN Bus Hi

System OK out to IDMs

System OK return from IDMs

Safety Shield

Safety Enable Input 1

Safety Enable Common


Strip

Length

mm (in.)

Signal

–

42V +

42V COM

IDM CAN SHIELD

IDM CAN LO

IDM CAN HI

IDM SYSOKOUT

IDM SYSOKRTN

SAFETY SHIELD

SH1 6.4 (0.25)

42+

42-

SH2

CN-

CN+

OUT

RTN

SH3

SAFETY ENABLE 1+ SE1

SAFETY ENABLESE-


Torque

N•m (lb•in)

0.235 (2.0)


39

Chapter 4


Safe Torque-off Connector

This connector provides a termination point for connecting safety devices such as: emergency stop switches, light curtains, and floor mats. The redundant safety device outputs should be connected to Safety Enable Input 1 and 2 with reference to Safety Enable Common.

1

F2+F2-

F1+F1-

SE2SE-

24-

Remove the motionallowed jumper before connecting any safety devices.

Wiring Plug Header

Each IPIM module ships with the wiring-plug header and motion-allowed jumper installed in the safe torque-off connector.

IMPORTANT

With the motion-allowed jumper installed, the safe torque-off function is defeated.

IMPORTANT

Pins 8 and 9 (24V+) are used only by the motion-allowed jumper. When wiring to the wiring-plug header, the 24V supply (for an external safety device that triggers the safe torque-off request) must come from an

external source, otherwise system performance will be jeopardized.

This connector extends the safe-off signals for use in wiring single and multiple safe torque-off configurations, or to bypass (not use) the safe torque-off function.

Refer to

page 107 for further information.


1

6

7

4

5

8

2

3

9

Feedback Monitoring 2+

Feedback Monitoring 2-

Feedback Monitoring 1+

Feedback Monitoring 1-




Signal

FDBK2+

(1)

FDBK2-

(1)

FDBK1+

(1)

FDBK1-

(1)

F1+

F1-


SAFETY ENABLESE-


24+

(2)

24+

Strip

Length

mm (in.)

F2+ 7.0

(0.275)

F2-

Safety Bypass Supply, +24V

DC, 320 mA max

Safety Bypass supply,

Common

24V COM

(2)

24-

Torque

N•m (lb•in)

Min/Max

Wire Size

(3)

mm

2

(AWG)

0.235 (2.0) 0.14…1.5

(30…14)

(1) Feedback monitoring terminals are provided for compatibility with the Kinetix 6000 safety connector only.

(2) Refer to page 107

for information on the proper use of these terminals.

(3) Maximum/minimum that the connector will accept—these are not recommendations.

40



Chapter 4

Sercos Fiber-optic Connectors

The sercos fiber-optic ring is connected by using the sercos receive (RX) and transmit (TX) connectors.

Receive Transmit

ATTENTION: To avoid damage to the sercos RX and TX connectors use only finger-tight torque when attaching the fiber-optic cables. Do not use a wrench or any other mechanical assistance. For more information, refer to Fiber-optic

Cable Installation and Handling Instructions, publication 2090-IN010 .

Table 12 - Sercos Specifications

Attribute

Data rates

Light intensity

Cyclic update period

Node addresses

Value

8 Mbps (fixed)

Adjustable, low or high power, selectable via the keypad/LCD display (see

page 68

).

500 μs, minimum

Assigned on each IDM unit, see

page 70 . The IPIM module does not have a sercos address

since it is not a sercos device.

Enable Input

EN

+

-

One digital input is supplied to enable all connected IDM units.

The enable status is transmitted to all of the IDM units.


1

2

3

+24V DC Enable Supply

Enable Input

24V DC Common

Signal

ENABLE 24V+

ENABLE INPUT

ENABLE 24V COM

+

EN

-

Strip

Length

mm (in.)

7.0

(0.275)

(1) Maximum/minimum that the connector will accept—these are not recommendations.

Torque

N•m (lb•in)

Min/Max

Wire Size

(1)

mm

2

(AWG)

0.235 (2.0) 0.14…1.5

(30…14)

1

Table 13 - Enable Input Specifications

Signal Description

ENABLE Optically isolated, single-ended active high signal. Current loading is nominally 10 mA. A 24V DC input is applied to this terminal to enable all modules. The reaction time for all IDM units connected to the IPIM is 30 ms, maximum.

IDM Unit

Reaction

Time

30 ms

Edge/Level

Sensitive

Level


41

Chapter 4


EtherNet/IP Connectors

Two connectors are provided for firmware upgrades, troubleshooting, and integration with Logix. The Ethernet ports also support a web browser interface to provide access to status information for the IPIM module and IDM units.

EtherNet/IP Ports

8-pin Control Module

Ethernet Connector

1 8

7

8

5

6

3

4

1

2

Transmit+

Transmit-

Receive+

Reserved

Reserved

Receive-

Reserved

Reserved

–

–

RD-

–

–

Signal Name

TD+

TD-

RD+

IPIM Module Network Connector Pinouts

The IDM system network is routed by using 2090-CNS

xPxS-AAxx cables. A

2090-CNSSPRS-AA

xx or 2090-CNSSPSS-AAxx cable is required for connection to the IPIM module. The connector type is B-coded M12.

1

IDM Network

Connector

3

4

1

2

Transmit (TX+) to IDM unit

Return (RX-) from IDM unit

Return (RX+) from IDM unit

Transmit (TX-) to IDM unit

Signal Name

TX+

RTN RX-

RTN RX+

TX-

REF

5

2

4

3

42


IDM Unit Connectors and

Indicators


Chapter 4

Figure 12 - Integrated Drive-motor Unit Features, Connectors, and Indicators

➊

➋

➍

➎

➌

6 7

8 9

34

➓

6 7

8 9

34

S1

S10

1

D N

2

➏

3

➒

➑

➐


➊

Hybrid cable input connector (from IPIM module or previous IDM unit)

Input and output connecting points for the

Hybrid Power and Communication cables.

➋

Hybrid cable output connector (to IDM unit)

➌

IDM network output connector (to IDM unit) Input and output connecting points for the IDM network cables.

➍

IDM network input connector (from IPIM module or previous IDM unit)

➎

Drive status indicator

➏

Network status indicator

➐

HOME Digital Input (connector 3)

➑

REG1/OT+ Digital Input (connector 2)

➒

REG2/OT- Digital Input (connector 1)

➓

Node address switch S10 – 10’s digit (most significant)

Provides communication status for the IDM unit.

Provides general status for the IDM unit.

Digital input for home.

Registration1/positive overtravel digital input.

Registration2/negative overtravel digital input.

Sets the IDM network node address.

See page

39

39

91

91

45

45

45

70

Node address switch S1 – 1’s digit (least significant)


43

Chapter 4


IDM Unit Connector and

Signal Descriptions

Hybrid Cable Connector

The information below provides connector pinouts for the IDM unit hybrid connectors.

Hybrid Input

Connector

Input Connector Output Connector

Hybrid

Output

Connector

1

2

3

8

7

9

10

6

4

5

E

D

A

C B

5

4

6

7

8

10

9

3

2

1

A

E

B C

D

B

C

Pin Description

A DC Bus +

D

DC Bus -

Control Power +42V DC

Control Power -42V DC

Signal Name

DC +

DC -

42V +

42V COM

7

8

5

6

3

4

1 Reserved

2 Brake Override 24V Supply

Brake Override Supply Common




IDM CAN Bus Hi

IDM CAN Bus Lo

9 System OK from IPIM or prior IDM

10 System OK return to IPIM

Reserved

BRAKE +24V

BRAKE 24V COM

SAFETY ENABLE 1+

SAFETY ENABLE-

SAFETY ENABLE 2+

IDM CAN HI

IDM CAN LO

IDM SYSOKIN

IDM SYSOKRTN

Signal Name

DC +

DC -

42V +

42V COM

Reserved

SAFETY ENABLE 1+

SAFETY ENABLE-

SAFETY ENABLE 2+

IDM CAN HI

IDM CAN LO

IDM SYSOKOUT

IDM SYSOKRTN

44



Chapter 4

IDM Network Input and Output Connector Pinouts

Pinout information is provided below for the IDM unit network connectors.

Input Connector Output Connector

Network

Input

Connector

Network

Output

Connector

2

5

5

2

3 1

1 3

4

4

Pin Signal Name Signal Name

Digital Input Connectors

S1

D N

Three digital input connectors allow sensors to be easily connected to the system without the need to route cables back to the control enclosure.

S10

1 2

Digital In 1

The connectors accommodate common input functions, including the following:

• Home, negative over-travel and positive over-travel inputs

• Two registration inputs

3

Digital In 2

Digital In

3

If the digital inputs are not being used for their assigned functions, they can also be used as general purpose inputs by reading the status of the their tags in the application program.

24V DC is supplied at each input for the purpose of registration, home, enable, over-travel positive, and over-travel negative inputs. These are sinking inputs that require a sourcing device. A 24V DC power and common connection is provided for each input. A total of 200 mA is supplied for all three input connectors.


45

Chapter 4


46

IDM units have three 5-pin, M12, digital input connectors. Allen-Bradley

(Bulletin 889D) DC micro-style patchcords, splitters, and V-cables are available with straight and right-angle connectors for making connections from the IDM unit to input sensors.

For the most popular patchcord specifications, refer to the Connection Systems

Quick Selection Guide, publication CNSYS-BR001 . For complete information, refer to On-Machine™ Connectivity, publication M117-CA001 .

IMPORTANT

Unused input connectors must have protective covers installed to maintain the

IDM IP rating. Torque each cover to 0.6 N•m (5 lb•in) to ensure a tight seal.

IMPORTANT

To improve registration input EMC performance, refer to the System Design for

Control of Electrical Noise Reference Manual, publication GMC-RM001 .

IMPORTANT

Overtravel limit input devices must be normally closed.

Pin

2

3

Digital Input Connector 1

Overtravel -/Registration 2


Overtravel +/Registration 1


Home

3

5

4

2

1

Signal Name

Overtravel -

24V COM

3

5

4

2

1

Signal Name

24V+

Overtravel +

24V COM

3

5

4

2

1

Signal Name

24V+

Reserved

24V COM

Shield/Chassis Ground

The IDM unit only supports PNP (active high or sourcing) inputs.

Single Normally Closed (NC) Sensor Connection

Normally closed sensors are used for limit (overtravel) switches on the IDM unit.

Any 4-pin or 5-pin, M12, A-code, 1-1 pass through cable can be used to connect a normally closed sensor. Refer to

Figure 13 .

Figure 13 - Single NC Sensor Connection Example

IDM

Unit

3

4

1

2

5

889D-x4ACDx-xx Patchcord

I/O 24V +

Signal

I/O 24V COM

3

4

1

2

5

Normally Closed

PNP Sensor



Chapter 4

Single Normally Open (NO) Sensor Connection

Normally open sensors are used for registration or home switches on the IDM unit. Any 4-pin or 5-pin, M12, A-code, 1-1 pass through cable can be used to connect a normally open sensor. Refer to

Figure 14

.

Figure 14 - Single NO Sensor Connection Example

889D-x4ACDx-xx Patchcord

I/O 24V +

IDM

Unit

3

4

5

1

2

I/O 24V COM

Signal

3

4

5

1

2

Normally Open

PNP Sensor

Combined NC & NO Sensor Connection

There may be applications where two sensors must be connected to a one input connector. Typically, a limit switch (NC) is connected to pin 2 and a registration switch (NO) to pin 4 of the connector.

In the figure below the 889D-

x4ACDx-xx patchcord swaps the NC signal from pin 2 to pin 4. The micro splitter then swaps it back for proper connection to pin

2 of the IDM input connector. The NO sensor goes straight through on pin 4.

Figure 15 - Combined NO & NC Sensor Connection using a Micro Splitter

889D-x4ACDx-xx

Patchcord

879D-F5DM

DC Micro Splitter or

879-F5xCDM-xx Cable

A

889D-x4ACDx-xx

Patchcord

I/O 24V +

I/O 24V COM

Signal

IDM

Unit

3

4

1

2

5

I/O 24V +

NC Sensor

I/O 24V COM

NO Sensor

I/O 24V +

Signal

I/O 24V COM

B

1

4

5

2

3

3

4

1

2

5

889D-x4ACDx-Vxx

Patchcord

Normally Open

PNP Sensor

Normally Closed

PNP Sensor


47

Chapter 4


Digital Input Cable Examples

Figure 16 - Digital Inputs Used for Home and Overtravel Functions

MDF-SBxxxxx

IDM Units

Input Assignments:

1 = Overtravel- (NC)

2 = Overtravel+ (NC)

3 = Home (NO)

S1

S10

1

D N

2

3

1 2 3

Digital Inputs

(1, 2, 3)

889D-x4ACDx-xx

Patchcords

871TS-N12BP18-D4

Proximity Sensors

S1

S10

1

D N

2

3

Input Assignments:

1 = Registration 2 (NO)

2 = Registration 1 (NO)

1 2

MDF-SBxxxxx IDM Unit

879D-F4DM

Splitter

Figure 17 - Digital Inputs Used for Home, Overtravel, and Registration Functions

Digital Inputs

(1, 2, 3)

Input Assignment:

3 = Home (NO)

Sensors

Input Assignments:

2A = Registration 1 (NO)

2B = Overtravel+ (NC)

1A = Overtravel- (NC)

1B = Registration 2 (NO)

889D-x4ACDx-x

Patchcords

879D-x4ACDM-x

V-cable

889D-x4ACDx-x (NO) or

889D-x4ACDx-Vx (NC)

Patchcords

48



Chapter 4

Table 14 - Understanding the Digital Inputs

Pin Connector Signal Description

4 1 HOME Optically isolated, single-ended active high signal. Current loading is nominally 10 mA. Home switch (normally open contact) inputs for each axis require 24V DC (nominal).

4 2/3 REG1

REG2

Fast registration inputs are required to inform the motor interface to capture the positional information with less than 4

μ s uncertainty. Optically isolated, single-ended active high signal. Current loading is nominally 10 mA. A 24V

DC input is applied to this terminal.

Capture

Time

30 ms

Edge/Level

Sensitive

Level

500 ns Edge

2 2/3 OT+

OT-

Overtravel detection is available as an optically isolated, single-ended active high signal. Current loading is nominally

10 mA per input. The pos/neg limit switch (normally closed contact) inputs for each axis require 24V DC (nominal).

30 ms Level

Table 15 - Digital Input Specifications

Parameter

On-state voltage

On-state current

Off-state voltage

Description

Voltage applied to the input, with respect to IOCOM, to assure an on-state.

HOME, and OT+/OT-

REG1 and REG2

Current flow to guarantee an on-state.

Voltage applied to the input, with respect to IOCOM, to assure an off-state.

Min

21.6V

21.6V

3.0 mA

-1.0V

Max

26.4V

26.4V

10.0 mA

3.0V

Figure 18 - Standard Digital Input Circuits

24V DC

(1)

I/O SUPPLY

INPUT

3k

Ω

0.1

μ

F 511

Ω

Customer-supplied

Input Device

IO_COM

IDM

(1) 24V DC source (range) = 21.6V - 26.4V (supplied by IPIM, not to exceed 250 mA total). Maximum current input = 10 mA.

Figure 19 - High Speed Digital Input Circuits

24V DC

I/O SUPPLY

INPUT

2.49k

Ω

0.001

μ

F 1.27k

Ω

Customer-supplied

Device

IO_COM

IDM


49

Chapter 4


Power Specifications

Brake Override Input

ATTENTION: To guard against personal injury and/or component damage, the brake override must only be used for machine assembly when the IPIM module

is not connected to the IDM unit.

The brake override connection is made on two dedicated pins of the hybrid input connector. The hybrid cable has no connection on those pins.

The brake override may only be activated when the hybrid input cable is not connected. A brake override cable is attached at the location where the hybrid input cable would normally be attached.

Two connections are required for the motor/brake override input power.

Connections are rated for +24V and current as shown in the table below. An active signal releases the motor brake.

Table 16 - Brake Specification

Specification Value

Nominal brake voltage 24 V DC

Minimum voltage 21.6 V DC

Maximum voltage

Maximum brake current

27.6 V DC

650 mA

Peak Duty Cycle

Table 17 - Peak Duty Cycle Definition of Terms

Term

Continuous Current Rating (I

Cont

)

Peak Current Rating (I

PKmax

)

Duty Cycle (D)

Time at Peak (T

PK

)

Peak Current (I

PK

)

Base Current (I

Base

)

Loading Profile

Application Period (T)

Definition

(1)

The maximum value of current that can be output continuously.

The maximum value of peak current that the drive can output. This rating is valid only for overload times less than T

PKmax

.

The ratio of time at peak to the Application Period and is defined as:

D = T

T

PK x 100%

The time at peak current (I

PK equal to T

PKmax

.

) for a given loading profile. Must be less than or

The level of peak current for a given loading profile. I

PK equal to the Peak Current Rating (T

PKMAX

) of the drive. must be less than or

The level of current between the pulses of peak current for a given loading profile. I

Base of the drive.

must be less than or equal to the continuous current rating (I

Cont)

The loading profile is comprised of I

PK

, I

Base

, T

PK

, and D (or T) values and completely specify the operation of the drive in an overload situation. These values are collectively defined as the Loading Profile of the drive.

The sum of the times at I

PK

(T

PK

) and I

Base

.

(1) All current values are specified as rms.

50


MDF-1003 Peak Inverter Overload (T

PK

< 2.0 s)

35%

30%

25%

20%

15%

10%

5%

0%

0% 20% 40% 60%

% Base Current (IBase/Icont)


PK

< 2.0 s)

35%

30%

25%

20%

15%

10%

5%

0%

0% 20% 40% 60%



PK

< 2.0 s)

35%

30%

25%

20%

15%

10%

5%

0%

0% 20% 40% 60%



Chapter 4

Ipk = 200%

Ipk = 350%

Ipk = 471%

80%

80%

80%

Ipk = 200%

Ipk = 350%

Ipk = 443%

Ipk = 200%

Ipk = 344%

100%

100%

100%


51

Chapter 4


Feedback Specifications

Kinetix 6000M integrated drive-motors are available with high performance digital encoders with multi-turn high resolution feedback:

• 524,288 counts per revolution

• High-resolution absolute position feedback within 4096 turns.

The IDM unit does not support an auxiliary feedback device.

Absolute Position

The drive’s absolute position feature tracks the position of the motor, within the multi-turn retention limits, while the drive is powered off. The absolute position feature is available on all IDM units.

Table 18 - Absolute Position Designator Examples

Encoder Type

Hengstler BiSS

Motor Cat. No. Designator

-Q

Motor Cat. No. Example

MDF-SB1003P-Q

Figure 20 - Absolute Position Retention Limits

-2048 -1024

Position at Power Down

+1024 +2048

52


Connecting the Kinetix 6000M System

Chapter

5

This chapter provides procedures for wiring the integrated drive-motor system components.

Topic

Basic Wiring Requirements

Grounding the IDM System

General IDM System Wiring

How to Bypass an IDM Unit

The Sercos Fiber-optic Ring

Ethernet Cable Connections

58

59

63

54

56

Page

53

Basic Wiring Requirements

This section contains basic wiring information for the Kinetix 6000M integrated drive-motor system. Refer to the Kinetix 6000 user manual, publication

2094-UM001 , or the Kinetix 6200 user manual, publication 2094-UM002 , for specific wiring information.


SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2094 power rail and IPIM modules prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use.


53

Chapter 5

Connecting the Kinetix 6000M System

IMPORTANT

IDM system wiring differs from common PWM servo system wiring configurations in the following ways:

• Hybrid and network cables can be tie-wrapped together and occupy the same cable run

• Hybrid and network cables do not require physical segregation as a result of more effective wire shielding and improved grounding techniques.

This exception applies only to the hybrid and network cables that connect to an

IPIM module or between IDM units, and does not apply to cabling elsewhere in a Kinetix drive system. Refer to the System Design for Control of Electrical Noise

Reference Manual, publication GMC-RM001 , for more information.

National Electrical Code, local electrical codes, special operating temperature, duty cycles, or system configurations take precedence over the information presented above and the values and methods provided in the document referenced above.

Routing the Power and Signal Cables

Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic devices can be induced into I/O communication, or other sensitive low voltage signals. This can cause system faults and communication anomalies.

The hybrid cables and network cables are UL listed with 1000V and 105

°

C

(221

°

F) insulation ratings, and can be routed in a common wireway.

Refer to

Electrical Noise Reduction

on

page 27

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.

Grounding the IDM System

All equipment and components of a machine or process system should have a common earth ground point connected to chassis. A grounded system provides a ground path for short circuit protection. Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.

ATTENTION: The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system.

For CE grounding requirements, refer to Agency Compliance on page 19

.

ATTENTION: High voltage can buildup on the shields of a hybrid cable, if the shield is not grounded. Verify that there is a connection to ground for all shields in the hybrid cable. Failure to observe these safety procedures could result in personal injury or damage to equipment.

54



Chapter 5

Signal integrity is very important for successful operation of an integrated drivemotor system. You must be sure that all cables are properly grounded through the

IPIM module to the ground plane of the Kinetix drive system.

• Verify that every cable shield directly connects to chassis ground.

• Clamp the exposed section of the hybrid cable shield in the cable (chassis)

ground connection on the drive. Refer to Apply the Cable Shield Clamp .

Figure 21 - Hybrid Cable Shields

Cable insulation is removed to expose the overall shield of the cable.

SE2

SE-

SH3

RTN

OUT

SE1

CN-

CN+

SH2

42-

42+

DC+

PE

DC-

Power Wires and Ground

Grouped Signal

Wires and Shields

Apply the Cable Shield Clamp

The cable shield clamp assures a solid bond to the shield and secures the cable.

1. Depress the spring loaded clamp.

2. Position the exposed portion of the cable braid directly in line with the clamp.

3. Release the spring, making sure the cable and cable braid are held secure by the clamp.

Outer Insulation

Exposed Braid (under clamp)


55

Chapter 5


General IDM System Wiring

ATTENTION: Arcing or unexpected motion can occur if cables are connected or disconnected while power is applied to the IDM system. Before working on the system, disconnect power and wait the full time interval indicated on the IPIM module warning label or verify the DC bus voltage at the IPIM module measures less than 50V DC.

Failure to observe this precaution could result in severe bodily injury or loss of life, and damage to the product will occur.

ATTENTION: Be sure that installed cables are restrained to prevent uneven tension or flexing at the cable connectors. Provide support at 3 m (10 ft) intervals throughout the cable run.

Excessive and uneven lateral force at the cable connectors may result in the connector’s environmental seal opening and closing as the cable flexes, or wires separating at the cable gland.

Failure to observe these safety procedures could result in damage to the motor and its components.

IMPORTANT

Building your own cables is not an option for the hybrid and network cables used in the IDM system.

Always form a drip loop in the cables directly before each cable enters and exits the IDM unit. A drip loop is a low spot in the cable that lets liquids gather and drip off the cable rather than flow along the cable to an electrical connection or the motor.

Connect the network and hybrid cables only after the IDM unit is mounted.

ATTENTION: Cable connectors must be properly aligned before the connection is secured with the recommended degrees of turn or torque value. Improper connector alignment is indicated by the need for excessive force, such as the use of tools, to fully seat connectors. Failure to observe these safety procedures could result in damage to the IDM unit, cables, and connector components.

Hybrid Cable

A hybrid cable, catalog number 2090-CHBIFS8-12AAxx, transfers DC bus power and inter-module communication signals from the IPIM module to the first IDM unit. Additional IDM units are daisy chained by using a

2090-CHBP8S8-12AAxx cable as shown in Figure 22

.

ATTENTION: Verify that all connections are correct when wiring the connector plugs and that the plugs are fully engaged in the module connectors. Incorrect wiring/polarity or loose wiring can cause explosion or damage to equipment.

56



Chapter 5

Figure 22 - IDM System Wiring

(Catalog numbers are in parenthesis.)

IPIM to IDM Hybrid Cable


IPIM Module

IDM to IDM Hybrid Cable


Hybrid Terminator

Last IDM Unit

(2090-CTHP8)

Network Cable

(2090-CNSRPRS-AAxx)

Network Terminator

Last IDM Unit

(2090-CTSRP)

PORT 1 PORT 2 NETWORK

IDM Unit

Network Cable to First IDM

(2090-CNSSPRS-AAxx)

IDM Unit

The colored rings on the hybrid cable connector and the mating cable must match: red-to-red or green-to-green.

Hand-tighten the knurled collar on a hybrid cable approximately 45 degrees to fully seat and lock the connector.

Wiring the Connectors

Use these guidelines as a reference when wiring the hybrid cable to the IPIM module.

Figure 23 - 2090-CHBIFS8-12AAxx Hybrid Cable

SE2

SE-

SH3

RTN

OUT

SE1

CN-

CN+

SH2

DC+

PE

DC-

42-

42+

DC+ (brown)

PE (green)

DC- (grey)

42- (white/blue)

42+ (blue)

CN- (white/brown)

CN+ (brown)

SH2 (drain)

RTN (pink)

OUT (white/pink)

SE1 (orange)

SE2 (yellow)

SE- (violet)

SH3 (drain)

1. Route the cable/wires to the module.

2. Insert wires into connector plugs.

3. Tighten the connector screws.

Refer to

page 39 for torque specifications.

4. Gently pull on each wire to make sure it does not come out of its terminal; reinsert and tighten any loose wires.

5. Insert the connector plug into the module connector.


57

Chapter 5


Figure 24 - Hybrid Cable Installed

Hybrid Cable

42+

42-

SH2

CN-

CN+

OUT

RTN

42-

SH2

CN-

CN+

OUT

RTN

SH3

SE1

SE-

SE2

Hybrid Cable DC Bus Connector

Hybrid Cable Communication

Signals Connector

Network Cable

The IDM system network is routed by using 2090-CNS

xPxS-AAxx cables. A

2090-CNSSPRS-AA

xx or 2090-CNSSPSS-AAxx cable is required for connection to the IPIM module.

2090-CNSSPRS-AAxx

2090-CNSRPSS-AAxx

(1)

2090-CNSRPRS-AAxx

(1)

2090-CNSSPSS-AAxx

(1) Not for connection to an IPIM module.

When installing network cables, torque the connector plug to 0.8…1.2 N•m

(7.1…10.6 lb•in) to fully seat the contacts and secure the connection.

How to Bypass an IDM Unit

A 2090-CCPPS8S coupler cable joins two hybrid cables to bypass an IDM unit or extend the length of a cable. This can be desired when performing maintenance on a unit or to simply extend a hybrid cable. IDM to IDM cable lengths should not exceed 25 m (82.0 ft) during normal operation when a coupling cable is used.

The IDM network cables can be joined to together without the need of a coupler to bypass an IDM unit or extend network cables.

58



Chapter 5

The Sercos Fiber-optic Ring

The sercos fiber-optic ring is connected by using the sercos receive (RX) and transmit (TX) connectors. Refer to

Sercos Fiber-optic Connectors on page 41

for details. Refer to the documentation supplied with your Logix sercos interface module or PCI card for connector locations.

Plastic cable is available in lengths up to 32 m (105.0 ft). Glass cable is available in lengths between 50 m (164.2 ft) and 200 m (656.7 ft).

Connect the cable from transmit on the Logix module to receive on the first

IPIM module, then transmit to receive (module to module), and from transmit on the last module back to receive on the Logix module.

ATTENTION: To avoid damage to the sercos RX and TX connectors use only finger-tight torque when attaching the fiber-optic cables. Do not use a wrench or any other mechanical assistance. For more information, refer to Fiber-optic

Cable Installation and Handling Instructions, publication 2090-IN010 .

IMPORTANT

Clean the fiber-optic cable connectors prior to installation. Dust in the connectors can reduce signal strength. For more information, refer to Fiberoptic Cable Installation and Handling Instructions, publication 2090-IN010 .

The IPIM module has fiber-optic cable connectors positioned identical to the

Kinetix 6000 (2094-BM

xx-S) drives, the IPIM module uses the same fiber-optic cable lengths as the drive modules.

In the following example (

Figure 25 ), all of the drive modules and the IPIM

module are on the same sercos ring. The ring begins and ends at the 1756-M16SE sercos module. IDM units connected to the IPIM module (not shown for simplicity) are also part of this sercos ring.

Figure 25 - Fiber-optic Cable Example - Logix Platform with IPIM Module

1756-M16SE Sercos

Interface Module

Logix Platform

(ControlLogix controller is shown)

SERCOS interface TM

CP OK

Sercos Fiber-optic Ring

0.1 m

(5.1 in.)

Tx (rear)

Rx (front)

Kinetix 6000 System

(4-axis power rail)

2094-SEPM-B24-S IPIM Module

2094-BMxx-x Single-wide AM Modules


59

Chapter 5


In this five-axis Bulletin 2094 power rail configuration, the IAM module and two

AM modules power three of the axes and two IPIM modules are each connected to four IDM units. All eleven axes are on the same sercos ring.

1756-M16SE Sercos

Interface Module

Logix Platform


SERCOS interface TM

CP OK

Tx (rear)

Rx (front)

IMPORTANT

It is not required that all Kinetix 6000 drives be on the same sercos ring; however, it is required that all IDM units be on the same sercos ring as the

IPIM module they are connected to.

Figure 26 - Kinetix 6000M Network Cable Example - IPIM Module to IDM Units (1 sercos ring)



Bulletin 2090

Power/Brake Cables

2094-BCxx-Mxx-x

(400V-class) IAM Module

Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

2094-SEPM-B24-S

IPIM Modules

2094-BMxx-x

AM Modules

Bulletin 2090

Network Cables

Bulletin 2090

Hybrid Cables

Bulletin 2090

Feedback Cables

Compatible 400V-class

Rotary /Linear Motors or Actuators

(Bulletin MPL motors are shown)

IDM System 1 IDM System 2


60



Chapter 5

This configuration has the same drive modules and IPIM modules as shown in

Figure 26 , except the five modules are split between two sercos rings. Each ring

has its own 1756-M08SE sercos module in the ControlLogix controller chassis.

IMPORTANT



Figure 27 - Kinetix 6000M Network Cable Example - IPIM Module to IDM Units (2 sercos rings)

1756-M08SE Sercos

Interface Modules

Logix Platform


SERCOS interface TM SERCOS interface TM

CP OK

CP OK

Tx (rear)

Rx (front)

Tx (rear)

Rx (front)

Sercos Fiber-optic Ring 2


Bulletin 2090

Power/Brake Cables

2094-BCxx-Mxx-x


Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

2094-SEPM-B24-S

IPIM Modules

2094-BMxx-x

AM Modules

Bulletin 2090

Network Cables

Bulletin 2090

Hybrid Cables

Bulletin 2090

Feedback Cables




IDM System 1 IDM System 2



61

Chapter 5


1756-M08SE Sercos

Interface Modules

In this configuration, the 8-axis Bulletin 2094 power rail has four drive modules and four IPIM modules. Each IPIM module is connected to four IDM units.

There are five sercos rings and each ring has its own 1756-M08SE sercos module in the ControlLogix controller chassis.

IMPORTANT



Figure 28 - Kinetix 6000M Network Cable Example - IPIM Module to IDM Units (5 sercos rings)

SERCOS interface TM SERCOS interface TM SERCOS interface TM SERCOS interface TM SERCOS interface TM

CP OK CP OK CP OK CP OK CP OK

Logix Platform


Tx (rear)

Rx (front)

Tx (rear)

Rx (front)

Tx (rear)

Rx (front)

Tx (rear)

Rx (front)

Tx (rear)

Rx (front)






Bulletin 2090

Power/Brake Cables

2094-SEPM-B24-S

IPIM Modules

2094-BCxx-Mxx-x


Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

Bulletin 2090

Hybrid Cables

Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

Bulletin 2090

Hybrid Cables

Bulletin 2090

Network Cables

2094-BMxx-x

AM Modules

Bulletin 2090

Hybrid Cables

Bulletin 2090

Feedback Cables




62

IDM System 1

IDM System 2 IDM System 3 IDM System 4




Chapter 5

Ethernet Cable Connections

This procedure assumes you have your ControlLogix or CompactLogix

EtherNet/IP module and Bulletin 2094 control modules mounted and are ready to connect the Ethernet network cables.

The EtherNet/IP network is connected by using the PORT 1 and/or PORT 2 connectors. The IPIM module uses the EtherNet/IP network only for

configuring the Logix program. Refer to page 42

to locate the Ethernet connector on your IPIM module.

Refer to the Figure 29

to locate the connector on your EtherNet/IP controller module.

Figure 29 - ControlLogix and CompactLogix Ethernet Port Locations

ControlLogix Platform

1756-ENxT EtherNet/IP Module is Shown

CompactLogix 5370 L1, L2, and L3 Controllers

1769-L3xERM Controller is Shown

ControlLogix Ethernet Ports

The 1756-EN2T modules have only one port,

1756-EN2TR and 1756-EN3TR modules have two.

Front Views

00:00:BC:2E:69:F6

1 (Front)

2 (Rear)

Bottom Views

Port 1, Front

Port 2, Rear


63

Chapter 5


Notes:

64


Configuring the Kinetix 6000M System

Chapter

6

This chapter provides procedures for configuring your Kinetix 6000M system components with your Logix sercos module.

Topic

Understanding the IPIM Module Display

Configuring the IPIM Module

Configuring the IDM Unit

Add-on Profiles

Configure the Logix Sercos Interface Module

Apply Power to the System

Test and Tune the Axes

82

83

73

73

69

70

Page

66

TIP

Before you begin, make sure you know the catalog number for each IDM unit,

IPIM module, and the Logix module in your motion control application.

Configure the Kinetix 6000M

Integrated Drive-motor

System

Configuration for the Kinetix 6000M integrated drive-motor system follows a procedure similar to what is described in the Kinetix 6000 Multi-axis Servo

Drives User Manual and Kinetix 6200 and Kinetix 6500 Modular Multi-axis

Servo Drives User Manual. You will assign each IDM unit a node address and configure the IDM system in RSLogix 5000 software.

The IPIM module does not require configuration for your IDM units to be configured in the sercos ring. However, you can include the IPIM module in your

RSLogix 5000 project by connecting it to a configured Ethernet module in the

Logix chassis and adding it under the Ethernet module in the I/O configuration tree. An Add-On Profile is also needed to use the IPIM module in the RSLogix

5000 project, and as a result you can view IPIM module status information in

RSLogix 5000 software and use it in your Logix program. The Ethernet connection is also used to upgrade the IPIM module firmware by using

ControlFLASH software.

TIP

The factory default communication rate for all Kinetix 6000 modules is 4 Mbps.

The modules must be changed to 8 Mbps to be compatible with the Kinetix

6000M.


65

Chapter 6

Configuring the Kinetix 6000M System

Understanding the IPIM

Module Display

The IPIM module has six status indicators (see Interpret Status Indicators

on

page 90

) and a four-line LCD display. The indicators and display are used to monitor the system status, set network parameters, and troubleshoot faults. Four navigation buttons are located directly below the display and are used to select items from a soft menu.

Figure 30 - IPIM Module LCD Display

01

07

13

02

08

14

« »

03

09

15

IPIM

04

10

16 info

05

11

06

12 tools

01

07

13

02

08

14

« »

03

09

15

IPIM

04

10

16 info

05

11 tools

06

12

Soft Menu

Navigation Buttons

Status Indicators (see page 90

)

The soft menu provides a changing selection that will correspond to the current display. Use the navigation buttons to perform the following.

« »

V V

back

cancel

enter info

home

tools

save

Selecting either arrow will move the selection to the next (or previous) item or value. Depending on the menu displayed, both arrows may not be shown.

Selecting either arrow will move the selection to the next menu item. It will also change a selected value. Depending on the menu or item displayed, both arrows may not be shown.

Discards changes and returns to the previous screen or home.

Discards any changes and returns to the home display.

Accepts current selection/value.

Selects the Information display for the IPIM or a selected IDM unit.

Selecting “home” will discard changes and return to the home display.

Displays the tools menu.

Accepts the current selection/value.

66



Chapter 6

Startup Sequence

On initial powerup, the IPIM module performs a self test of the system. Upon successful completion, the following confirmation is displayed, followed by the firmware version and IP address.

Running Self

Tests . . . OK

FW Version

1.xx.xx

IP Address:

192.169.1.111

Next, the home screen displays the address of each connected IDM unit.

01

07

13

02

08

14

« »

IPIM

03 04

09

15

10

16 info

05

11

06

12 tools

If an IDM unit is reporting a fault, the IDM address is either underlined or outlined. It is outlined for severe faults and underlined for less severe faults.

Information Display

Use the arrows to select “IPIM” or a specific IDM unit.

“IPIM” selected

01

07

13

02

08

14

« »

IPIM

03 04

09

15

10

16 info

05

11

06

12 tools

IDM unit 8 selected

01

07

13

02

08

14

« »

IPIM

03 04

09

15

10

16 info

05

11

06

12

Pressing “info” displays a new screen with detailed information about the IPIM module or selected IDM unit.

IPIM

IP Addr:

Bus Reg Cap:

192.168.1.1

33 %

Bus Voltage:

600 V

Active Faults:

V

V home tools

IDM 8

Status:

Safety:

Sercos Phase:

Active Faults:

V

V

Stopped

Safe-off home tools

4

IPIM Information

IDM Information


67

Chapter 6


The following information is displayed.

IPIM Information

Module

Status:

- IP Address

- OK

-Standby (OK, but no CIP connection)

-Faulted

-Init Fault (Requires reboot)

IDM Information

Status: Displays IDM status values.

Bus Reg Cap Percent of shunt capacity being utilized.

Active

Faults:

Active faults (one per line) will be displayed.

Safety:

Sercos

Phase:

“Motion-allowed” or “Safe-off.”

Current sercos phase of the IDM: 0 -5.

Utilization: Percent of continuous DC bus current.

Active Faults: Active faults (one per line) will be displayed.

Tools Menu

The tools menu provides network setup, sercos light intensity adjustment and fault help.

Network configuration

Sercos light intensity

IPIM fault help

V

IDM fault help

V back enter

68

To edit a menu item or value, use the arrow keys to select the desired item, then press “enter.” The up arrow lets you increment the value that is highlighted.

Values will rollover when reaching the end of the list.



IPIM fault help

V

IDM fault help

V back enter enter

Network mode

Static IP

V

Subnet mask

Gateway address

V back enter enter

V

Static IP

1 11.222.333.444

» cancel save

Use the right arrow to move and the up arrow to change value

The tools menu provides viewing/editing of the following.

Selection



IPIM fault help

IDM fault help

Description

Mode

IP Address

Subnet mask

Gateway address

Primary address

Select Static or DHCP configuration.

Edits the IP address.

Edits the subnet mask.

Edits gateway address.

Edits primary name server IP address.

Secondary Name Server Edit the secondary name server IP address.

Selects high or low intensity. Changes to the light intensity will take effect immediately and be stored in non-volatile memory. The default setting is “High.”

Displays help text for the selected IPIM fault.

Displays help text for the selected IDM fault.



Chapter 6

Configuring the IPIM Module

You can include the IPIM module in your RSLogix 5000 project by connecting it to a configured Ethernet module in the Logix chassis and adding it under the

Ethernet module in the I/O configuration tree. As a result, you can view the

IPIM module status information in RSLogix 5000 software and use it in your

Logix program. To select the IPIM module in RSLogix 5000 software, version

20, you must load an Add-on Profile (see page 73

).

Setting the IPIM Module Network Address

To perform monitoring, diagnostics, and upgrade firmware, it is necessary to program the following using the LCD display:

• Mode - Static or DHCP

• IP address

• Gateway

• Subnet mask

Settings are stored in non-volatile memory. You can select a static address, or enable DHCP. IP addressing may also be changed through the Module

Configuration dialog in RSLinx software. Changes to the IP addressing take effect immediately. The factory setting of the IP address is the static address

192.168.1.1. Refer to

Understanding the IPIM Module Display on page 66

for programming guidelines.

Follow these steps to program the network settings:

1. Apply control power.

2. After initialization is complete and the home screen is displayed, select: tools>Network configuration>Net mode.

3. Use the arrow keys to select Static or DHCP.

4. Press “save.”

5. Select tools>Network configuration>Net mode>Static IP.

6. Use the right arrow to select the first digit to change.

7. Use the up arrow to increment the value until the desire value is displayed.

Then use the right arrow to select the next digit and so on. Continue until the IP address is correct.

8. Press “save.”

9. Repeat

step 1 through step 8

to set the subnet mask and gateway address.

10. Save your settings and remove control power.


69

Chapter 6


Configuring the IDM Unit

Setting the Node Address

The node address is set by switches on each IDM unit. This address is the actual sercos node address, not an offset from the IAM module. The address is read at power up, so if the switch settings are changed while power is applied, the changes do not take effect until the next power cycle.

Refer to

Figure 31

and remove the two protective covers to gain access to the switches. Using a small screwdriver, rotate the switches to the proper setting.

Replace covers and torque to 0.6 N•m (5 lb•in), repeat for any other units.

Figure 31 - Node Address Switches

S1 – 1’s Digit

(least significant)

6 7

8 9

34

S1

6 7

8 9

34

S10 – 10’s Digit

(most significant)

S10

1

D N

2

3

70



Chapter 6

In the following example (

Figure 32 ), the Kinetix 6000 power rail contains two

single-wide axis modules and one IDM system. A sercos node address is not assigned to the slot-filler or the IPIM module. However, the system identifies both modules with slot locations.

Node addresses 02 and 05 are available for any of the IDM units, but to avoid confusion, the node addressing for the IDM units was started at 20. Unlike axis modules, each IDM unit has switches that determine its node address. In example

1, the IDM unit node addressing is sequential, but it doesn’t have to be.

IMPORTANT

Creating a duplicate node address between the axis modules mounted on the power rail and the IDM system generates error code E50. Each node address on the sercos ring must be unique within the range of 01…99.

IMPORTANT

Slot-filler modules must be used to fill any unoccupied slot on the power rail.

However, you can replace slot-filler modules with AM modules or the 2094-

BSP2 shunt module (maximum one 2094-BSP2 shunt module per power rail).

Figure 32 - Node Addressing Example 1

1756-MxxSE Sercos

Interface Module

Logix Platform


SERCOS interface

CP OK

Transmit

Tx (rear)

Rx (front)

Receive


0.1 m

(5.1 in.)

Receive Transmit

Kinetix 6000 System

(5-axis power rail)

0 1

Base Node Address

Switches

05 = Slot-filler module slot location

04 = AM module (axis 3) node address


02 = IPIM module slot location

01 = IAM module (axis 1) base node address

MDF-SBxxxxx

IDM Unit

Network Node Address

Switches (covers removed)

6 7

8 9

S1

6 7

8 9

S10

1

D

2

N

3

20 = IDM unit 1

45

6 7

8 9

23

S1

21 = IDM unit 2

45

6 7

8 9

23

S1

45

6 7

8 9

23

S10

45

6 7

8 9

23

S10

22 = IDM unit 3

45

6 7

8 9

23

45

6 7

8 9

23

S1

S10

23 = IDM unit 4

45

6 7

8 9

23

45

6 7

8 9

23


71

Chapter 6


In example 2 (

Figure 33 ), the Kinetix 6000 power rail contains two single-wide

axis modules and two IDM systems. A sercos node address is not assigned to the slot-filler or the IPIM module, but the system identifies both with slot locations.

Node addressing for the IDM system example 2 is similar to the first. Each IDM unit has switches that determine its node address. In this example, the IDM unit node addressing starts at 30 and is sequential.

IMPORTANT

Creating a duplicate node address between the axis modules mounted on the power rail and the IDM system generates error code E50. Each node address on the sercos ring must be unique within the range of 01…99.

Figure 33 - Node Addressing Example 2

1756-MxxSE Sercos

Interface Module

Logix Platform


SERCOS interface

CP OK

Transmit

Tx (rear)

Rx (front)

Receive


Receive

0.1 m

(5.1 in.)

Transmit

Kinetix 6000 System

(6-axis power rail)

0 1

Base Node Address

Switches

06 = Slot-filler module slot location





01 = IAM module (axis 1) base node address

MDF-SBxxxxx

IDM Unit

Network Node Address

Switches (covers removed)

6 7

8 9

S1

6 7

8 9

S10

1

D

2

N

IDM System

1

3

IDM System

2

30 = IDM unit 5

45

6 7

8 9

23

S1

31 = IDM unit 6

45

6 7

8 9

23

S1

45

6 7

8 9

23

S10

45

6 7

8 9

23

S10

32 = IDM unit 7

45

6 7

8 9

23

45

6 7

8 9

23

S1

S10

33 = IDM unit 8

45

6 7

8 9

23

45

6 7

8 9

23

20 = IDM unit 1

45

6 7

8 9

23

S1

21 = IDM unit 2

45

6 7

8 9

23

S1

45

6 7

8 9

23

S10

45

6 7

8 9

23

S10

22 = IDM unit 3

45

6 7

8 9

23

45

6 7

8 9

23

S1

S10

23 = IDM unit 4

45

6 7

8 9

23

45

6 7

8 9

23

72


Add-on Profiles


Chapter 6

To select the IPIM module in RSLogix 5000 software, version 20, you must load an Add-on Profile from www.ab.com

.

To navigate to the Add-on Profiles, follow this path:

• Technical Support

• Software Updates, Firmware and Other Downloads

• RSLogix 5000 I/O Modules Add-On-Profiles

You will be required to establish a login and provide the serial number of your drive to access the download file.

Configure the Logix Sercos

Interface Module

This procedure assumes that you have wired your Kinetix drive system and have configured the communication rate and optical power switches.

For help using RSLogix 5000 software as it applies to configuring the

ControlLogix, CompactLogix, or SoftLogix sercos modules, refer to Additional

Resources on page 7 .

IMPORTANT

RSLogix 5000 software, version 20.00 or later, is required.

Configure the Logix Controller

Follow these steps to configure the Logix controller.

1. Apply power to your Logix chassis containing the sercos interface module/

PCI card and open your RSLogix 5000 software.

2. From the File menu, choose New.

The New Controller dialog box opens.

3. Configure the new controller.


73

Chapter 6

Configuring the Kinetix 6000M System a. From the Type pull-down menu, choose the controller type.

b. From the Revision pull-down menu, choose the revision (V20).

c. Type the file Name.

d. From the Chassis Type pull-down menu, choose the chassis.

e. Enter the Logix processor slot.

4. Click OK.

5. From the Edit menu, choose Controller Properties.

The Controller Properties dialog box opens.

6. Click the Date/Time tab.

7. Check Enable Time Synchronization.

This assigns the controller as the Grandmaster clock. The motion modules set their clocks to the module you assign as the Grandmaster.

IMPORTANT

You can assign only one module in the Logix chassis as the

Grandmaster clock.

8. Click OK.

74



Chapter 6

Configure the Logix Module

Follow these steps to configure the Logix module.

1. Right-click I/O Configuration in the Controller Organizer and choose

New Module.

The Select Module dialog box opens.

2. Scroll to select the sercos module as appropriate for your actual hardware configuration.

In this example, the 1756-M16SE module is selected.

3. Click Create.

The New Module dialog box opens.

4. Configure the new module.

a. Type the module Name.

b. Enter the Logix sercos module slot (leftmost slot = 0).

c. Check Open Module Properties.

5. Click OK.

Your new module appears under the I/O Configuration folder in the

Controller Organizer and the Module Properties dialog box opens.


75

Chapter 6


TIP

The IDM system data rate is fixed at 8 Mbps.

6. Verify that the data rate DIP switches on the IAM module and any AM modules on the same sercos ring are set to 8 Mbps.

7. Click the SERCOS Interface tab.

76

8. From the Data Rate pull-down menu choose 8 Mb or choose the Auto

Detect setting.

9. From the Cycle Time pull-down menu, choose the Cycle Time according to the table below.

Data Rate

8 Mbps

(1)

Number of Axes

Up to 4

Up to 8

Up to 16

(1) The Kinetix 6000M system supports only 8 Mbps.

Cycle Time

0.5 ms

1 ms

2 ms

TIP

TIP

The factory default data rate setting for all Kinetix 6000 modules is

4 Mbps.

The number of axes/module is limited to the number of axes as shown in the table below.

Logix Sercos Module

1756-M03SE or 1756-L60M03SE

1756-M08SE

1756-M16SE or 1784-PM16SE

1768-M04SE

Number of Axes

Up to 3

Up to 8

Up to 16

Up to 4

Data Rate

8 Mbps

10. From the Transmit Power pull-down menu, choose High.

The default setting is High; however, this setting is dependent on the cable length (distance to next receiver) and cable type (glass or plastic).

11. Enter the Transition to Phase setting.

The Transition to Phase default setting is 4 (phase 4). The Transition to

Phase setting stops the ring in the phase specified.

12. Click OK.

13. Repeat

step 1 through

step 12

for each Logix module.



Chapter 6

Configure the IDM Units

Follow these steps to configure the IDM units.

1. Right-click the Logix module you just created and choose New Module.

The Select Module dialog box opens.

2. Scroll to select the IDM unit appropriate for your actual hardware configuration.

IMPORTANT

To configure IDM units (catalog numbers MDF-SBxxxxx) you must be using RSLogix 5000 software, version 20.01 or later. Version 20.00 can be used if the motion database has been updated.

3. Click Create.

The New Module dialog box opens.

4. Configure the new module.

a. Type the module Name.

b. Enter the Node address.

Set the node address in the software to match the node setting on the IDM

unit. Refer to Setting the Node Address on page 70

.

c. Check Open Module Properties.

5. Click OK.


77

Chapter 6


6. Click the Associated Axes tab.

7. Click New Axis.

The New Tag dialog box opens.

78

8. Type the axis Name.

AXIS_SERVO_DRIVE is the default Data Type.

9. Click Create.

The axis appears under the Ungrouped Axes folder in the Controller

Organizer.

10. Assign your axis to Node 1.

TIP

Auxiliary feedback is not supported by the IDM units.

11. Click OK.

12. Repeat

step 1 through

step 11

for each IDM unit.



Chapter 6

Configure the Motion Group

Follow these steps to configure the motion group.

1. Right-click Motion Groups in the Controller Organizer and choose New

Motion Group.

The New Tag dialog box opens.

2. Type the new motion group Name.

3. Click OK.

The new motion group appears under the Motion Groups folder.

4. Right-click the new motion group and choose Properties.

The Motion Group Properties dialog box opens.

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.


79

Chapter 6


Configure Axis Properties

Follow these steps to configure the Axis properties.

1. Right-click an axis in the Controller Organizer and choose Properties.

The Axis Properties dialog box opens.

80

2. On the Drive/Motor tab, check Drive Enable Input Checking.

When checked (default), means a hard drive-enable input signal is required. Uncheck to remove that requirement.

TIP

The drive-enable input signal is located on the IPIM module.

3. Click Apply.

4. Click the Units tab and edit default values as appropriate for your application.

5. Click the Conversion tab and edit default values as appropriate for your application.

6. From the Positioning Mode pull-down menu and choose Rotary.

7. Click Apply.


8. Click the Fault Actions tab.


Chapter 6

9. Click Set Custom Stop Action.

The Custom Stop Action Attributes dialog box opens and lets you set delay times for IDM units.

10. Configure the delay times.

a. Type the Brake Engage Delay Time.

b. Type the Brake Release Delay Time.

Cat. No.

Brake Engage Delay

ms

20

Brake Release Delay

ms

50 MDF-SB1003

MDF-SB1153

MDF-SB1304

25 110 c. Click Close.

11. Click OK.

12. Repeat

step 1

through step 11

for each IDM unit.

13. Verify your Logix program and save the file.

Download the Program

After completing the Logix configuration you must download your program to the Logix processor.


81

Chapter 6


Apply Power to the System

This procedure assumes that you have wired and configured your Kinetix drive system (with or without the LIM module) and your sercos interface module.

ATTENTION: Capacitors on the DC bus may retain hazardous voltages after input power has been removed. Before working on the IPIM module or disconnecting/connecting any IDM unit, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the front of the drive. Failure to observe this precaution could result in severe bodily injury or loss of life.

Refer to the Chapter 4

for connector locations and Chapter 7 when

troubleshooting the IPIM module and IDM unit status indicators.

Follow these steps to apply power to the Kinetix 6000M system.

1. Disconnect the load to the IDM units.

ATTENTION: To avoid personal injury or damage to equipment, disconnect the load to the IDM units. Make sure each IDM unit is free of all linkages when initially applying power to the system.

2. Apply control power and 3-phase power to your Kinetix drive system and observe the status indicators on your Kinetix 6000 or Kinetix 6200 drive modules.

Refer to the user manual for your Kinetix 6000 or Kinetix 6200 drive system for the proper status indicator response. When the drive system is powered up and has reached sercos phase 4, continue to

step 3 .

3. Observe the IDM unit drive status indicator and verify with the table below.

Indication Status

Alternating green/red Module is performing self test

Flashing green

Solid green

Solid or flashing red

Module is in standby mode

Module is operating

Fault has occurred

Do This

Wait for steady green.

Go to Test and Tune the Axes on page 83 .

Refer to Chapter 7 .

4. Verify the Hardware Enable Input signal is at 0 volts.

The Hardware Enable input for the IDM system is on the IPIM module

(see page 41

).

5. Remove the Hardware Enable Input connection, if one exists.

6. Observe the three sercos indicators on the Logix sercos module.

Three Sercos Indicators Status

Flashing green and red

Steady green

Not flashing green and red/ not steady green

Establishing communication

Communication ready

Sercos module is faulted

Do This

Wait for steady green on all three indicators.

Go to Test and Tune the Axes on page 83

.

Go to the appropriate Logix manual for specific instructions and troubleshooting.

82


Test and Tune the Axes


Chapter 6

This procedure assumes that you have configured your Kinetix 6000M system, your Logix sercos interface module, and applied power to the system.

For help using RSLogix 5000 software as it applies to testing and tuning your axes with ControlLogix, CompactLogix, or SoftLogix sercos modules, refer to

Additional Resources on page 7 .

Test the Axes

Follow these steps to test the axes.

1. Verify the load was removed from each axis.

2. Right-click an axis in your Motion Group folder and choose Properties.

The Axis Properties dialog box opens.

3. Click the Hookup tab.

4. Type 2.0 as the number of revolutions for the test or another number more appropriate for your application.

This Test

Test Marker

Test Feedback

Test Command & Feedback

Performs this Test

Verifies marker detection capability as you rotate the motor shaft.

Verifies feedback connections are wired correctly as you rotate the motor shaft.

Verifies motor power and feedback connections are wired correctly as you command the motor to rotate.

5. Apply Hardware Enable Input signal for the axis you are testing.

IMPORTANT

Hardware Enable input for IDM units is on the IPIM module.


83

Chapter 6


6. Select the desired Test (Marker/Feedback/Command & Feedback) to verify connections.

The Online Command dialog box opens. Follow the on-screen test instructions. When the test completes, the Command Status changes from

Executing to Command Complete.

7. Click OK.

The Online Command - Apply Test dialog box opens (Feedback and

Command & Feedback tests only). When the test completes, the

Command Status changes from Executing to Command Complete.

8. Click OK.

9. Determine if your test completed successfully.

If

Your test completes successfully, this dialog box opens.

Then

1. Click OK.

2. Remove Hardware Enable Input signal

(1)

.

3. Go to Tune the Axes on page 85

.

Your test failed, this dialog box opens.

(1) The hardware enable input for IDM units is on the IPIM module.

1. Click OK.

2. Verify the Bus status indicator turned solid green during the test.

3. Verify that the Hardware Enable Input

(1)

signal is applied to the axis you are testing.

4. Verify conversion constant entered in the

Conversion tab.

5. Return to main

step 6

and run the test again.

84



Chapter 6

Tune the Axes

Follow these steps to tune the axes.

1. Verify the load is still removed from the axis being tuned.

ATTENTION: To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then re-attach the load and perform the tuning procedure again to provide an accurate operational response.

2. Click the Tune tab.

3. Type values for Travel Limit and Speed.

In this example, Travel Limit = 5 and Speed = 10. The actual value of programmed units depend on your application.

4. From the Direction pull-down menu, choose a setting.

Forward Uni-directional is default.

5. Check Tune boxes as appropriate for your application.

6. Apply Hardware Enable Input signal for the axis you are tuning.

IMPORTANT

Hardware Enable input for IDM units is on the IPIM module.

7. Click Start Tuning to auto-tune your axis.

The Online Command - Tune Servo dialog box opens. When the test completes, the Command Status changes from Executing to Command

Complete.


85

Chapter 6


8. Click OK.

The Tune Bandwidth dialog box opens.

86

Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.

9. Record your bandwidth data for future reference.

10. Click OK.

The Online Command - Apply Tune dialog box opens. When the test completes, the Command Status changes from Executing to Command

Complete.

11. Click OK.

12. Determine if your test completed successfully.

If

Your test completes successfully, this dialog box opens.

Then

1. Click OK.

2. Remove the Hardware Enable Input signal applied earlier

(1)

.

3. Go to

step 13 .

Your test failed, this dialog box opens.

(1) The hardware enable input for IDM units is on the IPIM module.

13. Repeat

Test and Tune the Axes

for each axis.

1. Click OK.

2. Make an adjustment to motor velocity.

3. Refer to the appropriate Logix motion module user manual for more information.

4. Return to step 7

and run the test again.


Chapter

7

Troubleshooting the Kinetix 6000M System

Topic

Safety Precautions

IDM System Error Codes

Interpret Status Indicators

General System Anomalies

IPIM Module Fault Diagnosis

IDM Unit Fault Diagnosis

Use a Web Browser to Monitor System Status

95

97

92

93

87

90

Page

87

Safety Precautions

ATTENTION: Capacitors on the DC bus may retain hazardous voltages after input power has been removed. Before working on the IDM system, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the front of the IPIM module. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Do not attempt to defeat or override the fault circuits. You must determine the cause of a fault and correct it before you attempt to operate the system. Failure to correct the fault could result in personal injury and/or damage to equipment as a result of uncontrolled machine operation.

ATTENTION: Provide an earth ground for test equipment (oscilloscope) used in troubleshooting. Failure to ground the test equipment could result in personal injury.

IDM System Error Codes

The IAM module reports a single, generic IPIM fault whenever a fault occurs on any IPIM module in the same backplane as the IAM module. All IPIM faults result in an open contactor. The Logix Axis Tag for this fault is IPIMFault.

The IPIM module is not a sercos device, so the IAM module reports any IPIM faults to the Logix motion subsystem. IPIM faults are reset by performing a fault reset on the IAM module. Issuing a fault reset command to the IAM module also generates a fault reset to all the IPIM modules in the same backplane as the IAM.

Detailed information about the IPIM fault status may be obtained by messaging to the IAM.


87

Chapter 7

Troubleshooting the Kinetix 6000M System

Connecting the IPIM module into the Logix environment as an EtherNet/IP device does not disable fault reporting through the IAM module. Only the IAM fault reporting lets the Logix motion sub-system take action based on the IPIM module fault status. IPIM faults are also reported to Logix over the Ethernet connection. However, IPIM faults must be reset by applying a fault reset instruction to the IAM module. The integration of the IPIM module into the

Logix environment through the EtherNet/IP network provides additional capabilities you may choose to take advantage of in your Logix program.

Reading the Fault Status of the IPIM Module

The IAM module supports two IDNs to allow reading the fault status from the

IPIM, P-0-113 and P-0-114. Both of these IDNs have a data type of INT. To read the fault status from an IPIM module, first write the slot number of the IPIM module you want to read to IDN P-0-114. The left-most slot (the slot occupied by the IAM module) is slot 1, and the slot numbers increment as you move to the right. After the slot number has been written, the IPIM module fault status can be obtained by reading IDN P-0-113. The 16-bit value returned is a bitfield representing the state of the IPIM faults, as follows:

– Value: IPIM diagnostics: (1 = active, 0 = inactive)

– Bit 0: Backplane Communication error

– Bit 1: IDM Communication error

– Bit 2: Bus Overload (excessive current usage by IDMs)

– Bit 3: DC+ Fuse open

– Bit 4: DC- Fuse open

– Bit 5: Control Power Overload

– Bit 6: DC Bus Overcurrent Error (instantaneous overcurrent)

– Bit 7: Shunt Overload

– Bit 8: Overtemp Error

– Bit 9: Open DC Bus Error

– Bits 10-15: Reserved/Not Used

Setting the Message Configuration Parameters

Set the write message configuration parameters as shown in Figure 34

.

88


Figure 34 - Message Configuration - Write


Chapter 7

1. Set the Source field to a tag that contains the slot location for the IPIM module.

The slot location valid range is 2 - 8, (assuming an 8 slot power rail). The

IAM module is always in slot 1.

2. Set the path field on the communication tab to the IAM module on the power rail where the IPIM module is located.

Set the read message configuration parameters as shown

Figure 35

.

Figure 35 - Message Configuration - Read

1. Set the Source field to a tag where the IPIM module status will be stored.

2. Set the path field on the communication tab to the IAM module on the power rail where the IPIM module is located.

Refer to the user manual for your Kinetix 6000 or Kinetix 6200 drive system for further information on reading and writing IDNs.


89

Chapter 7


Interpret Status Indicators

When a fault condition is detected, the appropriate status indicator will illuminate (IDM unit or IPIM module) and the IPIM module will annunciate

the fault on its front panel display. Refer to Figure 36

for IPIM status indicator

descriptions and Figure 37

for IDM unit indicators.

IPIM Module Status Indicators

IPIM module fault descriptions, types and actions start on

page 94 .

Figure 36 - IPIM Display and Status Indicators

90

01

07

13

02

08

14

IPIM

03 04

09

15

10

16

Info

05

11

Tools

06

12

Control Bus

Module Status

Network Status

DC Bus

Port 1

Port 2

Control Bus

Module Status

Network Status

DC Bus

Port 1

Port 2

Indicator

Control

Bus

Module

Status

Network

Status

DC Bus

Status of the

Control Bus

IPIM Module

Status

Indication

Off

Solid Green

Solid Red

Description

Control bus is not present

Control bus is present

A fault has occurred

Off

Flashing Green

Power is not applied to the module

Module is in Standby mode - configuration may be required

Solid Green

Flashing Red

Solid Red

Module is operating correctly

A recoverable fault has occurred

(1)

An unrecoverable fault has occurred

Alternating Green/Red Self-test mode during powerup

(1)

Network Status Off

Flashing Green

Solid Green

Flashing Red

Status of the DC

Bus

Not powered or no IP address

No connections, but an IP address has been obtained

An established connection exists

A connection has timed out

Solid Red Duplicate IP is present

Alternating Green/Red Self-test mode during powerup

Off

Flashing Green

Solid Green

DC Bus is not present

DC bus is present and all IDM units are disabled

DC bus is present and at least one IDM unit is enabled



Chapter 7

Indicator

Port 1

Port 2

Status of the

EtherNet/IP ports

Indication

Off

Flashing Green

Solid Green

Description

Port is not connected

Port is connected and communication is occurring

Port is connected, but no communication is not occurring

(1) A reset or cycling the power may clear a recoverable fault (depending on the state of the IDM). An unrecoverable fault will require power cycling and/or modifying the hardware configuration while unpowered to clear the fault.

IDM Unit Status Indicators

IDM unit fault descriptions and actions start on page 95

.

Figure 37 - IDM Unit Indicators

Drive Status (D)

Network Status (N)

S1

S10

1

D N

2

3

Indicator

Network

Status (N)

Drive

Status (D)

Provides communication status for the IDM unit.

Provides general status for the IDM unit.

Indication

Off

Flashing green

(1 s interval)

Solid green

Solid red

Fast flashing green

(0.5 s interval)

Slow flashing green

(2 s interval)

Off

Flashing green

Solid green

Flashing red

Solid red

Description

Communication is not active

Communication is being established

Communication has been established

A duplicate address exists

Firmware update in process

Firmware update in process on another IDM

Power is not applied

Module is in standby mode

Module is operating

Recoverable fault has occurred

(1)

Unrecoverable (or hardware) fault has occurred

(1)

(1) A reset or cycling the power may clear a recoverable fault (depending on the state of the IDM). An unrecoverable fault will require power cycling and/or modifying the hardware configuration while unpowered to clear the fault.


91

Chapter 7


General System Anomalies

These anomalies do not always result in a fault code, but may require troubleshooting to improve performance.

Condition

Axis or system is unstable.

You cannot obtain the acceleration/ deceleration that you want.

IDM unit does not respond to a velocity command.

Presence of noise on wires/cables.

Sercos ring not phasing up.

Potential Cause

Unintentionally in Torque mode.

IDM unit tuning limits are set too high.

Position loop gain or position controller accel/decel rate is improperly set.

Mechanical resonance.

Possible Solution

Check to see what primary operation mode was programmed.

Run Tune in RSLogix 5000 software.


Notch filter or output filter may be required

(refer to Axis Properties dialog box, Output tab in RSLogix 5000 software).

Verify that current limits are set properly.

Torque Limit limits are set too low.

The system inertia is excessive.

The system friction torque is excessive.

Available current is insufficient to supply the correct accel/decel rate.

Acceleration limit is incorrect.

• Check IDM unit size versus application need.

• Review servo system sizing.

Check IDM unit size versus application need.

• Check IDM size versus application need.

• Review servo system sizing.

Velocity Limit limits are incorrect.

The axis cannot be enabled for 1.5 seconds after disabling.

The IDM wiring is open.

The IDM thermal switch has tripped.

Verify limit settings and correct them, as necessary.

Verify limit settings and correct them, as necessary.

Disable the axis, wait for 1.5 seconds, and enable the axis.

Replace the IDM unit.

The IDM unit has malfunctioned.

The coupling between IDM unit and machine has broken (for example, the IDM unit moves, but the load/machine does not).

• Check for a fault.

• Check the wiring.

Replace the IDM unit.

Check and correct the mechanics.

Primary operation mode is set incorrectly.

Check and properly set the limit.

Velocity or current limits are set incorrectly.

Check and properly set the limits.

Recommended grounding per installation instructions have not been followed.

• Verify grounding.

• Route wire away from noise sources.

• Refer to System Design for Control of

Electrical Noise, publication GMC-RM001 .

Line frequency may be present.

Duplicate node settings.

Incompatible data rates.

• Verify grounding.

• Route wire away from noise sources.

Change the node address.

Verify that the data rate is set to 8 Mbps for all

Kinetix 6000 modules.

92



Chapter 7

Condition

No rotation

Potential Cause

The IDM unit connections are loose or open.


Check IDM unit wiring and connections.

Foreign matter is lodged in the IDM unit.

Remove foreign matter.

The IDM unit load is excessive.

Verify the servo system sizing.

The bearings are worn.

The IDM unit brake is engaged (if supplied).

The IDM unit is not connect to the load.

IDM unit overheating The duty cycle is excessive.

Return the IDM unit for repair.

• Check brake wiring and function.

• Return the IDM unit for repair.

Check coupling.

Change the command profile to reduce accel/ decel or increase time.

Return the IDM unit for repair.

Abnormal noise

The rotor is partially demagnetized causing excessive IDM unit current.

IDM unit tuning limits are set too high.

Loose parts are present in the IDM unit.

Through bolts or coupling is loose.

The bearings are worn.

Mechanical resonance.


• Remove the loose parts.

• Return IDM unit for repair.

• Replace IDM unit.

Tighten bolts.

Return IDM unit for repair.

Notch filter may be required (refer to Axis

Properties dialog box, Output tab in

RSLogix 5000 software).

IPIM Module Fault Diagnosis

When a fault condition is detected, it is added to a fault log, opens the power rail

SYSOK and reports the fault to the IAM module. This causes a loss of bus power to all modules on the Bulletin 2094 power rail and associated IDM units. If an

IPIM module fault is detected, the fault will be displayed on the IPIM module.

In addition, the IPIM module will display IDM unit faults.

The IAM module generates a fault whenever an IPIM module fault occurs, regardless of the state of the contactor. IDM unit faults are not displayed by the

IAM module.

Issuing a fault reset command to the IAM module will also send a fault reset command to the IPIM module.

The IPIM module maintains a log of the last 50 faults reported by the IPIM module or any of the connected IDM units. Each fault contains the source of the fault (IDM unit number or IPIM module), the fault number, and a timestamp with the cumulative power-on time of the IPIM module.


93

Chapter 7


IPIM Module Fault Types

The IPIM has two fault types: resettable and non-resettable.

When an IPIM module fault occurs, the fault is reported to the IAM module.

The IAM module reports an IPIM fault to the Logix controller.

Resettable faults - when the IPIM module fault is cleared from the IAM module, the fault is removed from its display (if the condition has been removed).

Non-resettable faults - the control power must be cycled and the fault may be cleared if the condition that created the fault has been removed.

Table 19 - IPIM Fault Types, Descriptions and Actions

Fault

IPIM FLT 01

IPIM FLT 02

IPIM FLT 03

IPIM FLT 04

IPIM FLT 05

IPIM FLT 08

IPIM FLT 09

Type

Resettable

Resettable

Resettable

Resettable

Resettable

Description Potential Cause

Backplane Comm Lost backplane communication with IAM module.

IDM Comm Lost communication with IDM unit.


Verify control power to IAM module.

DC+ Fuse Blown Wiring error or DC bus short.

Verify control power to IDM units.

DC Bus Overload Excessive RMS current usage by IDM units.

Reduce the amount of current required by the IDM units or add an additional

IPIM module to the Kinetix 6000 rail.

Check wiring and IDM units for DC bus integrity. Once the wiring issue or damaged IDM unit has been removed and replaced, change the DC+ fuse.

DC- Fuse Blown Wiring error or DC bus short.

IPIM FLT 06 Not Resettable Control Power

IPIM FLT 07 Resettable

Resettable

Resettable

Overcurrent

DC Bus

Overcurrent

Bus Regulator

Thermal Overload

Overtemp

Excessive control power usage by the IDM units.

Excessive instantaneous current usage by

IDM units.

Thermal model of IPIM shunt indicates overheating due to excessive current regeneration.

Excessive temperature measured in the

IPIM module.

Check wiring and IDM units for DC bus integrity. Once the wiring issue or damaged IDM unit has been removed and replaced, change the DC- fuse.

Check for control power wiring shorts. Reduce number of ID units. Reduce the number of power cycles.

Reduce number of IDM units per IPIM module or modify motion profiles to reduce current draw.

Modify the IDM unit or Kinetix 6000 motion profiles and/or applications to reduce the regenerative energy. Add external shunt modules.

Verify ambient operating conditions. Replace the IPIM module.

IPIM FLT 10

IPIM FLT 11

–

Resettable

Not Resettable

Open DC Bus

Runtime Error

Not Resettable Display is blank and Module Status is Solid Red

IDM unit hybrid cable disconnected.

Unexpected firmware error.

Corrupted Main Firmware.

Check hybrid cable connections at the IPIM module and each IDM unit.

Reboot.

Replace IPIM module.

Table 20 - IPIM Initialization Fault Types, Descriptions and Actions

Fault Type Description

IPIM INIT FLT 03 Resettable IAM Version

IPIM INIT FLT 05 Not

Resettable

Custom Logic

Watchdog

Potential Cause

IAM module firmware version does not support IPIM modules.

Main firmware has lost communication.


Update IAM module firmware.

Cycle power on the IPIM module. Check for firmware updates. Contact

Allen-Bradley Technical Support.

94


IDM Unit Fault Diagnosis


Chapter 7

Logix Controller/IDM Unit Fault Behavior

These RSLogix 5000 fault actions are configurable from the Axis Properties dialog box, Fault Actions tab.

Table 21 - Fault Action Definitions

Fault Action

Shutdown

Disable Drive

Stop Motion

Status Only

Definition

Axis is disabled as defined in

Table 22 . In addition, the axis in Logix enters the Shutdown

state, which disables any axes that are using this axis as a camming or gearing master. The

AxisHomedStatus tag for the faulted axis is cleared. Shutdown is the most severe action to a fault and it is usually reserved for faults that could endanger the machine or operator if power is not removed as quickly as possible.

The axis is disabled as defined in the Table 22 .

The axis decelerates at the maximum deceleration rate (set in RSLogix 5000 software>Axis

Properties>Dynamics tab). Once the axis has come to a stop, the servo loops remain enabled but no further motion can be generated until the fault is reset. This is the gentlest stopping mechanism in response to a fault. It is usually used for less severe faults.

System continues to operate. Status is displayed on the IPIM module.

Only selected faults are programmable.

Table 22

indicates which faults have a programmable RSLogix Fault Action. Faults that do not have a programmable fault action will have the Shutdown action described in

Table 21

.

Figure 38 - RSLogix 5000 Axis Properties - Fault Actions Tab

Drive Fault Action/Attribute for

IDM Overtemp fault (E04).

Table 22 - Exception/Fault Behavior

IPIM Display

(RSLogix Drive Fault)

E04 – Motor Overtemp

(MotorOvertempFault)

E05 – Power Fault

(DriveOvercurrentFault)

IDM Status

Indicator Potential Cause

Flashing

Red

Excessive IDM unit temperature.

Flashing

Red

Operation above the IGBT instantaneous current rating or IPIM module power supply undervoltage.


• Lower ambient temperature, increase IDM unit cooling.

RSLogix

Programmable

Fault Action

Yes

Fault Behavior

Decel/Disable

• Operate within the instantaneous power rating.

• Reduce acceleration rates.

• If fault persists, replace IDM unit.

No Coast/Disable/

Open Contactor

Enable


95

Chapter 7


Table 22 - Exception/Fault Behavior (continued)

IPIM Display


E06 – Positive/Negative Hard

Overtravel

(Pos/NegHardOvertravelFault)

E09 – Bus Under Voltage

(DriveUndervoltageFault)

E10 – Bus Over Voltage

(DriveOvervoltageFault)

E50 – Sercos Same Addr

(SercosRingFault)

E54 – Current Feedback

Hardware Fault

(DriveHardFault)

E65 – Hookup

(DriveHardFault)

IDM Status


Flashing

Red

Axis moved beyond the physical travel limits in the positive/negative direction.

Flashing

Red

Flashing

Red

DC bus voltage fell below the undervoltage limit while the axis was enabled.

The DC bus voltage is above limits.

Flashing

Red

Positive/Negative software overtravel limit exceeded.


• Verify motion profile.

• Verify axis configuration in software.

• Disable prior to removing power.

• Check wiring.

No

• Change the deceleration or motion profile.

• Use a larger IDM unit.

• Install shunt module.

• Verify motion profile.

• Verify overtravel settings are appropriate.

No

Yes

RSLogix

Programmable

Fault Action Fault Behavior

Yes Decel/Disable

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Decel/Disable E16 – Positive/Negative Soft

Overtravel

(Pos/NegSoftOvertravelFault)

E18 – Over Speed

(OverspeedFault)

E19 – Follow Error

(PositionErrorFault)

E30 – Motor Feedback Comm

(MotFeedbackFault)

E37 – Phase Loss

(PowerPhaseLossFault)

E38 – Sercos Ring Flt

(SercosFault)

E43 – Drive Enable Flt

(DriveEnableInputFault)

E48 – Internal

Communications Fault

(DriveHardFault)

E49 – Safety Fault

(DriveHardFault)

Flashing

Red

Flashing

Red

Flashing

Red

Flashing

Red

Excessive IDM unit speed.

Excessive position error.

• Check tuning.

• Verify user limit.

• Increase the feed forward gain.

• Increase following error limit or time.

• Check position loop tuning.

• Verify sizing of system.

• Verify mechanical integrity of system within specification limits.

• Cycle power.


No

Yes

Error communicating with position feedback device.

Problem with the AC power connection on IAM module.

Lost sercos communications.

• Check IAM input AC voltage on all phases.

• Disable the IDM unit before removing power.

• Check that sercos cable is present and connected properly.

No

No

No Flashing

Red

Flashing

Red

Missing IPIM module Enable input signal.

Solid Red Noise or hardware failure on the I2C or

SPI bus.

• Disable the IPIM module Enable hardware input fault.

• Verify that IPIM module Enable hardware input is active whenever the IPIM module is enabled.

• Power Cycle.


Yes

No

Flashing

Red

Safe-off input timing mismatch.

Solid Red

Solid Red

Flashing

Red

Duplicate node address detected on sercos ring.

Excessive feedback current was detected.

Hookup procedure failed.

• Verify wire terminations, cable/header connections, and +24V.

• Reset error and run proof test.

• If fault persists, replace module.

• Verify that each sercos module is assigned a unique node address.

No

No

• Power Cycle.


No

• Check IDM unit power/feedback wiring.

• Refer to RSLogix 5000 on-screen message for resolution.

No

Coast/Disable

Coast/Disable

Decel/Disable

Decel/Disable

Decel/Disable

Decel/Disable

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Decel/Disable

Coast/Disable/

Open Contactor

Enable

Coast/Disable

96



Chapter 7

Table 22 - Exception/Fault Behavior (continued)

IPIM Display


E66 – Autotune

(DriveHardFault)

E67 – Task Init

(DriveHardFault)

E69 – Objects Init

(DriveHardFault)

E70 – NV Mem Init

(DriveHardFault)

E71 – Memory Init

(DriveHardFault)

E72 – Drive Overtemperature

(DriveOvertempFault)

E76 – CAN Init

(DriveHardFault)

E78 – Sercos Init

(DriveHardFault)

E109 – IGBT Over-temperature

(DriveOvertempFault)

IDM Status


Flashing

Red

Solid Red

Flashing

Red

Autotune procedure failed.

Operating system failed.

Solid Red Non-volatile memory is corrupt due to control board hardware failure.

Solid Red Non-volatile memory is corrupt due to control board software error.

Solid Red

Flashing

Red

Solid Red

Solid Red

RAM or Flash memory validation failure.

Excessive heat in the circuitry.

CAN hardware initialization fault detected.

Sercos hardware fault detected.

Excessive IGBT temperature.


• Check IDM unit power/feedback wiring.

• Refer to RSLogix 5000 on-screen message for resolution.

• Perform Hookup Test in RSLogix 5000 software.

• Consult RSLogix 5000 help screen.

• Cycle power.


No

RSLogix

Programmable

Fault Action Fault Behavior

No Coast/Disable

• Load default parameters, save to nonvolatile memory, and recycle power or reset the IPIM module.

• Load default parameters, save to nonvolatile memory, and recycle power or reset the IPIM module.

• Cycle power.


No

No

No

Yes

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Decel/Disable • Replace the failed module.

• Check the ambient temperature.

• Change the command profile to reduce speed or increase time.

• Check the mounting clearance.

• Reset System.

• If fault persists, replace system module.

No

• Cycle power.


• Lower ambient temperature.

• Reduce motion profile.

No

No

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Coast/Disable/

Open Contactor

Enable

Use a Web Browser to

Monitor System Status

The IPIM module supports a basic web interface for common status reporting and network configuration attributes, including:

• Diagnostics

• IPIM Indicators

• IPIM Information

• Network Settings

• Ethernet Statistics

• CIP Statistics

• Monitor Signals

• Fault Log

• Browse IDMs

• IDM Indicators

• Monitor IDM Signals


97

Chapter 7


To access the web interface:

1. Using an Ethernet cable, connect your computer to one of the Ethernet ports on the IPIM module (refer to

Figure 11 on page 38

for location).

2. Open a web browser program (1)

and enter the IP address of the IPIM module.

The Home screen will be displayed.

3. Selecting IPIM Indicators provides indicator status.

4. Network settings displays a summary of the various parameters.

98

(1) Internet Explorer version 6.0 (or greater) or Mozilla Firefox version 4.0 (or greater) is required.


Before You Begin

Chapter

8

Removing and Replacing the Kinetix 6000M

IPIM Module

This chapter provides removal and replacement procedures for your

Kinetix 6000M IPIM module.

Refer to your Kinetix 6000 Multi-axis Servo Drives User Manual, publication

2094-UM001 , or Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo

Drives User Manual, publication 2094-UM002 , for other replacement procedures.

Topic

Before You Begin

Remove the IPIM Module

Replace the IPIM Module

Page

99

100

101

ATTENTION: This drive contains electrostatic discharge (ESD) sensitive parts and assemblies. You are required to follow static-control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Guarding Against Electrostatic Damage, publication

8000-4.5.2

, or any other applicable ESD awareness handbook.

You will need these tools available before you begin removal and replacement procedures:

• A small screwdriver, 3.5 mm (0.14 in.)

• Voltmeter


99

Chapter 8

Removing and Replacing the Kinetix 6000M IPIM Module

Remove the IPIM Module

Follow these steps to remove your IPIM module from the Bulletin 2094 power rail.

1. Verify that all control and input power has been removed from the system.

ATTENTION: To avoid shock hazard or personal injury, assure that all power has been removed before proceeding. This system may have multiple sources of power. More than one disconnect switch may be required to de-energize the system.

2. Wait five minutes for the DC bus to discharge completely before proceeding.

ATTENTION: This product contains stored energy devices. To avoid hazard of electrical shock, verify that all voltage on capacitors has been discharged before attempting to service, repair, or remove this unit. You should attempt the procedures in this document only if you are qualified to do so and are familiar with solid-state control equipment and the safety procedures in publication NFPA 70E.

3. Label and remove all connectors from the IPIM module you are removing.

To identify each connector, refer to

page 38 .

4. Remove the hybrid cable from the cable shield clamp, as shown.

5. Loosen the mounting screw (bottom center of module).

6. Grasp the top and bottom of the module with both hands and gently pull the module away from the connectors enough to clear the guide pins

(module will pivot on top bracket).

100



Chapter 8

7. Lift the bracket out of the power rail slot and remove the module from the power rail.

Power Rail

Guide Pin

Pivot Module Upward

Fuse A ccess

See U ser Manual B ving efore Remo

Side View

Replace the IPIM Module

Follow these steps to replace the IPIM module on the Bulletin 2094 power rail.

1. Inspect the module connector pins and power rail connectors and remove any foreign objects.

2. Hang the module mounting bracket from the slot on the power rail.

IMPORTANT

Power rails must be in vertical orientation before replacing drive modules or pins may not seat properly.

3. Pivot module downward and align the guide pin on the power rail with the guide pin hole in the back of the module (refer to the figure above).

4. Gently push the module against the power rail connectors and into the final mounting position.

5. Use 2.26 N•m (20 lb•in) torque to tighten the mounting screw.

6. Reconnect the module connectors.

7. Reapply power to the system.

8. Verify that the system is operating properly.


101

Chapter 8


Notes:

102


Certification

Appendix

A

Using the Safe Torque-off Feature with the

Kinetix 6000M System

This appendix introduces you to how the safe torque-off feature meets the requirements of Performance Level d (PLd) and Category 3 (Cat3) per EN ISO

13849-1 and SIL CL 2 per IEC EN 61508, EN 61800-5-2 and EN 62061.

Topic

Certification

Description of Operation

PFD, PFH, and MTTFd Definitions

PFD, PFH, and MTTFd Data

Wiring Your Safe Torque-off Circuit

IDM Safe Torque-off Feature

IDM System Safe Torque-off Example

Cascading the Safe Torque-off Signal

Safe Torque-off Signal Specifications

107

107

108

109

Page

103

104

107

110

111

The TÜV Rheinland group has approved the Kinetix 6000M integrated drivemotor system for use in safety-related applications up to EN ISO 13849-1 performance level d (PLd) and category 3, SIL CL 2 per IEC EN 61508, EN

61800-5-2 and EN 62061, in which removing the motion producing power is considered to be the safe state.

Important Safety Considerations

The system user is responsible for the following:

• Validation of any sensors or actuators connected to the system

• Completing a machine-level risk assessment

• Certification of the machine to the desired EN ISO 13849-1 performance level or EN 62061 SIL level

• Project management and proof testing


103

Appendix A

Using the Safe Torque-off Feature with the Kinetix 6000M System

Category 3 Requirements According to EN ISO 13849-1

Safety-related parts are designed with these attributes:

• A single fault in any of these parts does not lead to the loss of the safety function

• A single fault is detected whenever reasonably practicable

• Accumulation of undetected faults can lead to the loss of the safety function, which results in failure to remove motion producing power from the motor.

Stop Category Definition

Stop category 0 as defined in EN 60204 or Safe Torque Off as defined by EN

61800-5-2 is achieved with immediate removal of motion producing power to the actuator.

IMPORTANT

In the event of a malfunction, the most likely stop category is category 0. When designing the machine application, timing and distance should be considered for a coast to stop. For more information regarding stop categories, refer to

EN 60204-1.

Performance Level (PL) and Safety Integrity Level (SIL)

For safety-related control systems, Performance Level (PL), according to EN ISO

13849-1, and SIL levels, according to EN 61508 and EN 62061, include a rating of the systems ability to perform its safety functions. All of the safety-related components of the control system must be included in both a risk assessment and the determination of the achieved levels.

Refer to the EN ISO 13849-1, EN 61508, and EN 62061 standards for complete information on requirements for PL and SIL determination.

Description of Operation

The safe torque-off feature provides a method, with sufficiently low probability of failure, to force the power-transistor control signals to a disabled state. When disabled, or any time power is removed from the safety enable inputs, all of the

IDM output-power transistors are released from the On-state. This effectively removes power generated by each IDM unit connected to a single IPIM module and utilizing connections to an external safety device (E-stop, light curtains, etc.).

This results in a condition where the IDM unit is coasting (stop category 0).

Disabling the power transistor output does not provide mechanical isolation of the electrical output, which may be required for some applications.

Under normal operation, the safe torque-off inputs are energized. If either of the safety enable inputs are de-energized, then all of the output power transistors will turn off. The safe torque-off response time is less then 12 ms.

104



Appendix A

ATTENTION: Permanent magnet motors may, in the event of two simultaneous faults in the IGBT circuit, result in a rotation of up to 180 electrical degrees.

ATTENTION: If any of the safety enable inputs de-energize, then the

SafeOffModeActiveStatus bit of the drive status word in the Axis Tag structure will be set to 1. It will reset to 0 when both safety enable inputs are energized within 1 second (see

Figure 39

). The safety fault occurs after 1 second.

Figure 39 - System Operation when Inputs are Meeting Timing Requirements

24V DC

SAFETY ENABLE1+

0V DC

24V DC

SAFETY ENABLE2+

0V DC

1

DriveHardFault

0

1

SafeOffModeActiveStatus

0

1 Second

1 Second

➊ ➋ ➌ ➍ ➎ ➏

➍

➎

➏


➊

At least one input is switched-off. SafeOffModeActiveStatus bit is set to 1.

➋

➌

Second input is switched-off within 1 second.

First input is switched-on.

Second input is switched-on within 1 second of the first input.

Both inputs change state within 1 second, therefore DriveHardFault is not posted.

SafeOffModeActiveStatus bit set back to 0 if events 3 and 4 occur within a 1 second time interval.

Troubleshooting the Safe Torque-off Function

Error

Code

Fault Message

RSLogix (HIM)

E49 DriveHardFault

(safe torque-off HW Flt)

Anomaly

Safe torque-off function mismatch.

System will not allow motion. Safe torque-off mismatch is detected when safety inputs are in a different state for more than 1 second.

Potential Cause

• Loose wiring at safe torque-off connector.

• Miswiring of the safe torque-off connector.

• Cable/header not seated properly in safe torque-off connector.

• Safe torque-off circuit missing +24V DC.

Possible Resolution

• Verify wire terminations, cable/ header connections, and +24V.

• Reset error and run proof test.

• If error persists, return the module to

Rockwell Automation.


105

Appendix A


Figure 40

demonstrates when the safe torque-off mismatch is detected and a

DriveHardFault is posted.

Figure 40 - System Operation in the Event that the Safety Enable Inputs Mismatch

24V DC

SAFETY ENABLE1+

0V DC

24V DC

SAFETY ENABLE2+

0V DC

1

DriveHardFault

0

1


0

1 Second

When one safety input is turned off, the second input must also be turned off, otherwise a fault is asserted (see

Figure 41

). The fault is asserted even if the first safety input is turned on again.

Figure 41 - System Operation in the Event that the Safety Enable Inputs Mismatch Momentarily

24V DC

SAFETY ENABLE1+

0V DC

24V DC

SAFETY ENABLE2+

0V DC

1

DriveHardFault

0

1


0

1 Second

ATTENTION: The safe torque-off fault (E49) is detected upon demand of the safe torque-off function. After troubleshooting, a safety function must be executed to verify correct operation.

IMPORTANT

The Safe Torque Off fault (E49) can be reset only if both inputs are in the Offstate for more than 1 second. After the E49 reset requirement is satisfied, an

MASR command in RSLogix software should be issued to reset the

DriveHardFault.

106


PFD, PFH, and MTTFd

Definitions


Appendix A

Safety-related systems can be classified as operating in either a Low Demand mode, or in a High Demand/Continuous mode:

• Low Demand mode: where the frequency of demands for operation made on a safety-related system is no greater than one per year or no greater than twice the proof-test frequency.

• High Demand/Continuous mode: where the frequency of demands for operation made on a safety-related system is greater than once per year.

The SIL value for a low demand safety-related system is directly related to orderof-magnitude ranges of its average probability of failure to satisfactorily perform its safety function on demand or, simply, average probability of failure on demand

(PFD). The SIL value for a High Demand/Continuous mode safety-related system is directly related to the probability of a dangerous failure occurring per hour (PFH).

PFD, PFH, and MTTFd Data

These PFD and PFH calculations are based on the equations from EN 61508 and show worst-case values.

This table provides data for a 20-year proof test interval and demonstrates the worst-case effect of various configuration changes on the data.

Determination of safety parameters is based on the assumption that the system operates in high demand mode and that the safety function will be requested at least once a year.

Table 23 - PFD and PFH for 20-year Proof Test Interval

Attribute Value

PFH (1e-9)

PFD (1e-3)

Proof test (years)

0.35

0.062

20

Wiring Your Safe Torque-off

Circuit

Refer to

Safe Torque-off Connector on page 40 for wiring details.

IMPORTANT

The National Electrical Code and local electrical codes take precedence over the values and methods provided.

IMPORTANT

To be sure of system performance, run wires and cables in the wireways as established in the user manual.

IMPORTANT

Pins 8 and 9 (24V+) are used only by the motion-allowed jumper. When wiring to the wiring-plug header, the 24V supply (for an external safety device that triggers the safe torque-off request) must come from an

external source, otherwise system performance will be jeopardized.


107

Appendix A


European Union Directives

If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply.

CE Conformity

Conformity with the Low Voltage Directive and Electromagnetic Compatibility

(EMC) Directive is demonstrated by using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. The safe torque-off circuit complies with the EN standards when installed according instructions found in this manual.

EMC Directive

This unit is tested to meet Council Directive 2004/108/EC Electromagnetic

Compatibility (EMC) by using these standards, in whole or in part:

• EN 61800-3 - Adjustable Speed Electrical Power Drive Systems,

Part 3 - EMC Product Standard including specific test methods

• EN 61326-2-1 EMC - Immunity requirements for safety-related systems

The product described in this manual is intended for use in an industrial environment.

CE Declarations of Conformity are available online at http://www.rockwellautomation.com/products/certification/ce .

Low Voltage Directive

These units are tested to meet Council Directive 2006/95/EC Low Voltage

Directive. The EN 60204-1 Safety of Machinery-Electrical Equipment of

Machines, Part 1-Specification for General Requirements standard applies in whole or in part. Additionally, the standard EN 50178 Electronic Equipment for use in Power Installations apply in whole or in part.

Refer to the Kinetix Rotary Motion Specifications Technical Data, publication

GMC-TD001 , for environmental and mechanical specifications.

IDM Safe Torque-off Feature

The safe torque-off circuit, when used with suitable safety components, provides protection according to EN ISO 13849-1 (PLd), Cat3 or according to EN 62061

(SIL2). The safe torque-off option is just one safety control system. All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding.

The safe torque-off circuit is designed to safely turn off all of the output-power transistors.

You can use the safe torque-off circuit in combination with other safety devices to achieve the stop and protection-against-restart as specified in IEC 60204-1.

108



Appendix A

Refer to the Kinetix Safe-off Feature Safety Reference Manual, publication

GMC-RM002 , for wiring examples.

ATTENTION: This option may be suitable for performing mechanical work on the drive system or affected area of a machine only. It does not provide electrical safety.

SHOCK HAZARD: In Safe Torque-off mode, hazardous voltages may still be present at the IDM unit. To avoid an electric shock hazard, disconnect power to the system and verify that the voltage is zero before performing any work on the IDM unit.

Safe Torque-off Feature Bypass

Each IPIM module ships with the (9-pin) wiring-plug header and motionallowed jumper installed in the safe-off connector. With the motion-allowed jumper installed, the safe-off feature is not used.

Motion-allowed Jumper Installed

(Safe-off feature bypassed)

IDM System Safe Torque-off

Example

Figure 42 shows a typical safe torque-off configuration. Refer to Kinetix Safe-off

Feature Safety Reference Manual, publication GMC-RM002 , for further information and wiring diagrams.

For additional information regarding Allen-Bradley safety products, including safety relays, light curtain, and gate interlock applications, refer to the Safety

Products Catalog, website http://www.ab.com/catalogs .


109

Appendix A


Safe-off Control Circuit

Connections

Figure 42 - Typical Kinetix 6000M and Kinetix 6000 Safe-off Configuration

Middle-drive Headers

(2090-XNSM-M)

Last-drive Header

(2090-XNSM-T)

First-drive Wiring Header

(2090-XNSM-W)

Drive-to-Drive Safe-off Cables

1202-C02 1202-C03

1202-C02

1202-C10 1202-C03

System 1

Kinetix 6000 and Kinetix 6000M

Systems

Network Cable

(2090-CNSxPxS)

IDM Unit

IDM Unit

IPIM to IDM Hybrid Cable


IDM to IDM Hybrid Cable


System 2

Kinetix 6000

Drive System

Cascading the Safe Torqueoff Signal

The total number of IAM, AM, and IPIM modules in a single cascaded safety circuit is limited due to the current carrying capacity of the cascaded safety wiring.

Use the following equation to calculate the number of IDM units that can be added to a cascaded safety chain if Kinetix 6000-S safety accessories are used.

m = (16-n) x 3

where: m = maximum number of IDM units n = number of Kinetix 6000-S modules in the safety chain.

EXAMPLE

Using

Figure 42

, n equals 5 since there are 5 Kinetix 6000-S modules in the system. The maximum number of IDM units that can be connected to the cascaded safety circuit through one or more IPIM modules is: m = (16-5) x 3 = 33.

110


Safe Torque-off Signal

Specifications


Appendix A

This table provides specifications for the safe torque-off signals used.

Attribute

Safety inputs Input current

Input ON voltage range

Maximum input OFF voltage

Input OFF current

Pulse rejection width

External power supply

Input type

Value

less than10 mA

18…26.4 V DC

5V DC

2 mA @ Vin less than 5V DC

700

μ s

SELV/PELV

Optically isolated and reverse voltage protected


111

Appendix A


Notes:

112


Appendix

B

Interconnect Diagram

This appendix provides a wiring example for the IDM system.

Topic

IPIM Module and IDM Unit Wiring Example

Page

114


113

Appendix B

Interconnect Diagram

Figure 43 - IPIM Module and IDM Unit Wiring Example

2094-SEPM-B24-S

Kinetix 6000M IPIM Module

Cable Shield

Clamp

DC Bus

Connector

DC-

DC+

1

2

3

Inter-module

Communication

Connector

Network Cable

Output Connector

TX+

RTN_RX-

RTN_RX+

TX-

REF

CN+

OUT

RTN

SH3

SE1

SE-

SE2

SH1

42+

42-

SH2

CN-

10

11

8

9

12

6

7

4

5

2

3

1

2

3

4

5

Safe-off

Connector

F2+

F2-

F1+

F1-

SE2

SE-

SE1

24+

24-

1

4

5

2

3

8

9

6

7

Enable Input

Connector

+

EN

–

1

2

3

+24V

COM

2090-CHBIFS8-12AAxx

Hybrid Cable

Grey

Green

Brown

To Safe-off

Control Circuit

B

A

MDF-SBxxxxx-Qx8xA-S

Kinetix 6000M IDM Unit

Hybrid Cable

Input Connector

Blue

White/Blue

Drain

White/Brown

Brown

White/Pink

Pink

Drain

Orange

Violet

Yellow

2090-CNSSPxS-AAxx

Network Cable

Blue

White/Brown

Brown

White/Blue

Green

8

7

9

10

4

5

6

C

D

RX+

RTN_TX-

RTN_TX+

RX-

REF

1

2

3

4

5

Network Cable

Input Connector

Hybrid Cable

Output Connector

Digital Input

Connector 1

Digital Input

Connector 2

3

4

5

1

2

B

A

8

7

9

10

4

5

6

Network Cable

Output Connector

3

4

1

2

5

1

4

5

2

3

C

D

TX+

RTN_RX+

RTN_RX-

TX-

REF

I/O 24V+

Overtravel-

I/O 24V COM

Registration 2

Shield

I/O 24V+

Overtravel+

I/O 24V COM

Registration 1

Shield

2090-CTHP8 Terminator

2090-CTSRP Terminator

1

2

3

4

8

7

9

10

2090-CTHP8 Terminator or

2090-CHBP8S8-12AAxx

Hybrid Cable to Next IDM Unit

2090-CTSRP Terminator or

2090-CNSxPxS-AAxx

Network Cable to Next IDM Unit

To Sensor

To Sensor

EtherNet/IP

Connectors (2)

TD+

TD-

RD+

RD-

1

2

3

6

To Ethernet Module or Switch

Digital Input

Connector 3

3

4

1

2

5

I/O 24V+

Reserved

I/O 24V COM

Home

Shield

To Sensor

114


Before You Begin

Appendix

C

Upgrading the Kinetix 6000M System Firmware

This appendix provides procedures for upgrading firmware for the

Kinetix 6000M integrated drive-motor (IDM) units and IDM power interface modules (IPIM).

Topic

Before You Begin

Configure Logix Communication

IPIM Module Firmware Upgrade

IDM Unit Firmware Upgrade

Verify the Firmware Upgrade

Page

115

116

117

122

126

Upgrading firmware for the Kinetix 6000M system is done by using

ControlFLASH software. The procedure for upgrading the IDM units uses the sercos interface, similar to axis modules. However, upgrading firmware on the

IPIM module is accomplished over the EtherNet/IP network.

You need the following software and information before you begin.

Description

RSLogix 5000 software

ControlLogix sercos module

CompactLogix sercos module

SoftLogix sercos PCI card

RSLinx® software

ControlFLASH software kit

(1)

Cat. No.

9324-RLD300NE

1756-MxxSE

1768-M04SE

1784-PM16SE

Catalog number of the targeted IPIM module and IDM unit you want to upgrade

Network path to the targeted IPIM module and IDM unit.

Firmware Revision or

Software Version

20.01

(2)

or later

20.007 or later

20.007 or later

20.007 or later

2.59 or later

From website

(1) Download the ControlFLASH kit from http://support.rockwellautomation.com/controlflash . Contact Rockwell Automation Technical

Support at (440) 646-5800 for assistance.

For more ControlFLASH information (not drive specific), refer to the ControlFLASH Firmware Upgrade Kit Quick Start, publication

1756-QS105 .

(2) Version 20.00 may be used if the motion database has been updated.

IMPORTANT

Control power must be present prior to upgrading your IPIM module or IDM units.

ATTENTION: To avoid personal injury or damage to equipment during the firmware upgrade due to unpredictable motor activity, do not apply 3-phase AC or common-bus DC input power to the IAM module.


115

Appendix C

Upgrading the Kinetix 6000M System Firmware

Configure Logix

Communication

This procedure assumes that your communication method to the Logix controller is using the Ethernet protocol. It is also assumed that your Logix

Ethernet module has already been configured.

For more information, refer to the ControlLogix System User Manual, publication 1756-UM001 .

Follow these steps to configure Logix communication.

1. Open your RSLinx Classic software.

2. From the Communications pull-down menu, choose Configure Drivers.

The Configure Drivers dialog box opens.

116

3. From the Available Drive Types pull-down menu, choose Ethernet devices.

4. Click Add New.

The Add New RSLinx Classic Driver dialog box opens.

5. Type the new driver name.

6. Click OK.

The Configure driver dialog box opens.

7. Type the IP address of your Logix Ethernet module.

The IP address shown is an example. Yours will be different.



Appendix C

8. Click OK.

The new Ethernet driver appears under Configured Drivers.

9. Click Close.

10. Minimize the RSLinx application dialog box.

IPIM Module Firmware

Upgrade

IMPORTANT

The IPIM module will not accept a firmware upgrade request when it has an active CIP I/O connection.

An active CIP I/O connection exists when the IPIM module has been integrated into the I/O configuration tree in RSLogix 5000 software. The IPIM module only accepts a firmware upgrade request when the connection is inhibited. The connection can be inhibited from I/O Configuration>Enet Module>IPIM

Module Properties>Connection tab (see below). The IPIM module always accepts a firmware upgrade request if it is connected to a Logix Ethernet module, but has not been integrated in the I/O configuration tree.

Additionally, the firmware upgrade can be accomplished by disconnecting the

IPIM module from the Logix Ethernet module and establishing a direct connection to a computer with ControlFlash software.


117

Appendix C


Follow these steps to select the IPIM module to upgrade.

1. Make sure the IPIM module will accept a firmware request prior to

attempting the firmware upgrade (see page 117

).

2. Open your ControlFLASH software.

You can access the ControlFLASH software by either of these methods:

• From the Tools menu in RSLogix 5000 software, choose

ControlFLASH.

• Choose Start>Programs>FLASH Programming Tools>

ControlFLASH.

The Welcome to ControlFLASH dialog box opens.

3. Click Next.

The Catalog Number dialog box opens.

118

4. Select your IPIM module.

5. Click Next.



Appendix C

The Select Device to Update dialog box opens.

6. Expand your Ethernet node and EtherNet/IP network module.

7. Select the IPIM module to upgrade.

8. Click OK.

The Firmware Revision dialog box opens.

9. Select the firmware revision to upgrade.

10. Click Next.


119

Appendix C


The Summary dialog box opens.

11. Confirm the IPIM module catalog number and firmware revision.

12. Click Finish.

This ControlFLASH warning dialog box opens.

120

13. Click Yes (only if you are ready).


14. Acknowledge the warning and click OK.



Appendix C

The Progress dialog box opens and upgrading begins.

After the upgrade information is sent to the IPIM module, the module resets and performs diagnostic checking.

15. Wait for the Progress dialog box to time out.

It is normal for this process to take several minutes.

IMPORTANT

Do not cycle power to the drive during this process or the firmware upgrade will not complete successfully.

16. The Update Status dialog box opens and indicates success or failure as described below

Upgrading Status

Success

Failure

If

1. Update complete appears in a GREEN Status dialog box.

2. Go to step 17

.

1. Update failure appears in a RED Status dialog box.

2. Refer to ControlFLASH Firmware Upgrade Kit Quick Start, publication

1756-QS105 , for troubleshooting information.

17. Click OK.


121

Appendix C


IDM Unit Firmware Upgrade

Follow these steps to select the IDM unit to upgrade.

1. Open your ControlFLASH software.

You can access the ControlFLASH software by either of these methods:

• From the Tools menu in RSLogix 5000 software, choose

ControlFLASH.

• Choose Start>Programs>FLASH Programming Tools>

ControlFLASH.

The Welcome to ControlFLASH dialog box opens.

2. Click Next.

The Catalog Number dialog box opens.

122

3. Select your IDM unit.

4. Click Next.



Appendix C

The Select Device to Update dialog box opens.

5. Expand your Ethernet node, Logix backplane, and EtherNet/IP network module.

6. Select the IDM unit to upgrade.

7. Click OK.

The Firmware Revision dialog box opens.

8. Select the firmware revision to upgrade.

9. Click Next.


123

Appendix C


The Summary dialog box opens.

10. Confirm the IDM unit catalog number and firmware revision.

11. Click Finish.


124

12. Click Yes (only if you are ready).


13. Acknowledge the warning and click OK.



Appendix C

The Progress dialog box opens and upgrading begins.

After the upgrade information is sent to the IDM unit, the unit resets and performs diagnostic checking.

14. Wait for the Progress dialog box to time out.

It is normal for this process to take several minutes.

IMPORTANT

Do not cycle power to the drive during this process or the firmware upgrade will not complete successfully.

15. The Update Status dialog box opens and indicates success or failure as described below.

Upgrading Status

Success

Failure

If

1. Update complete appears in a GREEN Status dialog box.

2. Go to step 16

.

1. Update failure appears in a RED Status dialog box.

2. Refer to ControlFLASH Firmware Upgrade Kit Quick Start, publication

1756-QS105 , for troubleshooting information.

16. Click OK.


125

Appendix C


Verify the Firmware Upgrade

Follow these steps to verify your firmware upgrade was successful. This procedure uses an IDM unit as an example, but applies to IPIM modules too.

TIP

Verifying the firmware upgrade is optional.

1. Open your RSLinx software.

2. From the Communications pull-down menu, choose RSWho.

3. Expand your Ethernet node, Logix backplane, and EtherNet/IP network module.

4. Right-click the device (IPIM or IDM) and choose Device Properties.

The Device Properties dialog box opens.

126

5. Verify the new firmware revision level.

6. Click Close.


Definitions

Appendix

D

Kinetix 6000M System Sizing

It is recommended that Motion Analyzer (version 6.000 or greater), be used for sizing your system. If manual calculation is desired, the following procedure can be used.

Topic

Definitions

Manually Sizing the Kinetix 6000M System

Page

127

128

• Control power = 120/240 single-phase AC voltage connected to the IAM unit.

• IDM system control power = 42V DC (nominal) voltage from the IPIM module that is connected to all IDM units.

• IDM system control power load current = IDM unit control power current consumed by any single IDM unit.

• Total IDM system control power load current = Total IDM unit control power current consumed by all IDM units and connected to a single IPIM module.

• IPIM module control power load current = Total IDM unit control power load current (same as above).


127

Appendix D

Kinetix 6000M System Sizing

Manually Sizing the

Kinetix 6000M System

Step 1: Calculate the IDM unit control power load current for each

IDM unit.

There are three components to the control power load current for each IDM unit:

• Constant power load

• Digital input loads

• Brake loads

Refer to the IDM unit constant load, brake load, and control power load specifications shown below.

IDM Unit

Cat. No.

with

Brake

MDF-SB1003 No

MDF-SB1003 Yes

MDF-SB1153 No

MDF-SB1153 Yes

MDF-SB1304 No

MDF-SB1304 Yes

Constant Control Power Load

(W)

Brake Control Power Load

(W)

8

8

8

8

8

8

0

15

0

19.5

0

19.5

Output Power Rating

(kW)

1.10

1.02

1.15

1.00

1.39

1.24

The digital input load is calculated as follows:

Digital Input Watts =

Σ

I inputs

* V *

η

Where:

Σ

I inputs

= The sum of all load currents on the digital input power supply to power the sensor and/or the sensor input current

V = 24V

η

= power supply efficiency = 80%

IMPORTANT

Confirm that the total IDM unit control power load is less than the specified limit for the IPIM module output rating (270 W). See the Kinetix Rotary Motion

Specifications Technical Data, publication GMC-TD001 .

IMPORTANT

Confirm that the

Σ

I inputs value is less than the specified limit (200 mA). See the Kinetix Rotary Motion Specifications Technical Data, publication GMC-

TD001 .

128



Appendix D

Example

Example System:

• Common bus leader IAM module

• Two AM modules

• One IPIM module

• Six IDM units (shown below)

• 72 total meters of hybrid cable

• Control power = 120V AC, 60 Hz

• Main power = 480V AC => 675V DC

For this example, assume that each digital input uses 50 mA at 24V DC.

IDM Unit Cat.

No.

MDF-SB1153

MDF-SB1003

MDF-SB1304

MDF-SB1304

MDF-SB1003

MDF-SB1153

0

2

3

0

Digital

Inputs

2

0

No

Yes

No

No

with

Brake

Yes

No

Constant Load

(W)

8

8

8

8

8

8

Dig Input Load

(W)

3.0

0

Brake Load

(W)

19.5

0

4.5

0

0

3.0

0

19.5

0

0

Total IDM Unit Control Power Load

Total Load

(W)

30.5

8

12.5

27.5

8

11

97.5

The total IDM control power load is less than the specified limit for the IPIM so this is a valid system configuration.

Step 2: Estimate the IDM system control power load current for all

IDM units connected to each IPIM module.

Estimating the load current for each IDM depends on the IDM control power voltage applied to each IDM. The loads calculated in step 1 are specified in watts, so the load current is estimated as:

I i

=

W i

V i

I

L

=

∑

I i

Where:

I i

= IDM unit control power load current for IDM i

W i

= load watts for IDM i

V i

= voltage applied to IDM i

I

L

= Total IDM unit control power load current out of the IPIM


129

Appendix D


130

It is important to understand that each IDM unit passes the load current for all

IDM units farther down the daisy chain. The voltage applied at each IDM unit is dependent on voltage drop in the IDM unit control power conductors of the hybrid cable. Therefore, the total cable length between an IDM unit and the

IPIM module affect the voltage applied to that IDM unit. Also, the number of

IDM units between an IDM unit and the IPIM module, and the cable length between each IDM unit also affects the voltage applied to the IDM unit. An accurate calculation requires modeling the system.

IMPORTANT

Motion Analyzer version 6.000 or later contains a detailed model and accurately predicts the IDM unit control power load current and the minimum

IDM unit control power voltage at the last IDM unit connected to each IDM unit.

This example illustrates a simplified load estimation method. The simplifying assumption is that all the IDM units are connected at the end of the hybrid cable so the entire cable length supports the total IDM unit control power current.

This also means that the voltage applied at each IDM unit is the same and all

IDM units experience the maximum voltage drop. The figure below illustrates a real system vs. the simplified system.

I

L

=

∑

I i

IPIM

V

1

IDM 1

I

1

V

2

IDM 2

I

2

V

3

IDM 3

I

3

IPIM

I

L

V

IDM 1

V

IDM 2

V

IDM 3

The specified voltage range for the IDM units is (32…44V DC). The IPIM module output voltage specification is (40.4…41.7V DC). See the Kinetix Rotary

Motion Specifications Technical Data, publication GMC-TD001 . The equations below illustrate three options for estimating the IDM unit control power load current assuming a range of 32…42V DC using the simplified system.

Steps 2 and 3 should be applied iteratively to get the best estimate, (see next step).

• Dividing the total IDM unit load power by 32V DC assumes that all the

IDM units are at the end of the total cable length, and the load current is sufficiently high to result in the maximum allowable voltage drop at the end of the cable. This is a very conservative method that always results in an overestimate of the load current.



Appendix D

• Dividing the total IDM unit load power by 42V DC assumes that all the

IDM units are at the IPIM module and experience no voltage drop from the hybrid cable. This is a very liberal method that always results in an underestimate of the load current.

• Dividing the total IDM unit load power by 37V DC represents more of an average situation where all the IDM units experience half the maximum voltage drop. This is a reasonable compromise between the other two extremes.

I

L

=

∑

W i

V

32

I

L

=

∑

W i

V

37

I

L

=

∑

W i

V

42

IMPORTANT

Confirm that the IDM control power current load is less than the specified limit for the IPIM module (6.5 A). See the Kinetix Rotary Motion Specifications

Technical Data, publication GMC-TD001 .

Repeat this procedure for all IPIM modules connected to the power rail.

Example

Using the three equations from this step, the following IDM unit control power load currents are calculated.

IDM Unit Control Power Voltage

Estimate (V DC)

32

37

42

IDM Unit Control Power Load Current

(A)

3.05

2.64

2.32

The IDM unit control power current load is less than the specified limit for the

IPIM module for all the load current estimates, so this is a valid system configuration.


131

Appendix D


Step 3: Confirm that all IDM units connected to each IPIM module will have sufficient control power voltage.

This is a complicated calculation to do accurately for the same reasons stated in step 2. The purpose of this step is to confirm that the last IDM unit in the daisy chain has sufficient voltage to operate. An estimate of the applied voltage assuming all the IDM units are at the end of the total cable length can be calculated as shown below. This calculation results in a very conservative estimate. It is conservative because it assumes the load current for all IDM units is carried by the total cable length, which overestimates the voltage drop on the cable significantly.

V

N

= 42 - I

L

* L t

* R

C

Where:

V

N

= voltage at the last (

Nth) IDM unit (actually at all IDM units in the simplified system)

I

L

= load current calculated in step 2

L t

= total hybrid cable length out to IDM unit

N in meters

R

C

= resistance of the hybrid cable control power conductors in ohms/ meter (0.0274275)

IMPORTANT

Confirm that V

N

is greater than the minimum voltage specification for the IDM

(32V DC). See the Kinetix Rotary Motion Specifications Technical Data, publication GMC-TD001 .

A better result may be obtained if step 2 and step 3 are repeated iteratively. The voltage determined for step 3 should be equal to the voltage value used in step 2.

This gives the most accurate value for the simplified system.

132



Appendix D

Example

The equations in step 3 are applied to augment the table from the previous step

(shown below). The estimate of the voltage assuming all IDM units are at the end of the total cable length is included in the last column.

Average IDM Unit Control

Power Voltage Estimate

(VDC)

32

37

42

IDM Unit Control Power Load

Current

(A)

3.05

2.64

2.32

Voltage Estimate at Last (all) IDM

Unit(s)

36.0

36.8

37.4

This illustrates how the 32V average voltage estimate is a poor choice for this system configuration. Using 32V as the applied IDM unit voltage for the load current calculation results in a calculated voltage at end of the total cable length of 36V, so the 32V estimate is obviously too small. Using 37V as the applied IDM unit voltage for the load current calculation results in a calculated voltage at the end of the total cable length of 36.8V. Therefore 37V is close to the best possible value and a load current value of 2.64 A will be used for the remainder of this example. The total IDM unit load current as a percentage is 2.64/6.5 = 40.6%.

The voltage at the end of the total cable length is greater than the minimum voltage specification for the IDM unit, so this is a valid system configuration.

Using a more sophisticated model, the IDM unit control power load current was calculated to be 2.42 A and the voltage at the last IDM unit to be 40.15V. The total IDM unit control power usage was 103 W, compared to 97.5 W calculated in step 1. The additional 5.5 W are losses in the hybrid cable. This illustrates how using the simplified system for sizing overestimates the total IDM unit control power current and the voltage drop along the hybrid cable.

Table 24

and

Table 25

show the maximum cable length per IPIM module using

Motion Analyzer.

The following is assumed:

• All IDM units are MDF-SB1304 (highest brake load).

• Cable length is identical between all IDM units.

• Minimum cable length is1 m (3.3 ft).

• Every other IDM unit includes a brake, starting with #2.

• When the number of brake IDM units are greater than 1/2 the total units, they are placed at the end of the daisy chain.

IMPORTANT

When using the simplified system to calculate cable length, the resulting maximum cable lengths will be much shorter.


133

Appendix D


Table 24 - Max Cable Length per IPIM Module using Motion Analyzer (no digital inputs)

6

7

8

4

5

2

3

1 2 3 4 5 6

Number of IDM Units

7 8 9 10 11 12 13 14 15 16

0

25 50 75 100 100 100 100 100 100 100 100 100 100 100 100 100

1

25 50 75 100 100 100 100 100 100 100 100 100 100 100 100 100

50 75

75

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100 100 100 100 100 100 100 95 84 72 61

100 94 88 85 83 72 59 42 27

92 77 60 44 30 13

110

100

70

60

90

80

50

40

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Total Number of IDM Units

No Brake IDM Units

3 Brake IDM Units

6 Brake IDM Units

1 Brake IDM Units

4 Brake IDM Units

7 Brake IDM Units

2 Brake IDM Units

5 Brake IDM Units

8 Brake IDM Units

Table 25 - Max Cable Length per IPIM Module using Motion Analyzer (Digital Input Load = 50%)

7

8

5

6

Number of IDM Units

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

0

25 50 75 100 100 100 100 100 100 100 100 100 100 100 100 100

3

4

1

25 50 75 100 100 100 100 100 100 100 100 100 100 100 100 100

2

50 75 100 100 100 100 100 100 100 100 100 100 100 100 100

75 100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

95

100

69

96

42

100 100 100 98 97 96 96 88 65 42 15

100 95 89 86 80 63 42 20

93 80 60 42 22

54 27

110

100

90

80

70

60

50

40

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Total Number of IDM Units

No Brake IDM Units

3 Brake IDM Units

6 Brake IDM Units

1 Brake IDM Units

4 Brake IDM Units

7 Brake IDM Units

2 Brake IDM Units

5 Brake IDM Units

8 Brake IDM Units

134



Appendix D

Step 4: Estimate the IAM control power load current and the power dissipation for each IPIM module based on the total IDM unit control power load.

See the Kinetix Rotary Motion Specifications Technical Data, publication

GMC-TD001 , for specifications on IPIM module dissipation and IPIM module control power loading. This information is also shown below. The table below contains equations that can be used to calculate the IAM control power load for each IPIM module and the heat dissipation for each IPIM module. The input value (x) is the total IDM unit control power load current (as a percentage) provided by the IPIM module. This value (in amps) was calculated in step 2. The value from step 2 must be divided by the rated IPIM module control power load current, (6.5 A).

IAM Control Power

Interface

120V AC, 50 Hz

240V AC, 50 Hz

120V AC, 60 Hz

240V AC, 60 Hz

IAM Control Power Current

Y = 3.91x + 0.77

Y = 2.39x + 0.60

Y = 3.72x + 0.83

Y = 2.45x + 0.61

(1)

IPIM Heat Dissipation

(2)

Y = 23.76x

2

+ 20.73x + 16.54

Y = 18.56x

2

+ 30.19x + 27.41

Y = 14.57x

2

+ 11.40x + 20.01

Y = 19.63x

2

+ 43.22x + 28.75

(1) Y = IAM control power current; x = Total IDM unit control power load current percentage (value from step 2).

(2) Y = IPIM module heat dissipation from control power load; x = Total IDM unit control power load current percentage (value from step 2).

Make these calculations for all IPIM modules connected to the power rail. The control power load current values will be used to confirm the system sizing for the

IAM, power rail and LIM in a later step.

Example

Using the equations provided, determine values for:

• Control power = 120V AC, 60 Hz

• IDM control power load current = 2.64 A or 40.6%

Result is an IAM control power load current of 2.32 A and an IPIM module heat dissipation value of 29 W.


135

Appendix D


Step 5: Sum the IAM control power load current for all devices on the power rail and confirm that the total IAM control power load current is less than the specified IAM and power rail limit.

• Calculate the total IAM control power load current by summing the load current calculated in step 4 for all IPIM modules.

• Use the “Control Power Current Requirements” table in the Kinetix 6000

Multi-axis Servo Drives User Manual, publication 2094-UM001 or the

Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives User

Manual, publication 2094-UM002 , to select the control power current requirements for the IAM and any AMs on the power rail.

• Sum these two values for the total control power current requirement.

The control power load current calculated in step 5 must be less than the values in

“Control Power Input Power Specifications” table in the Kinetix 6000 Multi-axis

Servo Drives User Manual, publication 2094-UM001 or the Kinetix 6200 and

Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-

UM002 .

Example

From the “Control Power Input Power Specifications” table in the Kinetix 6000

Multi-axis Servo Drives User Manual, publication 2094-UM001 or the Kinetix

6200 and Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-UM002, the total control power load current for the IAM and

AMs is 2.25 A. The value calculated in the previous step for the IPIM is 2.32 A, resulting in a total control power load current of 4.57 A.

The control power load current is less than the maximum current specification for the IAM and power rail, 6.0 A, so this is a valid system configuration.

136



Appendix D

Step 6: Determine if a LIM can be used to supply the IAM control power load current, or if individual discrete components must be used.

In order to use a LIM for the control power interface to the IAM, the control power load current calculated in step 5 must be less than the values listed in the

Line Interface Module (LIM) Installation Instructions, publication 2094-IN005 .

If control power load current exceeds the LIM rating, separate discrete components must be used for filtering, fusing and disconnection of control power. Refer to the Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001 or the Kinetix 6200 and Kinetix 6500 Modular Multiaxis Servo Drives User Manual, publication 2094-UM002 for further information,

Step 7: Estimate the DC bus load current for each IPIM.

One method to estimate the DC bus load current is to analyze the motion profile of each IDM unit axis and estimate the RMS power per motion cycle. Motion

Analyzer performs this analysis, and it can be challenging for complex motion profiles. Another option is to use the continuous output power specification for each IDM unit. Once an output power value is determined for each IDM unit, use the equation below to calculate a DC bus load current value for each IDM unit. This equation neglects the effect of voltage drop over the hybrid cable DC bus. However this affect is much less significant compared to the IDM control power voltage drop so ignoring it does not have a large impact on the estimation.

I bus

=

P out

η

* V bus

Where:

I bus

= IDM unit DC bus current load

P out

= IDM unit average shaft output power

η

= efficiency, 80% (average)

V bus

= DC bus voltage at the IPIM nodule

Calculate the total bus current by summing the I bus

current values for all the

IDM units connected to an IPIM module.

IMPORTANT

The total bus current must be less than the maximum current specification for the IPIM module (24 A rms). See the Kinetix Rotary Motion Specifications

Technical Data, publication GMC-TD001 .


137

Appendix D


Example

The six IDM units in this example are listed below with the corresponding output power. The equation for bus current is used to calculate the bus current values for each IDM unit. The DC bus voltage is 675V DC. The DC bus current as a percentage of the IPIM module rating is 12.93 / 24 = 53.9%.

IDM Unit Cat. No.

MDF-SB1153

MDF-SB1003

MDF-SB1304

MDF-SB1304

MDF-SB1003

MDF-SB1153

with Brake

Yes

No

No

Yes

No

No

Output Power Rating (kW) Estimated Bus Current (A rms)

1.00

1.85

1.10

1.39

2.04

2.57

1.24

1.10

1.15

Total

2.30

2.04

2.13

12.93

The DC bus current is less than the continuous current specification for the

IPIM module, so this is a valid system configuration.

Step 8: Estimate the IPIM module dissipation for the DC bus load current and the total IPIM module dissipation from the IDM unit control power and DC bus load current.

See the Kinetix Rotary Motion Specifications Technical Data, publication

GMC-TD001 for specifications on IPIM module dissipation. This information is also shown in the equation below. This equation can be used to estimate the dissipation, in Watts, of the IPIM module as a function of the DC bus load current, expressed as a percentage of the maximum rating (24 A rms).

Dissipation = 33.95x

2

+ 3.18x

Combine the dissipation value calculated from this equation with the dissipation from the total IDM system control power load current value from step 4. This is the total dissipation for the IPIM module.

Repeat for each IPIM module.

Example

The DC bus current was calculated as 12.93 A, or 53.9% of the IPIM rating. The dissipation for this DC bus current value is 11.7 W. The dissipation calculated for the total IDM control power (step 4) is 29 W. Therefore the total dissipation for the IPIM is 40.7 W.

138


A

about this publication

7

absolute position

52

accel/decel anomalies

92

accessories

catalog number explanation

17

acronyms

7

additional resources

7

add-on profiles

73

agency compliance

19

aligning the IDM unit

34

applying power

82

axis module

axis properties

80

axis unstable

92

B

bandwidth

86

brake override input

50

bypass, IDM unit

58

C

cable length

IDM units

19

restrictions

21

cable shield clamp

55

cables

categories

28

fiber-optic cable length

59

catalog number

accessories

17

explanations

17

IDM unit

17

IPIM module

17

replacement parts

17

categories, cable

28

category 3

requirements

104

stop category definitions

104

CE

comply with CE

108

conformity

108

meet requirements

108

requirements

19

certification clamp

PL and SIL

104

TÜV Rheinland

103

user responsibilities

103

cable shield

55

clearance requirements

IDM unit

26

IPIM module

25


communication configurations

typical

16

CompactLogix sercos module

115

compatibility

component

18

DriveExplorer

18

human interface module (HIM)

18

software

18

compliance

agency

19

CE

19

configuring

axis properties

80

delay times

81

drive modules

77

logix controller

73

node address

70

sercos

73

,

75

configuring the IDM system

65

connecting

Ethernet cables

63

connector descriptions

DC bus

39

enable

41

EtherNet/IP

42

hybrid

39

network

42

safe torque-off

40

sercos

41

ControlFLASH

firmware upgrade

115

software kit

115

troubleshooting

121

,

125

verify upgrade

125

controller properties

74

ControlLogix sercos module

115

conventions used in this manual

7

conversion tab

80

cycle time

76

D

data rate

76

data type

78

date/time tab

74

DC bus connector

39

DC bus status indicator

90

DC common bus

follower IAM

14

leader IAM

14

pre-charge

14

total bus capacitance

14

delay times

81

Index

139

Index

140 digital input

cable examples

48

connectors

45

sensor connections

46

specifications

49

disable drive

95

display

information

67

startup

67

tools

68

download program

81

drive status (D) indicator

91

DriveExplorer

18

E

electrical noise reduction

27

EMC

directive

108

EN 61508

104

EN 62061

104

enable connector

41

enable time synchronization

74

enclosure

requirements

22

selection

24

error codes, IDM system

87

EtherNet/IP

connecting cables

63

connector

42

PORT1 and PORT2 connectors

63

exception/fault behavior

95

F

fault action

tab

81

fault diagnosis

93

fault reset

93

fault status, reading

88

fault types

IPIM module

94

feedback specifications

52

fiber-optic

RX and TX connectors

41

,

59

fiber-optic cables

example

59

,

60

,

61

,

62

firmware upgrade

115

verify upgrade

125

follower IAM

14

fuse

catalog number

23

location

23

replacement

24

type

23


G

grounding the IDM system

54

H

hardware configurations

typical

11

hardware enable input

83

,

85

headers

motion-allowed jumper

40

heat dissipation

24

hookup tab

83

human interface compatibility

18

hybrid cable connectors

44

hybrid connector

39

I

IDM fault diagnosis

95

IDM system

connector data

37

firmware upgrade

115

IDM unit

aligning

34

cable length

19


17

connectors

43

digital input connectors

45

hybrid cable connectors

44

indicators

43

,

91

installing

33

mounting

34

network cable connectors

45

overheating

93

sensor connections

46

information display

67

installing your IDM system

21

,

33

clearance requirements

25

,

26

enclosure selection

24

mounting requirements

22

integrated axis module

axis properties

80

interconnect diagram, IDM system

113

interpreting status indicators

90

IPIM module


17

connectors

38

display

66

fault diagnosis

93

fault types

94

indicators

38

initialization faults

94

network address, setting

69

replacement

100

ISO 13849-1 CAT 3

requirements

104

stop category definitions

104

Index

L

leader IAM

14

low voltage directive

108

M

manually sizing the IDM system

128

module mounting order

30

module properties

drive modules

77

sercos

75

module status indicator

90

motion group properties

79

motion-allowed jumper

40

,

109

mounting the IPIM module

30

,

32

module mounting order

30

mounting brackets

30

power rail

30

N

network address

IPIM

69

network cable connector

IDM unit

45

IPIM module

42

network cables

58

network status (N) indicator

91

network status indicator, IPIM module

90

node address

77

example

71

,

72

noise

92

,

93

P

panel requirements

22

peak duty cycle

50

PFD, PFH and MTTFd definition

107

planning your installation

21

port status indicator

91

power rail

30

power specifications

50

power up

82

pre-charge

14

publications, related

7

R

related publications

7

replacement parts


17

replacing the IPIM module

100

routing power and signal wiring

54

RSLinx software

115

RSLogix 5000 software

73

,

115

S

safe torque-off

bypass

109

connector

40

feature, IDM unit

108

motion-allowed jumper

109

operation

104

PFD, PFH and MTTFd

107

specifications

111

troubleshooting

105

wiring

107

safety products catalog

109

sensor connections

46

sercos connectors

41

sercos module

73

,

75

shutdown

95

SoftLogix sercos PCI card

115

software

RSLogix 5000

73

software compatibility

18

specifications

brake override input

50

digital input

49

duty cycle

50

feedback

52

safe torque-off

111

startup sequence

67

status indicators

DC bus, IPIM

90

drive status (D), IDM

91

IPIM

90

module, IPIM

90

network (N), IDM

91

network, IPIM

90

port, IPIM

91

status only

95

stop motion

95

system components

9

system mounting requirements

22

system overview

common bus

15

with LIM

12

without LIM

13

system sizing

21

,

127

T

testing and tuning

83

testing axes

hookup tab

83

tools menu

68

total bus capacitance

14

training

7


141

Index troubleshooting

ControlFLASH

121

,

125

disable drive

95

error code E49

105

general system anomalies

92

abnormal noise

93

accel/decel

92

axis unstable

92

IDM unit overheating

93

no rotation

93

noise

92

sercos

92

velocity

92

Logix/drive fault behavior

95

safe torque-off

105

safety precautions

87

shutdown

95

status only

95

stop motion

95

tuning axes

bandwidth

86

tune tab

85

typical communication configurations

16

typical hardware configurations

11

typical installation

common bus

15

with LIM

12

without LIM

13

U

units tab

80

W

web browser, viewing status

97

wiring

Ethernet cables

63

general system

56

grounding

54

hybrid connector

57

network cables

58

requirements

53

routing power and signal wiring

54

safe torque-off circuit

107

142


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Publication 2094-UM003A-EN-P - May 2012

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