Kinetix 6000 Multi-axis Servo Drive User Manual

Kinetix 6000 Multi-axis Servo Drive User Manual
Kinetix 6000 Multi-axis
Servo Drive
Catalog Numbers
2094-AC05-MP5, 2094-AC05-M01,
2094-AC09-M02, 2094-AC16-M03,
2094-AC32-M05, 2094-BC01-MP5,
2094-BC01-M01, 2094-BC02-M02,
2094-BC04-M03, 2094-BC07-M05
2094-AC05-MP5-S, 2094-AC05-M01-S,
2094-AC09-M02-S, 2094-AC16-M03 -S,
2094-AC32-M05-S, 2094-BC01-MP5-S,
2094-BC01-M01-S, 2094-BC02-M02-S,
2094-BC04-M03-S, 2094-BC07-M05-S
2094-AMP5, 2094-AM01, 2094-AM02,
2094-AM03, 2094-AM05, 2094-BMP5,
2094-BM01, 2094-BM02, 2094-BM03,
2094-BM05
2094-AMP5-S, 2094-AM01-S,
2094-AM02-S, 2094-AM03-S,
2094-AM05-S, 2094-BMP5-S,
2094-BM01-S, 2094-BM02-S,
2094-BM03-S, 2094-BM05-S
2094-BSP2
User Manual
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://literature.rockwellautomation.com) 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
IMPORTANT
ATTENTION
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.
Identifies information that is critical for successful application and
understanding of the product.
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 located 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 located on or inside the equipment, for example, a drive
or motor, to alert people that surfaces may be at dangerous
temperatures.
Allen-Bradley, CompactLogix, ControlLogix, DriveExplorer, Kinetix, RSLogix, RSLogix 5000, SoftLogix, SCANport, and Rockwell
Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
About This Publication. . . . . . . . .
Who Should Use this Manual . . . .
Conventions Used in This Manual
Additional Resources . . . . . . . . . .
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9
9
9
10
Introduction . . . . . . . . . . . . . . . . . . . . . . .
About the Kinetix 6000 Drive System . . . . .
Catalog Number Explanation . . . . . . . . . . .
Agency Compliance . . . . . . . . . . . . . . . . . .
CE Requirements (System without LIM) .
CE Requirements (System with LIM) . . .
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11
12
16
16
17
17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Design Guidelines . . . . . . . . . . . . . . . . . . . .
System Mounting Requirements. . . . . . . . . . . . . .
Transformer Selection . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker/Fuse Selection. . . . . . . . . . . . . . .
Enclosure Selection. . . . . . . . . . . . . . . . . . . . . . .
Minimum Clearance Requirements . . . . . . . . . . .
Minimizing Electrical Noise . . . . . . . . . . . . . . . . . . .
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . .
Bonding Multiple Subpanels . . . . . . . . . . . . . . . .
Establishing Noise Zones . . . . . . . . . . . . . . . . . .
Cable Categories for Kinetix 6000 Systems . . . . . .
Noise Reduction Guidelines for Drive Accessories
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19
20
20
21
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23
26
27
27
29
30
37
39
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43
43
44
44
45
48
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating IAM/AM Connectors and Indicators. . . . . . . . . . . . .
Safe-off Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . .
I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Feedback Connector Pinouts . . . . . . . . . . . . . . . . .
Auxiliary Feedback Connector Pinouts . . . . . . . . . . . . . .
IAM Input Connector Pinouts . . . . . . . . . . . . . . . . . . . . .
IAM and AM Motor Power and Brake Connector Pinouts .
49
50
52
54
55
57
58
59
Chapter 1
Start
Chapter 2
Planning the Kinetix 6000 Drive
System Installation
Chapter 3
Mounting the Kinetix 6000 Drive
System
Introduction . . . . . . . . . . . . . . . . . .
Using 2094 Mounting Brackets . .
Installing the 2094 Power Rail . . .
Determining Mounting Order . . . . . .
Mounting the Modules . . . . . . . . . . .
Mounting the External Shunt Module
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Chapter 4
Kinetix 6000 Connector Data
3
Publication 2094-UM001A-EN-P — September 2006
4
Table of Contents
Understanding IAM/AM Signal Specifications. . . . .
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . .
SERCOS Connections . . . . . . . . . . . . . . . . . . .
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . .
Contactor Enable Relay . . . . . . . . . . . . . . . . . .
Motor/Resistive Brake Relay . . . . . . . . . . . . . .
Control Power Input . . . . . . . . . . . . . . . . . . . .
Understanding Feedback Specifications. . . . . . . . .
Motor and Auxiliary Feedback Specifications . .
Feedback Power Supply . . . . . . . . . . . . . . . . .
Locating Shunt Module Connectors and Indicators.
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60
60
61
62
63
64
65
66
66
67
68
Chapter 5
Connecting the Kinetix 6000 Drive Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Understanding Basic Wiring Requirements . . . . . . . . . . . . . 69
System
Building Your Own Cables . . . . . . . . . . . . . . . . . . .
Routing Power and Signal Wiring . . . . . . . . . . . . . .
Determining Your Type of Input Power . . . . . . . . . . . .
Grounded Power Configurations . . . . . . . . . . . . . . .
Ungrounded Power Configurations . . . . . . . . . . . . .
DC Common Bus Configurations . . . . . . . . . . . . . . . . .
Common Bus Fusing Requirements . . . . . . . . . . . . .
Setting the Ground Jumper in Ungrounded
Power Configurations . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Ground Jumper . . . . . . . . . . . . . . . . . . .
Grounding Your Kinetix 6000 System . . . . . . . . . . . . . .
Grounding Your System to the Subpanel . . . . . . . . .
Grounding Multiple Subpanels . . . . . . . . . . . . . . . .
Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . .
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring the LIM Connectors . . . . . . . . . . . . . . . . . . . . . .
Wiring the Auxiliary Input Power (APL) Connector. .
Wiring the VAC LINE (IPL) Connector . . . . . . . . . . .
Wiring the VAC LOAD (OPL) Connector . . . . . . . . .
Wiring the Control Power Output (CPL) Connector .
Wiring the Auxiliary Power Output (P2L) Connector
Wiring the Brake Power Output (24V dc) Connector
Wiring the IAM/AM Connectors . . . . . . . . . . . . . . . . . .
Wiring the Control Power (CPD) Connector . . . . . . .
Wiring the Input Power (IPD) Connector . . . . . . . . .
Wiring the Contactor Enable (CED) Connector . . . . .
Wiring the Safe-off (SO) Connector . . . . . . . . . . . . .
Wiring the Motor Power (MP) Connector . . . . . . . . .
Wiring the Motor/Resistive Brake (BC) Connector . .
Applying the Motor Cable Shield Clamp . . . . . . . . . . . .
Understanding Feedback and I/O Cable Connections . .
Flying-lead Feedback Cable Pin-outs . . . . . . . . . . . .
Publication 2094-UM001A-EN-P — September 2006
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70
70
71
71
73
74
75
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75
76
78
78
79
80
83
84
84
85
86
87
88
89
90
90
91
93
94
95
101
103
104
105
Table of Contents
5
Wiring Feedback and I/O Connectors. . . . . . . . . . .
Connecting Premolded Motor Feedback Cables .
Wiring Panel-mounted Breakout Board Kits. . . .
Wiring Low-profile Connector Kits . . . . . . . . . .
Understanding External Shunt Module Connections.
Understanding Resistive Brake Module Connections
Connecting Your SERCOS Fiber-optic Cables . . . . .
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108
108
109
110
113
114
115
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119
120
125
125
126
128
132
133
134
135
138
138
141
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interpreting Status Indicators . . . . . . . . . . . . . . . . . . . . . .
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IAM/AM Status Indicators . . . . . . . . . . . . . . . . . . . . . .
SM Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting General System Problems . . . . . . . . . . . .
Understanding Logix/Drive Fault Behavior . . . . . . . . .
Supplemental Troubleshooting Information . . . . . . . . . . .
Tools for Changing Parameters . . . . . . . . . . . . . . . . . .
Using Analog Test Points to Monitor System Variables .
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145
145
146
146
152
153
155
157
160
160
161
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163
163
164
165
166
167
Chapter 6
Configure and Startup the
Kinetix 6000 Drive System
Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
Configure the IAM/AM. . . . . . . . . . . . . . . . . .
Configure the Logix SERCOS interface Module
Configure the Logix Controller . . . . . . . . .
Configure the Logix Module . . . . . . . . . . .
Configure the Kinetix 6000 Modules . . . . .
Configure the Motion Group . . . . . . . . . . .
Configure Axis Properties . . . . . . . . . . . . .
Download the Program. . . . . . . . . . . . . . .
Apply Power to the Kinetix 6000 Drive. . . . . .
Test and Tune the Axes . . . . . . . . . . . . . . . . .
Test the Axes . . . . . . . . . . . . . . . . . . . . . .
Tune the Axes . . . . . . . . . . . . . . . . . . . . .
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Chapter 7
Troubleshooting the Kinetix 6000
Drive System
Chapter 8
Removing and Replacing the
Kinetix 6000 Drive Modules
Introduction . . . . . . . . . . . . . .
Before You Begin . . . . . . . . . .
Removing Power Rail Modules .
Replacing Power Rail Modules .
Removing the Power Rail . . . . .
Replacing the Power Rail . . . . .
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Publication 2094-UM001A-EN-P — September 2006
6
Table of Contents
Appendix A
Specifications and Dimensions
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Axis Module (converter) Power Specifications
Axis Module (inverter) Power Specifications. . . . . . . . . .
Shunt Module Power Specifications . . . . . . . . . . . . . . . .
Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . .
Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer Specifications for Control Power Input . . . .
Power Dissipation Specifications. . . . . . . . . . . . . . . . . . . . .
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . .
Environmental Specifications . . . . . . . . . . . . . . . . . . . . .
Weight Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . .
External Shunt Module Specifications . . . . . . . . . . . . . . . . .
Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
169
170
170
172
173
177
179
179
180
181
181
181
182
182
183
184
185
Appendix B
Interconnect Diagrams
Introduction. . . . . . . . . . . . . . . . . . . . . .
Wiring Examples . . . . . . . . . . . . . . . . . .
Power Wiring Examples . . . . . . . . . .
DC Common Bus Wiring Examples . .
Shunt Module Wiring Examples. . . . .
Axis Module/Motor Wiring Examples.
Controlling a Brake Example . . . . . . .
System Block Diagrams . . . . . . . . . . . . .
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191
192
193
197
201
204
210
212
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using ControlFLASH Software to Upgrade Drive Firmware.
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the Drive to Upgrade . . . . . . . . . . . . . . . . . .
Configuring Logix Communications . . . . . . . . . . . . . . .
Flashing Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting ControlFLASH . . . . . . . . . . . . . . . . . .
Verifying the Firmware Upgrade . . . . . . . . . . . . . . . . .
Using DriveExplorer Software to Upgrade Drive Firmware.
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Axis Modules to Upgrade . . . . . . . . . . . . . . .
HyperTerminal Configuration . . . . . . . . . . . . . . . . . . .
Flashing Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . .
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215
216
216
217
218
220
222
223
224
224
224
226
228
Appendix C
Upgrading Firmware
Publication 2094-UM001A-EN-P — September 2006
Table of Contents
7
Appendix D
DC Common Bus Applications
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculating Total Bus Capacitance . . . . . . . . . . . . . .
Calculating Additional Bus Capacitance . . . . . . . . . .
Kinetix 6000 Capacitance Values . . . . . . . . . . . . . . .
Common Bus Capacitance Example . . . . . . . . . . . . .
Setting the Additional Bus Capacitance Parameter . . .
Removing SERCOS Communication . . . . . . . . . . .
Setting the Additional Bus Capacitance Parameter
Saving the Add Bus Cap Parameter to
Non-Volatile Memory. . . . . . . . . . . . . . . . . . . .
Reconnecting SERCOS Communication . . . . . . . .
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231
231
232
232
233
234
235
235
236
. . . . . 237
. . . . . 238
Appendix E
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Integrating Resistive Brake
Modules with Kinetix 6000 Drives Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Understanding Safety Precautions . . . . . . . . . . . . .
Safety Standards for Reference . . . . . . . . . . . .
Background on Safety Design . . . . . . . . . . . . .
Stop Categories . . . . . . . . . . . . . . . . . . . . . . .
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . .
Control Reliability . . . . . . . . . . . . . . . . . . . . . .
Resistive Brake Module Wiring Examples . . . . . . .
Setting the RBM Delay Time Using DriveExplorer .
Removing SERCOS Communication . . . . . . . . .
Setting the RBM Delay Time Parameter . . . . . .
Saving the Delay Time Parameter to
Non-Volatile Memory. . . . . . . . . . . . . . . . . .
Reconnecting SERCOS Communication . . . . . .
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240
240
241
241
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252
252
253
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Publication 2094-UM001A-EN-P — September 2006
8
Table of Contents
Publication 2094-UM001A-EN-P — September 2006
Preface
Read this preface to familiarize yourself with the rest of the manual.
About This Publication
This manual provides detailed installation instructions for mounting,
wiring, and troubleshooting your Kinetix 6000 drive, and system
integration for your drive/motor combination with a Logix controller.
Who Should Use this
Manual
This manual is intended for engineers or technicians directly involved
in the installation and wiring of the Kinetix 6000 drive, and
programmers directly involved in the operation, field maintenance,
and integration of the Kinetix 6000 drive with a SERCOS interface
module.
If you do not have a basic understanding of the Kinetix 6000 drive,
contact your local Rockwell Automation sales representative before
using this product, for information on available training courses.
Conventions Used in This
Manual
9
The conventions starting 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 drive components, shown in the
table below, are used throughout this manual.
Kinetix 6000 Component
Catalog Numbers
Acronym
Integrated Axis Module
2094-xCxx-Mxx
IAM
Axis Module
2094-xMxx
AM
Shunt Module
2094-BSP2
SM
Power Rail
2094-PRx
PR
Power Rail (slim)
2094-PRSx
PRS
Power Rail Slot Filler
2094-PRF
PRF
Line Interface Module
2094-xLxx and -xLxxS-xx
LIM
Resistive Brake Module
2090-XBxx-xx
RBM
Publication 2094-UM001A-EN-P — September 2006
10
Additional Resources
The following documents contain additional information concerning
related Allen-Bradley products.
For
Read This Document
Publication Number
Information on the installation of your Bulletin 2094 Power Rail Kinetix 6000 Power Rail Installation Instructions
2094-IN003
Information on the installation and troubleshooting of your
Bulletin 2094 Line Interface Module (LIM)
Line Interface Module Installation Instructions
2094-IN005
Information on the installation of Bulletin 2094 Mounting
Brackets
2094 Mounting Bracket Installation Instructions
2094-IN008
Information on the installation and wiring of Bulletin 2090
Resistive Brake Modules
Resistive Brake Module Installation Instructions
2090-IN009
Information on proper handling, installing, testing, and
troubleshooting fiber-optic cables
Fiber-optic Cable Installation and Handling Instructions
2090-IN010
Information on installing, configuring, and how to calculate the
data needed to correctly select a 1336 dynamic brake
1336 Dynamic Braking Installation Instructions
1336-5.64
System Design for Control of Electrical Noise Reference
Manual
GMC-RM001
EMC Noise Management DVD
GMC-SP001
Information on wiring and troubleshooting your Kinetix 6000
safety drive
Kinetix Safe-off Feature Safety Reference Manual
GMC-RM002
Specifications, motor/servo-drive system combinations, and
accessories for Kinetix motion control products
Kinetix Motion Control Selection Guide
GMC-SG001
Drive and motor sizing with application analysis software
Motion Analyzer CD, v4.2 or later
PST-SG003
Information on configuring and troubleshooting your
ControlLogix and CompactLogix SERCOS interface modules
Motion Modules in Logix5000 Control Systems User
Manual
LOGIX-UM002
Information on configuring and troubleshooting your SoftLogix
PCI card
SoftLogix Motion Card Setup and Configuration Manual
1784-UM003
Information on installing, configuring, programming, and
operating a ControlLogix system
ControlLogix Controllers User Manual
1756-UM001
More detailed information on the use of ControlLogix motion
features and application examples
ControlLogix Motion Module Programming Manual
1756-RM086
The instructions needed to program a motion application
Logix5000 Controllers Motion Instructions Reference
Manual
1756-RM007
For ControlFLASH information not specific to any drive family
ControlFLASH Firmware Upgrade Kit User Manual
1756-6.5.6
Online product selection and system configuration tools,
including AutoCAD (DXF) drawings
Rockwell Automation Configuration and Selection Tools
website
http://www.ab.com/
e-tools
For declarations of conformity (DoC) currently available from
Rockwell Automation
Rockwell Automation Product Certification website
http://
www.rockwellautomation.
com/products/certification
An article on wire sizes and types for grounding electrical
equipment
National Electrical Code
Published by the National
Fire Protection Association
of Boston, MA.
A glossary of industrial automation terms and abbreviations
Rockwell Automation Industrial Automation Glossary
AG-7.1
Information, examples, and techniques designed to minimize
system failures caused by electrical noise
You can view or download publications at
http://literature.rockwellautomation.com. To order paper copies of
technical documentation, contact your local Rockwell Automation
distributor or sales representative.
Publication 2094-UM001A-EN-P — September 2006
Chapter
1
Start
Introduction
11
Use this chapter to become familiar with the Kinetix 6000 drive
components. This chapter also reviews design and installation
requirements for Kinetix 6000 drive systems.
Topic
Page
Introduction
11
About the Kinetix 6000 Drive System
12
Catalog Number Explanation
16
Agency Compliance
16
Publication 2094-UM001A-EN-P — September 2006
12
Start
About the Kinetix 6000
Drive System
The Kinetix 6000 multi-axis servo drive is designed to provide a
Kinetix Integrated Motion solution for applications with output power
requirements between 3 and 45 kW (4 and 49 A).
Kinetix 6000 Drive System Overview
Kinetix 6000
Component
Catalog Numbers
Description
2094-xCxx-Mxx-S (1)
Integrated Axis Module (IAM), with safe-off feature available with 230V and 460V ac input power and
contains an inverter and converter.
2094-xCxx-Mxx
Integrated Axis Module (IAM), available with 230V and 460V ac input power and contains an inverter
and converter.
2094-BMxx-S (1)
Axis Module (AM), with safe-off feature is a shared dc bus inverter (230V and 460V). The AM must be
used with an IAM.
2094-xMxx
Axis Module (AM), is a shared dc bus inverter (230V and 460V). The AM must be used with an IAM.
Shunt Module
2094-BSP2
Shunt Module (SM), This module mounts to the power rail and provides additional shunting capability in
regenerative applications.
Power Rail
2094-PRSx
2094-PRx
Power Rail (PR) 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 IAM,
AM, SM, and PRF modules mount to the power rail.
Power Rail Slot
Filler
2094-PRF
Power Rail Slot Filler (PRF) is used when one or more slots on the power rail are empty after all the
power rail components are installed. One PRF module is required for each empty slot.
Logix Controller
Platform
1756-MxxSE module
1768-M04SE module
1784-PM16SE PCI card
SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix
platform and 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
9324-RLD300ENE
RSLogix 5000 provides support for programming, commissioning, and maintaining the Logix family of
controllers.
Servo Motors
MP-Series, 1326AB,
TL-Series,
F- and Y-Series
Compatible servo motors include the MP-Series (Low Inertia, Integrated Gear, Food Grade, and Stainless
Steel) 230 and 460V motors; TL-Series motors; 1326AB (M2L/S2L) and 1326AB (resolver) motors; F- and
Y-Series motors.
Motor Power, Feedback,
and Brake cables
Motor power, feedback, and brake cables include integral molded, bayonet style, quick connect/
quick-release connectors at the motor. Power and brake cables have flying leads on the drive end and
straight connectors that connect to servo motors. Standard feedback cables have angled connectors
(45º) on the drive end and straight connectors that connect to servo motors. Optional feedback cables
have a straight connector on the motor end and flying leads that wire to a low-profile connector kit on
the drive end.
Fiber-optic cables
SERCOS fiber-optic cables are available in enclosure only, PVC, nylon, and glass with connectors at both
ends.
AC Line Filters
2090-XXLF-xxxx
Bulletin 2090-XXLF-xxxx three-phase ac line filters are required to meet CE and available for use in 230V
and 460V systems.
Line Interface
Module
2094-xLxx
2094-xLxxS
2094-XL75S-Cx
Line Interface Module (LIM), contains the circuit breakers, ac line filter (2094-AL09 and -BL02 only),
power supplies, and safety contactor required for Kinetix 6000 operation. This module does not mount to
the power rail. Individual components can be purchased separately in place of the LIM.
1394-SRxxxx
Bulletin 1394 external passive shunt modules can be used when the IAM/AM internal shunt and power
rail mounted shunt module (2094-BSP2) capability is exceeded.
1336-MOD-Kxxxx
Bulletin 1336 external active shunt modules can be used when the internal shunt resistor (IAM/AM)
capability is exceeded.
2090-XBxx-xx
Resistive Brake Module (RBM), includes a safety contactor for use in a control circuit. Contactors and
resistors reside in this module such that the motor leads can be disconnected from the drive with the
permanent magnet motor brought to an immediate stop. This module does not mount to the power rail.
Integrated Axis
Module
Axis Module
Cables
External Shunt
Modules
Resistive Brake
Module
(1)
Refer to the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002, for more information.
Publication 2094-UM001A-EN-P — September 2006
Start
13
Typical Kinetix 6000 system installations include three-phase ac
configurations, with and without the line interface module (LIM), and
dc common bus configurations.
SHOCK HAZARD
To avoid personal injury due to electrical shock, place a slot
filler module (catalog number 2094-PRF) in all empty slots on
the power rail.
Any power rail connector without a module installed will
disable the Kinetix 6000 three-phase power, however control
power is still present.
Typical Kinetix 6000 System Installation (with LIM)
Logix Controller Programming Network
Logix SERCOS interface Module
SERCOS interfaceTM
CP
OK
Logix Platform
(ControlLogix is shown)
RSLogix 5000
Software
Kinetix 6000 Multi-axis Servo Drive System
Tx (rear)
Rx (front)
SERCOS Fiber-optic Ring
2090-SCxxx-x
AC Line Filter
2090-XXLF-xxxx
Three-phase
Input Power
Shunt Module
(optional component)
2094-BSP2
115/230V Control Power
Integrated
Axis Module
2094-xCxx-Mxx-S
Slot Filler
Module
(required to
fill any unused
slots)
2094-PRF
MAIN VAC
Line Interface Module
(optional component)
2094-xLxxS
Power Rail
2094-PRSx
Axis Modules (5)
2094-xMxx-S
I/O Connections
To input sensors
and control string.
Motor Feedback Cable
2090-XXNFxx-Sxx
Low Profile Connector Kits for
I/O, Motor Feedback, and Aux Feedback
2090-K6CK-Dxxx
Motor Power Cable
2090-XXNPxx-xxSxx
MP-Series, TL-Series, 1326AB (M2L/S2L),
F- and Y-Series Motors
(MPL-xxxx motors shown)
Publication 2094-UM001A-EN-P — September 2006
14
Start
Typical Kinetix 6000 System Installation (without LIM)
Three-phase
Input Power
Logix Controller Programming Network
Logix SERCOS interface Module
Logix Platform
(ControlLogix is shown)
Line
Disconnect
Device
RSLogix 5000
Software
Input
Fusing
Kinetix 6000 Multi-axis Servo Drive System
Single-phase
Control Power
Magnetic
Contactor
AC Line Filter
2090-XXLF-xxxx
SERCOS Fiber-optic Ring
2090-SCxxx-x
Shunt Module
(optional component)
2094-BSP2
Slot Filler
Module
(required to
fill any unused
slots)
2094-PRF
Integrated
Axis Module
2094-xCxx-Mxx-S
I/O Connections
Power Rail
2094-PRSx
To input sensors
and control string.
Axis Modules (5)
2094-xMxx-S
Motor Feedback Cable
2090-XXNFxx-Sxx
MP-Series, TL-Series, 1326AB (M2L/S2L),
F- and Y-Series Motors
(MPL-xxxx motors shown)
Publication 2094-UM001A-EN-P — September 2006
Low Profile Connector Kits for
I/O, Motor Feedback, and Aux Feedback
2090-K6CK-Dxxx
Motor Power Cable
2090-XXNPxx-xxSxx
Start
15
Typical DC Common Bus System Installation
Logix Controller Programming Network
Kinetix 6000 Multi-axis Servo Drive System
Three-phase
Input Power
Logix SERCOS interface Module
AC Line Filter
2090-XXLF-xxxx
SERCOS interface
CP
OK
Logix Platform
(ControlLogix is shown)
RSLogix 5000
Software
Tx (rear)
Rx (front)
SERCOS Fiber-optic Ring
2090-SCxxx-x
115/230V Control Power
Shunt Module
(optional component)
2094-BSP2
Integrated
Axis Module
2094-xCxx-Mxx-S
Slot Filler Module
(required to fill any
unused slots)
2094-PRF
Power Rail
(2094-PRSx is shown)
Line Interface Module
(optional component)
2094-xLxxS
DC Common Bus
Motors and other details common to both three-phase
ac and dc common bus configurations are removed.
Axis Modules (5)
2094-xMxx-S
SERCOS Fiber-optic Ring
2090-SCxxx-x
Integrated
Axis Module
2094-xCxx-Mxx-S
Slot Filler Module
(required to fill any
unused slots)
2094-PRF
Power Rail
(2094-PRSx is shown)
Axis Modules (5)
2094-xMxx-S
In the example above, the leader IAM is connected to the follower
IAM via the dc common bus. When planning your panel layout, you
must calculate the total bus capacitance of your dc common bus
system to ensure that the leader IAM is sized sufficiently to pre-charge
the entire system.
Refer to Appendix D, beginning on page 231, for more information.
IMPORTANT
If total bus capacitance of your system exceeds the leader IAM
pre-charge rating and input power is applied, the IAM
seven-segment LED indicator will display error code E90
(pre-charge timeout fault). To correct this condition, you must
replace the leader IAM with a larger module or decrease the
total bus capacitance by removing axis modules.
Publication 2094-UM001A-EN-P — September 2006
16
Start
Catalog Number
Explanation
Kinetix 6000 drive catalog numbers and descriptions are listed in the
table below.
Kinetix 6000 Drive Catalog Numbers
Integrated Axis Modules (230V
Catalog Number
(with safe-off feature)
Catalog Number
(without safe-off feature)
Kinetix 6000, IAM, 230V, 3 kW converter, 5 A inverter
2094-AC05-MP5-S
2094-AC05-MP5
Kinetix 6000, IAM, 230V, 3 kW converter, 9 A inverter
2094-AC05-M01-S
2094-AC05-M01
Kinetix 6000, IAM, 230V, 6 kW converter, 15 A inverter
2094-AC09-M02-S
2094-AC09-M02
Kinetix 6000, IAM, 230V, 11 kW converter, 24 A inverter
2094-AC16-M03-S
2094-AC16-M03
Kinetix 6000, IAM, 230V, 23 kW converter, 49 A inverter
2094-AC32-M05-S
2094-AC32-M05
Kinetix 6000, IAM, 460V, 6 kW converter, 4 A inverter
2094-BC01-MP5-S
2094-BC01-MP5
Kinetix 6000, IAM, 460V, 6 kW converter, 9 A inverter
2094-BC01-M01-S
2094-BC01-M01
Kinetix 6000, IAM, 460V, 15 kW converter, 15 A inverter
2094-BC02-M02-S
2094-BC02-M02
Kinetix 6000, IAM, 460V, 28 kW converter, 30 A inverter
2094-BC04-M03-S
2094-BC04-M03
Kinetix 6000, IAM, 460V, 45 kW converter, 49 A inverter
2094-BC07-M05-S
2094-BC07-M05
Kinetix 6000, AM, 230V, 5 A
2094-AMP5-S
2094-AMP5
Kinetix 6000, AM, 230V, 9 A
2094-AM01-S
2094-AM01
Kinetix 6000, AM, 230V, 15 A
2094-AM02-S
2094-AM02
Kinetix 6000, AM, 230V, 24 A
2094-AM03-S
2094-AM03
Kinetix 6000, AM, 230V, 49 A
2094-AM05-S
2094-AM05
Kinetix 6000, AM, 460V, 4 A
2094-BMP5-S
2094-BMP5
Kinetix 6000, AM, 460V, 9 A
2094-BM01-S
2094-BM01
Kinetix 6000, AM, 460V, 15 A
2094-BM02-S
2094-BM02
Kinetix 6000, AM, 460V, 30 A
2094-BM03-S
2094-BM03
Kinetix 6000, AM, 460V, 49 A
2094-BM05-S
2094-BM05
N/A
2094-BSP2
Integrated Axis Modules (460V)
Axis Modules (230V)
Axis Modules (460V)
Shunt Module
Kinetix 6000, SM, 230V/460V, 200W
Agency Compliance
If this product is installed within the European Union or EEC regions
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 drive must match. Failure to do
this renders the filter ineffective and may cause damage to the
filter.
For grounding examples, refer to Grounded Power
Configurations on page 71.
Publication 2094-UM001A-EN-P — September 2006
Start
17
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)
To meet CE requirements when your Kinetix 6000 system does not
include the line interface module (LIM), the following requirements
apply.
•
Install an ac line filter (2090-XXLF-xxxx) as close to the integrated
axis module (IAM) as possible.
•
Use 2090 series motor power cables or use connector kits and
terminate the cable shields to the chassis clamp provided.
•
Combined motor power cable length for all axes on the same dc
bus must not exceed 240 m (787 ft) with 460V systems or 160 m
(525 ft) with 230V systems. Drive-to-motor power cables must not
exceed 90 m (295.5 ft).
•
Use 2090 series motor feedback cables or use connector kits and
properly terminate the feedback cable shield. Drive-to-motor
feedback cables must not exceed 90 m (295.5 ft).
•
Install the Kinetix 6000 system inside an enclosure. Run input
power wiring in conduit (grounded to the enclosure) outside of
the enclosure. Separate signal and power cables.
Refer to Chapter 5, beginning on page 69, for wiring instructions and
the Kinetix Motion Control Selection Guide, publication GMC-SG001,
for catalog numbers.
CE Requirements (System with LIM)
To meet CE requirements when your Kinetix 6000 system includes the
line interface module (LIM), follow all the requirements as stated in
CE Requirements (System without LIM) and these additional
requirements as they apply to the ac line filter.
•
Install the LIM (2094-AL09 or -BL02) as close to the integrated axis
module (IAM) as possible.
•
Install the LIM (2094-ALxxS, -BLxxS or -XL75S-Cx) with line filter
(2090-XXLF-xxxx) as close to the IAM as possible.
When the LIM (2094-ALxxS, -BLxxS or -XL75S-Cx) supports two
IAMs, each IAM requires an ac line filter installed as close to the
IAM as possible.
Publication 2094-UM001A-EN-P — September 2006
18
Start
Publication 2094-UM001A-EN-P — September 2006
Chapter
2
Planning the Kinetix 6000 Drive System
Installation
Introduction
This chapter describes system installation guidelines used in
preparation for mounting your Kinetix 6000 drive components.
Topic
Page
Introduction
19
System Design Guidelines
20
Minimizing Electrical Noise
27
ATTENTION
19
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.
Publication 2094-UM001A-EN-P — September 2006
20
Planning the Kinetix 6000 Drive System Installation
System Design Guidelines
Use the information in this section when designing your enclosure
and planning to mount your system components on the panel.
For on-line product selection and system configuration tools,
including AutoCAD (DXF) drawings of the product, refer to
http://www.ab.com/e-tools.
System Mounting Requirements
•
In order to comply with UL and CE requirements, the Kinetix 6000
system must be enclosed in a grounded conductive enclosure
offering protection as defined in standard EN 60529 (IEC 529) to
IP55 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 drive enclosure so as not to exceed the maximum
ambient temperature rating. Consider heat dissipation
specifications for all drive components.
•
Segregate input power wiring and motor power cables from
control wiring and motor feedback cables. Use shielded cable for
power wiring and provide a grounded 360° clamp termination.
•
Use high-frequency (HF) bonding techniques to connect the
modules, enclosure, machine frame, and motor housing, and to
provide a low-impedance return path for high-frequency (HF)
energy and reduce electrical noise.
Refer to the System Design for Control of Electrical Noise
Reference Manual, publication GMC-RM001, to better understand
the concept of electrical noise reduction.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation
21
Transformer Selection
The integrated axis module (IAM) does not require an isolation
transformer for three-phase input power. However, a transformer may
be required to match the voltage requirements of the controller to the
available service.
To size a transformer for the main ac power inputs, refer to the Circuit
Breaker/Fuse Specifications on page 177 and Transformer
Specifications for Control Power Input on page 179.
IMPORTANT
If using an autotransformer, make sure that the phase to
neutral/ground voltages do not exceed the input voltage ratings
of the drive.
IMPORTANT
Use a form factor of 1.5 for three-phase power (where form
factor is used to compensate for transformer, drive module and
motor losses, and to account for utilization in the intermittent
operating area of the torque speed curve).
Example: Sizing a transformer to the voltage requirements of a
2094-AC05-M01 Integrated Axis Module:
2094-AC05-M01 = 3 kW continuous x 1.5 = 4.5 KVA transformer
Publication 2094-UM001A-EN-P — September 2006
22
Planning the Kinetix 6000 Drive System Installation
Circuit Breaker/Fuse Selection
The Kinetix 6000 system utilizes internal short circuit output
protection and is suitable for use on a circuit capable of delivering up
to 100,000 amperes, when protected by class CC, J, L, and R fuses.
Circuit breakers with adequate widthstand and interrupt ratings, as
defined in NEC 2002, article 110.9 and 110.10, are also permitted.
The Bulletin 140M product may be another acceptable means of
protection with the Kinetix 6000 system. As with fuses and circuit
breakers, you must make sure that the selected components are
properly coordinated and meet applicable codes. When applying the
140M product, evaluation of the short circuit available current is
critical and must be kept below the short circuit rating of the 140M
product. As long as you do this review, and the conditions for use are
met, the 140M product is appropriate for use with the Kinetix 6000
system.
The line interface modules (LIM), (models 2094-AL09 and -BL02)
contain supplementary protection devices. When these models are
used, protection on the line side of the LIM with a maximum let
through current of 5000 amperes is required. Fuses must be class J or
CC only.
Overcurrent protection must be adequately coordinated per NEC
2002, article 240.
In most cases, fuses selected to match the drive input current rating
will meet the NEC requirements and provide the full drive capabilities.
Dual element, time delay (slow acting) fuses should be used to avoid
nuisance trips during the inrush current of power initialization.
Refer to Circuit Breaker/Fuse Specifications on page 177 for
recommended circuit breakers and fuses.
Refer to Power Specifications on page 170 for input current and inrush
current specifications for your IAM.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation
23
Enclosure Selection
The following example is provided to assist you in sizing an enclosure
for your Kinetix 6000 system. The example system consists of the
following components:
•
6-axis Kinetix 6000 servo drive system
•
Line Interface Module (LIM)
•
ControlLogix chassis and modules (controller)
Size the Kinetix 6000 servo drive and LIM and use the results to
predict the amount of heat dissipated into the enclosure. You will also
need heat dissipation data from other equipment inside the enclosure
(such as ControlLogix controller). Once the total amount of heat
dissipation (in watts) is known, the minimum enclosure size can be
calculated.
Kinetix 6000 System Heat Dissipation Example
Loading (1)
Heat Dissipation (1)
watts
Enclosure Component
Description
2094-AC09-M02
Integrated axis module (IAM),
200/230V
40%
73
2094-AM02
Axis module (AM), 200/230V, 15 A
60%
82
2094-AM02
Axis module (AM), 200/230V, 15 A
60%
82
2094-AM01
Axis module (AM), 200/230V, 9 A
40%
69
2094-AM01
Axis module (AM), 200/230V, 9 A
40%
69
2094-AM01
Axis module (AM), 200/230V, 9 A
20%
62
2094-AL09
Line interface module (LIM), 200/230V, 6 kW, 6 A; 24V dc 3 A
100%
72
2094-PR6
Power rail, 230V, 6 axis
N/A
0
2090-XB33-32
Resistive brake module (RBM), 33 A, 32 Ω
N/A
Total Kinetix 6000 system wattage
(1)
6 kW (converter section) 20%
15A (inverter section)
33
30
572
To determine heat dissipation specifications for the Kinetix 6000 components, refer to Power Dissipation Specifications on page 180.
Publication 2094-UM001A-EN-P — September 2006
24
Planning the Kinetix 6000 Drive System Installation
ControlLogix System Heat Dissipation Example
Enclosure
Component
Description
Backplane Power
Load (1) watts
Heat Dissipation (1)
watts
1756-M08SE
8-axis SERCOS interface module
3.2
0
1756-L55M12
5555 ControlLogix processor
4.5
0
1756-IB16D
16 -point input module
0.84
5.8
1756-OB16D
16 -point output module
4.64
3.3
1756-ENBT
Ethernet communications module
4.0
0
17.18 (2)
N/A
Backplane total
1756-PB72
24V dc ControlLogix power supply
N/A
25 (2)
1756-A7
7-slot mounting chassis
N/A
N/A
Total ControlLogix system wattage
34.1
(1)
For ControlLogix module specifications, refer to the ControlLogix Selection Guide, publication 1756-SG001.
(2)
Real power heat dissipation is determined by applying the backplane power load (17.18W) to the graph below.
ControlLogix Real Power
1756-P B72
1756-P B75
dc
Backplane
Power Load
(watts)
75
60
45
30
15
0
0
20
40
60
80
100
Real Power (watts)
For backplane power loading requirements of other ControlLogix
power supplies, refer to the ControlLogix Selection Guide, publication
1756-SG001.
In this example, the amount of power dissipated inside the cabinet is
the sum of the Kinetix 6000 system value (572 W) and the
ControlLogix system value (34 W) for a total of 606 W.
With no active method of heat dissipation (such as fans or air
conditioning) either of the following approximate equations can be
used.
Metric
Publication 2094-UM001A-EN-P — September 2006
Standard English
0.38Q
A = -----------------------1.8T – 1.1
4.08Q
A = ---------------T – 1.1
Where T is temperature difference between
inside air and outside ambient (°C), Q is heat
generated in enclosure (Watts), and A is
enclosure surface area (m2). The exterior surface
of all six sides of an enclosure is calculated as
Where T is temperature difference between
inside air and outside ambient (°F), Q is heat
generated in enclosure (Watts), and A is
enclosure surface area (ft²). The exterior surface
of all six sides of an enclosure is calculated as
A = 2dw + 2dh + 2wh
A = (2dw + 2dh + 2wh) / 144
Where d (depth), w (width), and h (height) are in
meters.
Where d (depth), w (width), and h (height) are in
inches.
Planning the Kinetix 6000 Drive System Installation
25
The maximum ambient rating of the Kinetix 6000 system is 50 °C
(122 °F) and if the maximum environmental temperature is 30 °C
(86 °F) then Q=606 and T=20 in the equation below.
0.38 ( 606 )
A = -------------------------------- ≈ 6.59m 2
1.8 ( 20 ) – 1.1
In this example, the enclosure must have an exterior surface of 6.59
meters2. If any portion of the enclosure is not able to transfer heat, it
should not be included in the calculation.
Since the minimum cabinet depth to house the 230V drive (selected
for this example) is 200 mm (7.9 in.), then the cabinet needs to be
approximately 2100 mm (high) x 1250 mm (wide) x 200 mm (deep).
2 x (0.2 x 1.25) + 2 x (0.2 x 2.1) + 2 x (1.25 x 2.1) = 6.59m2
Because this cabinet size is considerably larger than what is necessary
to house the system components, it may be more efficient to provide
a means of cooling in a smaller cabinet. Contact your cabinet
manufacturer for options available to cool your cabinet.
Publication 2094-UM001A-EN-P — September 2006
26
Planning the Kinetix 6000 Drive System Installation
Minimum Clearance Requirements
This section provides information to assist you in sizing your cabinet
and positioning your Kinetix 6000 system components.
IMPORTANT
Mount the module in an upright position. Do not mount the
module on its side.
Minimum Clearance Requirements
Clearance above
for airflow and installation.
Integrated Axis Module (IAM)
(2094-AC05-Mxx is shown
mounted on power rail)
Clearance right of the
module is not required. (1)
Clearance left of the
module is not required. (1)
Power Rail
(2094-PRSx is shown)
(1)
Clearance below
for airflow and installation.
The power rail (slim), catalog number 2094-PRSx, does not extend left or right of the first or last module
(respectively). When using power rail (catalog number 2094-PRx) the power rail extends approximately
25.4 mm (1.0 in.) left of the IAM and right of the last module mounted on the rail.
Minimum Clearance Dimensions
Cat. No.
Clearance Above, Min
Clearance Below, Min
2094-AC05, -AC09, -AMP5, -AM01, -AM02
2094-BC01, -BC02, -BMP5, -BM01, -BM02
200 mm (7.9 in.)
50.8 mm (2.0 in.)
50.8 mm (2.0 in.)
305 mm (12.0 in.)
50.8 mm (2.0 in.)
2094-BSP2
2094-AC16, -AC32, -AM03, -AM05
2094-BC04, -BC07, -BM03, -BM05
Cabinet Depth Clearance, Min
IMPORTANT
272 mm (10.7 in.)
200 mm (7.9 in.)
272 mm (10.7 in.)
Although clearance left and right of the power rail is not
necessary for ventilation, additional clearance is required when
mounted adjacent to noise sensitive equipment or clean
wireways.
Refer to page 180 for power dissipation specifications.
Publication 2094-UM001A-EN-P — September 2006
Planning the Kinetix 6000 Drive System Installation
Minimizing Electrical
Noise
27
This section outlines best practices which minimize the possibility of
noise-related failures as they apply specifically to Kinetix 6000 system
installations. For more information on the concept of high-frequency
(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.
Bonding Modules
Bonding is the practice of connecting metal chassis, assemblies,
frames, shields, and enclosures to reduce the effects of
electromagnetic interference (EMI).
Unless specified, most paints are not conductive and act as insulators.
To achieve a good bond between power rail and the subpanel,
surfaces need to be paint-free or plated. Bonding metal surfaces
creates a low-impedance return path for high-frequency energy.
IMPORTANT
To improve the bond between the power rail and subpanel,
construct your subpanel out of zinc plated (paint-free) steel.
Improper bonding blocks the direct return path and allows
high-frequency energy to travel elsewhere in the cabinet. Excessive
high-frequency energy can effect the operation of other
microprocessor controlled equipment.
Publication 2094-UM001A-EN-P — September 2006
28
Planning the Kinetix 6000 Drive System Installation
The illustrations that follow show details of recommended bonding
practices for painted panels, enclosures, and mounting brackets.
Recommended Bonding Practices for Painted Panels
Stud-mounting the Subpanel
to the Enclosure Back Wall
Stud-mounting a Ground Bus
or Chassis to the Subpanel
Subpanel
Back Wall of
Enclosure
Mounting Bracket or
Ground Bus
Subpanel
Welded Stud
Star Washer
Nut
Scrape Paint
Flat Washer
Welded Stud
Nut
Flat Washer
Use a wire brush to remove paint from
threads to maximize ground
connection.
Use plated panels or scrape paint on
front of panel.
If the mounting bracket is coated
with a non-conductive material
(anodized or painted), scrape the
material around the mounting hole.
Star Washer
Bolt-mounting a Ground Bus or Chassis to the Back-panel
Subpanel
Bolt
Tapped Hole
Ground Bus or
Mounting Bracket
Nut
Star Washer
Scrape paint on both sides of
panel and use star washers.
Star Washer
Flat Washer
Nut
Flat Washer
Star Washer
Publication 2094-UM001A-EN-P — September 2006
If the mounting bracket is coated
with a non-conductive material
(anodized or painted), scrape the
material around the mounting hole.
Planning the Kinetix 6000 Drive System Installation
29
Bonding Multiple Subpanels
Bonding multiple subpanels creates a common low impedance exit
path for the high frequency energy inside the cabinet. Subpanels that
are not bonded together may not share a common low impedance
path. This difference in impedance may affect networks and other
devices that span multiple panels.
Multiple Subpanels and Cabinet Recommendations
Bond the top and bottom of each subpanel to the cabinet using
25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Cabinet ground bus
bonded to the subpanel.
Scrape the paint around each fastener to
maximize metal to metal contact.
Publication 2094-UM001A-EN-P — September 2006
30
Planning the Kinetix 6000 Drive System Installation
Establishing Noise Zones
Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or
-XL75S-Cx) is used in the Kinetix 6000 system and mounted left of the
IAM with the ac (EMC) line filter mounted above the LIM:
•
The clean zone (C) is to the right and beneath the Kinetix 6000
system (grey wireway).
•
The dirty zone (D) is to the left and above the Kinetix 6000
system, and above and below the LIM (black wireway).
•
The very dirty zone (VD) is from the filter output to IAM. Shielded
cable is required on the EMC filter (load side) and the braided
shield attached to the clamp provided.
•
The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM mounted left of IAM)
Dirty Wireway
Clean Wireway
D
D
AC Line Filter
VD
Motor Power Cables
D
VAC Load
D
D
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
D
VAC Line
Fiber-optic Cable
VD
D
No sensitive
equipment within
150 mm (6.0 in.). (2)
MAIN VAC
Kinetix 6000 System
Line Interface Module
I/O (1) and Feedback Cables
D
D
Route 24V dc I/O
shielded cable.
Publication 2094-UM001A-EN-P — September 2006
C
Route encoder/analog/registration
shielded cables.
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM 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.
Planning the Kinetix 6000 Drive System Installation
31
Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or
-XL75S-Cx) is used in the Kinetix 6000 system and mounted right of
the IAM with the ac (EMC) line filter mounted behind the IAM:
•
The clean zone (C) is to the left and beneath the Kinetix 6000
system (grey wireway).
•
The dirty zone (D) is to the right and above the Kinetix 6000
system, and above and below the LIM (black wireway).
•
The very dirty zone (VD) is from the filter output to IAM. Shielded
cable is required on the EMC filter (load side) and the braided
shield attached to the clamp provided.
•
The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM with EMC filter behind IAM)
Dirty Wireway
Clean Wireway
Motor Power Cables
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
D
D
D
D
VAC Line
Control VAC,
AUX VAC Output,
and 24V dc Brake
Fiber-optic
Cable
VD
D
I/O
No sensitive
equipment within
150 mm (6.0 in.). (2)
VD
VAC Load
D
MAIN VAC
D
AC Line Filter
Kinetix 6000
System
C
I/O (1) and Feedback Cables
Line Interface Module
C
D
Route encoder/analog/registration
shielded cables.
Route 24V dc I/O
shielded cable.
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM 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.
Publication 2094-UM001A-EN-P — September 2006
32
Planning the Kinetix 6000 Drive System Installation
Observe the following guidelines when a LIM (2094-ALxxS or
-XLxxS-Cx) is used in the Kinetix 6000 system and mounted right of
the drive with the ac (EMC) line filter mounted behind the LIM:
•
The clean zone (C) is to the left and beneath the Kinetix 6000
system (grey wireway).
•
The dirty zone (D) is to the right and above the Kinetix 6000
system, and above and below the LIM (black wireway).
•
The very dirty zone (VD) is from the filter output to drive.
Shielded cable is required on the EMC filter (load side) and the
braided shield attached to the clamp (when provided).
Establishing Noise Zones (EMC filter behind LIM)
Dirty Wireway
Clean Wireway
Motor Power Cables
Control VAC,
Auxiliary VAC,
and 24V dc Brake
D
VAC Line
LIM
No sensitive
equipment within
150 mm (6.0 in.). (2)
PR/PRS
VD
VAC Load
PRS
D
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
PR
PR
D
D
LIM
D LIM
I/O
MAIN VAC
VD
C
I/O (1) and Feedback Cables
C
Route encoder/analog/registration
shielded cables.
Publication 2094-UM001A-EN-P — September 2006
PRS
LIM
PR
PR
Kinetix 6000
System
PR/PRS
AC (EMC)
Line Filter
Line Interface Module
(2094-ALxxS shown)
LIM
2094 Mounting
Brackets (3) x2
D
Route 24V dc I/O
shielded cable.
(1)
If drive system I/O cable contains (dirty) relay wires, route cable with LIM 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.
(3)
Only the 2094-ALxxS and -XL75S-Cx Line Interface Modules are compatible with the 2094 Mounting Brackets.
The 2094-BLxxS, -AL09, and -BL02 models are not compatible.
Planning the Kinetix 6000 Drive System Installation
33
Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or
-XL75S-Cx) is used in a dc common bus configuration and the
follower IAM is mounted below the leader IAM:
Keep the dc common bus cable (very dirty) segregated from all other
cables (not in a wireway).
Establishing Noise Zones (dc common bus)
Dirty Wireway
D
Clean Wireway
VD
AC Line Filter
Motor Power Cables
D
Very Dirty Filter/IAM Connections
Segregated (not in wireway)
D
D
Fiber-optic Cable
VD
VAC Line, AUX VAC Output, 24V
VAC Load
D
D
VAC Line
No sensitive
equipment within
150 mm (6.0 in.). (2)
MAIN VAC
Kinetix 6000 System
(leader IAM)
I/O (1) and Feedback Cables
D
Line Interface Module
C
D
D
D
D
VD
Fiber-optic Cable
Very Dirty DC Bus Connections
Segregated (not in wireway)
No sensitive
equipment within
150 mm (6.0 in.). (2)
Kinetix 6000 System
(follower IAM)
I/O (1) and Feedback Cables
C
Route 24V dc I/O
shielded cable.
Route encoder/analog/registration
shielded cables.
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM 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.
Publication 2094-UM001A-EN-P — September 2006
34
Planning the Kinetix 6000 Drive System Installation
Observe the following guidelines when a LIM (2094-AL09 or -BL02) is
used in the Kinetix 6000 system and mounted left of the IAM:
This layout is preferred due to the reduced size of the very dirty zone.
•
The clean zone (C) is to the right and beneath the Kinetix 6000
system (grey wireway).
•
The dirty zone (D) is to the left and above the Kinetix 6000
system, and above and below the LIM (black wireway).
•
The very dirty zone (VD) is limited to where the LIM VAC output
jumpers over to the IAM. Shielded cable is required only if the
very dirty cables enter a wireway.
•
The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM mounted left of IAM)
Dirty Wireway
Clean Wireway
Very Dirty Filter/IAM Connections
Segregated (not
(1)in wireway)
Motor Power Cables
D
Fiber-optic Cable
D
D
VD
No sensitive
equipment within
150 mm (6.0 in.). (2)
Kinetix 6000
System
D
Line Interface Module
C
D
Route 24V dc I/O
shielded cable.
Publication 2094-UM001A-EN-P — September 2006
C
I/O (1) and Feedback Cables
Route encoder/analog/registration
shielded cables.
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM 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.
Planning the Kinetix 6000 Drive System Installation
35
Observe the following guidelines when a LIM (2094-AL09 or -BL02) is
used in the Kinetix 6000 system and mounted above the IAM:
•
The clean zone (C) is to the right and beneath the Kinetix 6000
system (grey wireway).
•
The dirty zone (D) is to the left and above the Kinetix 6000
system, and above and below the LIM (black wireway).
•
The LIM VAC output is very dirty (VD). Use shielded cable with a
braid clamp attached at both ends of the cable to reduce the rating
to dirty (D).
•
The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (LIM mounted above IAM)
Dirty Wireway
Clean Wireway
VD
D
Very dirty LIM/IAM
connections must be
shielded with braid
clamp at both ends. (1)
Line Interface Module
D
Motor Power Cables
D
Fiber-optic Cable
No sensitive
equipment within
150 mm (6.0 in.). (2)
C
D
Kinetix 6000
System
C
I/O (2) and Feedback Cables
Route encoder/analog/registration
shielded cables.
Route 24V dc I/O
shielded cable.
(1)
For examples of shield clamp attachment, refer to the System Design for Control of Electrical Noise Reference
Manual, publication GMC-RM001.
(2)
If IAM/AM I/O cable contains (dirty) relay wires, route cable in dirty wireway.
(3)
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.
Publication 2094-UM001A-EN-P — September 2006
36
Planning the Kinetix 6000 Drive System Installation
Observe the following guidelines when individual input power
components are used in the Kinetix 6000 system and the LIM
(2094-xLxx or -xLxxS-xx) is not used:
•
The clean zone (C) is beneath the Kinetix 6000 system and
includes the I/O wiring, feedback cable, and dc filter (grey
wireway).
•
The dirty zone (D) is above the Kinetix 6000 system (black
wireway) and includes the circuit breakers, transformer, 24V dc
power supply, contactors, ac line filter, and motor power cables.
•
The very dirty zone (VD) is limited to where the ac line (EMC)
filter VAC output jumpers over to the IAM. Shielded cable is
required only if the very dirty cables enter a wireway.
•
The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (No LIM)
Dirty Wireway
Very Dirty Filter/IAM Connections
(1) Segregated (not in wireway)
D
(2)
VD
Contactors
24V Motor
Brake PS
Motor Power Cables
D
D
Circuit
Breaker
Clean Wireway
AC
Line Filter
(4)
XFMR
Kinetix 6000 System
DC
Filter
(3)
(2)
C
I/O (1) and Feedback Cables
C
D
Route 24V dc I/O
shielded cable.
Publication 2094-UM001A-EN-P — September 2006
Route encoder/analog/registration
shielded cables.
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable in dirty wireway.
(2)
When space to the right of the IAM does not permit 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.
(3)
This is a clean 24V dc available for any device that may require it. The 24V enters the clean wireway and exits
to the right.
(4)
This is a dirty 24V dc available for motor brakes and contactors. The 24V enters the dirty wireway and exits to
the left.
Planning the Kinetix 6000 Drive System Installation
37
Observe the following guidelines when installing your 1756-MxxSE
SERCOS interface module:
•
The clean zone (C) is beneath the less noisy modules (I/O, analog,
encoder, registration, etc. (grey wireway).
•
The dirty zone (D) is above and below the power supply and
noisy modules (black wireway).
•
The SERCOS fiber-optic cables are immune to electrical noise.
Establishing Noise Zones (ControlLogix)
Clean Wireway
Dirty Wireway
D
(1)
Route dirty wireways directly above the ControlLogix rack
(shielded by the chassis).
AC Line
Filter
D
Line Filter/Power Supply
Connections Segregated
(not in wireway)
Spare Slots
Dirty I/O
(24V dc I/O, ac I/O)
C
Clean I/O
(Analog, Encoder
Registration)
Cable Categories for Kinetix 6000 Systems
The table below indicates the zoning requirements of cables
connecting to the Kinetix 6000 drive components.
Integrated Axis Module (converter side)
Zone
Wire/Cable
Connector
CTRL 1 and 2
CPD
DC-/DC+ (unshielded cable)
L1, L2, L3 (shielded cable)
Very
Dirty
Dirty
Method
Clean
Ferrite
Sleeve
Shielded
Cable
X
X
IPD
L1, L2, L3 (unshielded cable)
X
X
X
CONT EN- and CONT EN+ (M1 contactor)
CED
DPI
DPI
X
X
X
Publication 2094-UM001A-EN-P — September 2006
38
Planning the Kinetix 6000 Drive System Installation
Integrated Axis Module or Axis Module (inverter side)
Zone
Wire/Cable
Connector
U, V, W (motor power)
Very
Dirty
MP
Dirty
Clean
Ferrite
Sleeve
Shielded
Cable
X
MBRK-, MBRK+ (motor brake)
X
MBRK-, MBRK+ (motor brake)
1326AB motors with resolver feedback
X
BC
DBRK-, DBRK+ (resistive brake)
Method
X
X
X
COM, PWR (24V dc), filtered (1)
X
COM, PWR (24V dc), unfiltered (2)
X
COM, PWR (24V dc), safety enable, and
feedback signals for safe-off feature
SO
Motor feedback
MF
X
X
Auxiliary feedback
AF
X
X
X
X
Registration and analog outputs
IOD
Others
Fiber-optic
X
X
Rx and Tx
No Restrictions
(1)
This is a clean 24V dc available for any device that may require it.
(2)
This is a dirty 24V dc available for motor brakes and contactors.
Line Interface Module
Zone
Wire/Cable
Connector
Very
Dirty
Dirty
VAC line (main input)
IPL
X
230V ac input
APL
X
VAC load (shielded option)
OPL
VAC load (unshielded option)
Control power output
MBRK PWR, MBRK COM
Method
Clean
Ferrite
Sleeve
Shielded
Cable
X
X
X
CPL
X
P1L/PSL
X
Status I/O
IOL
X
Auxiliary 230V ac
P2L
X
External Shunt Resistor Kit
Zone
Wire/Cable
COL, DC+ (shielded option)
COL, DC+ (unshielded option)
Connector
RC
Very
Dirty
Dirty
Clean
Shielded
Cable
X
X
X
X
Thermal switch
TS
X
Fan (if present)
N/A
X
Publication 2094-UM001A-EN-P — September 2006
Method
Ferrite
Sleeve
Planning the Kinetix 6000 Drive System Installation
39
Resistive Brake Module
Zone
Wire/Cable
Connections
Resistive brake module coil power
Resistive brake module I/O
Resistive brake module
drive and motor power
230V power
Very
Dirty
Dirty
TB3-6 and TB3-7
X
TB1-1...-5
and TB3-8
X
TB1 and TB2
X
TB4
X
Method
Clean
Ferrite
Sleeve
Shielded
Cable
X
Noise Reduction Guidelines for Drive Accessories
When mounting an ac (EMC) line filter or external shunt resistor refer
to the sections below for guidelines designed to reduce system
failures caused by excessive electrical noise.
AC Line Filters
Observe the following guidelines when mounting your ac (EMC) line
filter (refer to the figure on page 36 for an example):
•
Mount the ac line filter on the same panel as the Kinetix 6000
drive and as close to the power rail as possible.
•
Good HF bonding to the panel is critical. For painted panels, refer
to the examples on page 28.
•
Segregate input and output wiring as far as possible.
IMPORTANT
CE test certification applies only to ac line filter and single
power rail. Sharing a line filter with multiple power rails may
perform satisfactorily, but the user takes legal responsibility.
Publication 2094-UM001A-EN-P — September 2006
40
Planning the Kinetix 6000 Drive System Installation
External Shunt Resistor
Observe the following guidelines when mounting your external shunt
resistor outside the enclosure:
•
Mount circuit components and wiring in the very dirty zone or in
an external shielded enclosure. Run shunt power and fan wiring
inside metal conduit to minimize the effects of EMI and RFI.
•
Mount resistors (other than metal-clad) in a shielded and
ventilated enclosure outside the cabinet
•
Keep unshielded wiring as short as possible. Keep shunt wiring as
flat to the cabinet as possible.
•
Route thermal switch and fan wires separate from shunt power.
External Shunt Resistor Outside the Enclosure
Customer-supplied
Metal Enclosure
150 mm (6.0 in.)
clearance (min) on all four
sides of the shunt module.
Metal Conduit
(where required
by local code)
1394 Digital Servo Controller
300W Shunt Module
ALLEN-BRADLEY
R
BULLETIN 1394 300W SHUNT MODULE
CAT.
PART
SER.
INPUT DC
INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.
FOR USE WITH 1394-SJT22-X SYSTEM MODULE
Shunt thermal Switch and Fan Wires (when present)
Dirty Wireway
Clean Wireway
Shunt Power Wiring Methods:
Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
Twisted pair, two twists per foot (min) (3rd choice).
(1)
D
Very Dirty Connections Segregated
(not in wireway)
Motor Power Cables
D
D
D
VD
VD
2094-BSP2
Shunt Module
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
D
C
C
Line Interface Module
D
I/O and Feedback Cables
Route 24V dc I/O
shielded cable.
Publication 2094-UM001A-EN-P — September 2006
Enclosure
Route encoder/analog/registration
shielded cables.
Planning the Kinetix 6000 Drive System Installation
41
When mounting your shunt module inside the enclosure, follow these
additional guidelines:
•
Metal-clad modules can be mounted anywhere in the dirty zone,
but as close to the Kinetix 6000 system as possible.
•
Shunt power wires can be run with motor power cables.
•
Keep unshielded wiring as short as possible. Keep shunt wiring as
flat to the cabinet as possible.
•
Separate shunt power cables from other sensitive, low voltage
signal cables.
External Shunt Resistor Inside the Enclosure
Clean Wireway
Dirty Wireway
Enclosure
150 mm (6.0 in.)
clearance (min) on all four
sides of the shunt module.
1394 Digital Servo Controller
300W Shunt Module
ALLEN-BRADLEY
R
BULLETIN 1394 300W SHUNT MODULE
CAT.
PART
SER.
INPUT DC
INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.
FOR USE WITH 1394-SJT22-X SYSTEM MODULE
Shunt thermal Switch and Fan Wires (when present)
Very Dirty Connections Segregated
(not in wireway)
D
VD
Motor Power Cables
D
D
VD
Shunt Power Wiring Methods:
Twisted pair in conduit (1st choice).
Shielded twisted pair (2nd choice).
Twisted pair, two twists per foot (min) (3rd choice).
D
2094-BSP2
Shunt Module
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
D
Line Interface Module
D
C
C
I/O and Feedback Cables
Route 24V dc I/O
shielded cable.
Route encoder/analog/registration
shielded cables.
Publication 2094-UM001A-EN-P — September 2006
42
Planning the Kinetix 6000 Drive System Installation
Resistive Brake Modules
Observe the following guidelines when mounting your resistive brake
module (RBM):
•
Mount circuit components and wiring in the dirty zone or in an
external shielded enclosure. If mounting the RBM in a separate
ventilated shielded enclosure, run wiring inside metal conduit to
minimize the effects of EMI and RFI.
•
Keep unshielded wiring as short as possible. Keep wiring as flat to
the cabinet as possible.
•
Route RBM power and I/O cables separate from other sensitive
low voltage signal cables.
Establishing Noise Zones (RBM mounted above AM)
Dirty Wireway
Clean Wireway
D
RBM I/O
D
Very Dirty LIM/IAM Connections
Segregated (not in wireway)
Fiber-optic
Cable
LIM VAC Input Power
D
D
Motor Power
Cables
VD
No sensitive
equipment within
150 mm (6.0 in.).
Kinetix 6000
System
D
Line Interface Module
C
D
IAM/AM Feedback and
(clean) I/O
LIM and IAM/AM (dirty) I/O
Motor Brake and Thermal Switch
The thermal switch and brake are mounted inside the motor, but how
you connect to the axis module depends on the motor series.
Refer to Wiring the Motor/Resistive Brake (BC) Connector on page
101 for wiring guidelines. Refer to Axis Module/Motor Wiring
Examples beginning on page 204 for the interconnect diagram of your
drive/motor combination.
Publication 2094-UM001A-EN-P — September 2006
Chapter
3
Mounting the Kinetix 6000 Drive System
Introduction
This chapter provides the system installation procedures for mounting
your Kinetix 6000 drive components to the panel.
Topic
Page
Introduction
43
Determining Mounting Order
44
Mounting the Modules
45
Mounting the External Shunt Module
48
The procedures in this chapter assume you have prepared your panel
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
ATTENTION
To avoid hazard of electrical shock, perform all mounting and
wiring of IAM, AM, SM, LIM, RBM, or power rail prior to
applying power. Once power is applied, connector terminals
may have voltage present even when not in use.
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.
Using 2094 Mounting Brackets
Bulletin 2094 mounting brackets can be used to mount the power rail
or line interface module over the ac line filter. Refer to the 2094
Mounting Brackets Installation Instructions, publication 2094-IN008,
when using mounting brackets with your Kinetix 6000 drive system.
43
Publication 2094-UM001A-EN-P — September 2006
44
Mounting the Kinetix 6000 Drive System
Installing the 2094 Power Rail
The Kinetix 6000 power rail comes in lengths to support one
integrated axis module (IAM), and up to seven additional axis
modules (AM) or shunt module (SM). The connector pins for each slot
are covered by a protective boot. The boot 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
Determining Mounting
Order
To avoid damage to the power rail during installation, do not
remove the protective boots until the module for each slot is
ready for mounting.
Mount IAM, AM, SM, and slot filler (PRF) modules in the order (left to
right) as shown in the figure below. Mount axis modules according to
power utilization (highest to lowest) from left to right starting with the
highest power utilization. If power utilization is unknown, position
axis modules (highest to lowest) from left to right based on amp
rating.
Module Mounting Order
Highest Power Utilization or Amp Rating
Integrated Axis Module
2094-AC09-M02
Axis Module
2094-AM02
Publication 2094-UM001A-EN-P — September 2006
Axis Module
2094-AM02
Lowest Power Utilization or Amp Rating
Axis Module
2094-AM02
Axis Module
2094-AM01
Axis Module
2094-AM01
Shunt Module
2094-BSP2
Slot Filler Module
2094-PRF
Mounting the Kinetix 6000 Drive System
IMPORTANT
45
The integrated axis module (IAM) must be positioned in the
leftmost slot of the power rail. Position your axis modules (AM),
shunt module (SM), and slot fillers (PRF) to the right of the IAM.
The SM must be installed to the right of the last AM. Only slot
filler modules may be installed to the right of the SM.
Do not mount the SM on power rails with a follower IAM.
Common-bus follower IAMs will disable the internal, rail
mounted, and external shunt modules.
SHOCK HAZARD
To avoid personal injury due to electrical shock, place a slot
filler module (catalog number 2094-PRF) in all empty slots on
the power rail.
Any power rail connector without a module installed will
disable the Kinetix 6000 system, however control power will
still be present.
Mounting the Modules
Follow these steps to mount the IAM, AM, SM, and PRF modules. All
modules mount to the power rail using the same technique
(integrated axis module is shown).
1. Remove the protective boots from the power rail connectors.
IMPORTANT
The IAM must be positioned in the leftmost slot of the
power rail. Position your axis modules, shunt module, and
slot fillers to the right of the IAM.
2. Determine the next available slot and module for mounting.
3. Remove the label (applied to back and side of module) covering
the pins that mate with the power rail.
ATTENTION
To avoid damage to the pins located on the back of each
module (IAM, AM, SM, and PRF) and to make sure that
module pins mate properly with the power rail, hang
modules as shown in Steps 4...7.
The power rail must be mounted vertically on the panel
before hanging modules on the power rail. Do not mount
modules if the power rail is horizontal.
Publication 2094-UM001A-EN-P — September 2006
46
Mounting the Kinetix 6000 Drive System
4. Hang the mounting bracket from the slot on the power rail.
Mounting Bracket
Power Rail Slot
Slots for additional axis modules,
shunt module, or slot filler.
Integrated Axis Module
Power Rail
5. Pivot module downward and align the guide pins on the power
rail with the guide pin holes in the back of the module.
Pivot module downward
and align with guide pins.
Guide Pin
Holes
Integrated Axis Module
(rear view)
TIP
Publication 2094-UM001A-EN-P — September 2006
Power rail
(side view)
in upright
vertical position.
Guide Pins
Integrated Axis Module
(side view)
The IAM can have two or three power rail connectors and guide
pins, the AM can have one or two, all other modules have one.
Mounting the Kinetix 6000 Drive System
47
6. Gently push the module against the power rail connectors and
into the final mounting position.
Bracket secured in slot.
Power Rail
Integrated Axis Module
7. Use 2.26 Nm (20 lb-in.) torque to tighten the mounting screws.
Bottom front view of
single-wide AM, SM, or PRF
(AM is shown).
Bottom front view of
double-wide IAM or AM
(AM is shown).
Mounting Screws
IMPORTANT
There are two mounting screws when mounting
2094-AC32-M05, -BC04-M03, and -BC07-M05 (double-wide)
IAMs and 2094-AM05, -BM03, and -BM05 (double-wide) AMs.
8. Determine if you have additional modules to mount.
If You
Then
Have additional modules to mount
Return to Step 1 and complete installation of
your next AM, SM, or PRF module.
Do not have additional modules to mount
Go to Mounting the External Shunt Module.
Publication 2094-UM001A-EN-P — September 2006
48
Mounting the Kinetix 6000 Drive System
Mounting the External
Shunt Module
If your Kinetix 6000 drive requires a means of dissipating regenerative
energy that exceeds the capacity of the 2094 shunt module, install a
Bulletin 1394 external shunt module.
BURN HAZARD
To avoid the hazard of shock or burn and ignition of flammable
material, appropriate guarding must be provided. These
resistors can reach temperatures in excess of 350 ° C (662 ° F).
Install per local codes.
Follow these steps to install your external shunt module.
1. Layout the position for your shunt module in the enclosure.
Follow the panel layout recommendations as shown in External
Shunt Resistor on page 40.
2. Attach the shunt resistor to the cabinet. The recommended
mounting hardware is M6 metric (1/4 in.) bolts.
Follow the recommended high-frequency (HF) bonding
techniques as shown in the Bonding Modules on page 27.
3. Tighten all mounting fasteners.
For external shunt module mounting dimensions, refer to the Kinetix
Motion Control Selection Guide, publication GMC-SG001.
Publication 2094-UM001A-EN-P — September 2006
Chapter
4
Kinetix 6000 Connector Data
Introduction
49
This chapter provides power, feedback, and I/O connector locations
and signal descriptions for your Kinetix 6000 drive.
Topic
Page
Introduction
49
Locating IAM/AM Connectors and Indicators
50
Understanding IAM/AM Signal Specifications
60
Understanding Feedback Specifications
66
Locating Shunt Module Connectors and Indicators
68
Publication 2094-UM001A-EN-P — September 2006
50
Kinetix 6000 Connector Data
Locating IAM/AM
Connectors and Indicators
Although the physical size of the 460V modules is larger than the 230V
modules, the location of the connectors and indicators is identical.
Integrated Axis Module Connectors and Indicators
Integrated Axis Module, Top View
(2094-AM05-MP5-S is shown)
Motor Cable
Shield Clamp
CONT ENCONT EN+
MBRK MBRK +
COM
PWR
DBRK DBRK +
RX
TX
DPI
Motor Power
(MP) Connector
1 2 3 4 5 6
L3
L2
L1
W
V
U
1 2 3 4
CTRL 1
1 2 3 4 5 6 7 8 9
Safe-off
(SO) Connector
(present only on the 2094-xCxx-Mxx-S)
DCDC+
1 2
Contactor Enable
(CED) Connector
CTRL 2
1 2 3 4 5 6
DC Bus / AC Input Power
(IPD) Connector
1 2
Control Power
(CPD) Connector
Motor/Resistive Brake
(BC) Connector
BAUD
RATE
SERCOS Baud Rate
and Optical Power Switches
SERCOS Transmit (Tx) Connector
DPI Connector
SERCOS Receive (Rx) Connector
Integrated Axis Module, Front View
(2094-AC05-MP5-x is shown)
SERCOS
Node Address Switch
Seven-segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
Mounting Screw
Publication 2094-UM001A-EN-P — September 2006
Kinetix 6000 Connector Data
51
Axis Module Connectors and Indicators
W
V
U
1 2 3 4 5 6 7 8 9
Safe-off
(SO) Connector
(present only on the 2094-xMxx-S)
RX
1 2 3 4
Motor Cable
Shield Clamp
MBRK -
Motor Power
(MP) Connector
1 2 3 4 5 6
Axis Module, Top View
(2094-AMP5-S is shown)
MBRK +
COM
PWR
DBRK DBRK +
TX
Motor/Resistive Brake
(BC) Connector
BAUD
RATE
SERCOS Baud Rate
and Optical Power Switches
SERCOS Transmit (Tx) Connector
SERCOS Receive (Rx) Connector
Axis Module, Front View
(2094-AMP5 is shown)
Seven-segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
Mounting Screw
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52
Kinetix 6000 Connector Data
Integrated Axis Module/Axis Module Connectors
Designator
Description
Connector
Present on
IAM or AM
IOD
User I/O (drive)
26-pin high-density D-shell
IAM/AM
MF
Motor feedback
15-pin high-density D-shell (female)
IAM/AM
AF
Auxiliary feedback
15-pin high-density D-shell (male)
IAM/AM
CPD
Control input power (drive)
2-position plug/header
IAM
VAC Input Power (drive) 230V and
dc bus
6-position plug/header
IAM
VAC Input Power (drive) 460V and
dc bus
6-position plug/header
IAM
CED
Contactor enable
2-position plug/header
IAM
MP
Motor power
4-position plug/header
IAM/AM
BC
Dynamic/motor brake
6-position plug/header
IAM/AM
SO
Safe-off
9-position plug/header
IAM/AM
Tx and Rx
SERCOS transmit and receive
SERCOS fiber-optic (2)
IAM/AM
DPI
DPI
DPI
IAM
IPD
Safe-off Connector Pinout
Each IAM (2094-xCxx-Mxx-S) and AM (2094-xMxx-S) ships with the
(9-pin) wiring plug header and motion allowed jumper installed in the
safe-off (SO) connector. With the motion allowed jumper installed, the
safe-off feature is not used.
Motion Allowed Jumper
Kinetix 6000 IAM/AM
(Kinetix 6000 AM is shown)
1
1 2
3 4
5 6
7 8
9
Safe-off
(SO) Connector
Publication 2094-UM001A-EN-P — September 2006
Motion Allowed Jumper
Wiring Plug Header
Kinetix 6000 Connector Data
53
Headers in this table extend the safe-off (SO) connector signals for use
in wiring single and multiple safe-off drive configurations, or to
jumper around (not use) the safe-off feature.
IAM/AM Safe-off 9-pin (SO) Connector
Safe-off (SO)
Connector Pin
Also Applies to These
SO Connector Headers
Description
Signal
1
One side of the normally-closed monitoring contact of relay 2
FDBK2+
2
Other side of the normally-closed monitoring contact of relay 2
FDBK2-
• Wiring plug header
One side of the normally-closed monitoring contact of relay 1
FDBK1+
• First-drive wiring header
(2090-XNSM-W)
Other side of the normally-closed monitoring contact of relay 1
FDBK1-
Coil of safety-relay 2
SAFETY ENABLE2+
6
Return for safety-relay coil power (both relays)
SAFETY ENABLE-
7
Coil of safety relay 1
SAFETY ENABLE1+
3
4
5
8
• Wiring plug header
Power for continuous enable of the safety function, 500 mA max
24V+
9
• Motion allowed jumper
Power return used for continuous enable of safety function
24V_COM
IMPORTANT
Pins SO-8 and -9 (24V+) are only used by the motion allowed
jumper. When wiring to the wiring plug header, the 24V supply
must come from an external source.
Refer to the Kinetix Safe-off Feature Safety Reference Manual,
publication GMC-RM002, for more information on safe-off headers.
Publication 2094-UM001A-EN-P — September 2006
54
Kinetix 6000 Connector Data
I/O Connector Pinout
IAM/AM I/O 26-pin (IOD) Connector
IOD Pin
Description
Signal
IOD Pin
Description
Signal
1
Hardware enable 24V dc power supply
+24V_PWR
14
High speed registration 1 input
REG1
2
Hardware enable input
ENABLE
15
Common for registration
REG_COM
3
Common
+24V_COM
16
24V registration power
REG_24V
4
Home switch 24V dc power supply
+24V_PWR
17
High speed registration 2 input
REG2
5
Home switch input
HOME
18
Common for registration
REG_COM
6
Common
+24V_COM
19
Reserved
—
7
Positive overtravel 24V dc power supply
+24V_PWR
20
Reserved
—
8
Positive overtravel limit switch input
OT+
21
Reserved
—
9
Common
+24V_COM
22
Reserved
—
10
Negative overtravel 24V dc power supply
+24V_PWR
23
Analog output 0
DAC0
11
Negative overtravel limit switch input
OT-
24
Analog output common
DAC_COM
12
Common
+24V_COM
25
Analog output 1
DAC1
13
24V registration power
REG_24V
26
Analog output common
DAC_COM
IMPORTANT
Signals +24V_PWR and +24V_COM are a 24V dc source you
can use only for the inputs listed above.
Pin Orientation for 26-pin I/O (IOD) Connector
26-pin IAM/AM
I/O Connector
Pin 26
Pin 19
Pin 10
Publication 2094-UM001A-EN-P — September 2006
Pin 18
Pin 9
Pin 1
Kinetix 6000 Connector Data
55
Motor Feedback Connector Pinouts
Stegmann Hiperface (SRS/SRM)
MF Pin
Description
Signal
MF Pin
Description
Signal
1
Sine differential input+
SINE+
9
Reserved
—
2
Sine differential input-
SINE-
10
Hiperface data channel
DATA-
3
Cosine differential input+
COS+
11
Motor thermal switch (normally closed) (1)
TS
4
Cosine differential input-
COS-
12
Reserved
—
5
Hiperface data channel
DATA+
13
Reserved
—
6
Common
ECOMM
14
Encoder power (+5V)
EPWR_5VM
7
Encoder power (+9V)
EPWR_9VM
15
Reserved
—
8
Reserved
—
(1)
Not applicable unless motor has integrated thermal protection.
TTL or Sine/Cosine with Index Pulse and Hall Commutation
MF Pin
Description
Signal
MF Pin
Description
Signal
1
AM+ / Sine differential input+
AM+ / SINE+
9
Reserved
—
2
AM- / Sine differential input-
AM- / SINE-
10
Index pulse-
IM-
3
BM+ / Cosine differential input+
BM+ / COS+
11
Motor thermal switch (normally closed) (1)
TS
4
BM- / Cosine differential input-
BM- / COS-
12
Single-ended 5V hall effect commutation
S1
5
Index pulse+
IM+
13
Single-ended 5V hall effect commutation
S2
6
Common
ECOMM
14
Encoder power (+5V)
EPWR_5VM
7
Encoder power (+9V)
EPWR_9VM
15
Reserved
—
8
Single-ended 5V hall effect commutation
S3
(1)
Not applicable unless motor has integrated thermal protection.
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56
Kinetix 6000 Connector Data
Resolver Transmitter (transformation ratio = 0.25)
MF Pin
Description
Signal
MF Pin
Description
Signal
1
Sine differential input+
S2
9
Reserved
—
2
Sine differential input-
S4
10
Resolver excitation
R2
3
Cosine differential input+
S1
11
Motor thermal switch
(normally closed) (1) (2)
TS
4
Cosine differential input-
S3
12
Reserved
—
5
Resolver excitation
R1
13
Reserved
—
6
Common
ECOMM
14
Encoder power (+5V)
EPWR_5VM
7
Encoder power (+9V)
EPWR_9VM
15
Reserved
—
8
Reserved
—
(1)
Not applicable unless motor has integrated thermal protection.
(2)
When using 1326AB (resolver-based) motors, use Low-profile Connector Kit (2090-K6CK-D15MF) that connects the filtered thermal switch (pins 16 and 17) to MF-11 and
MF-6.
IMPORTANT
To meet CE requirements, combined motor power cable length
for all axes on the same dc bus must not exceed 240 m (787 ft)
with 460V systems or 160 m (525 ft) with 230V systems.
Drive-to-motor power cables must not exceed 90 m (295.5 ft).
Pin Orientation for 15-pin Motor Feedback (MF) Connector
15-pin IAM/AM
Motor Feedback Connector
Pin 15
Pin 11
Pin 6
Publication 2094-UM001A-EN-P — September 2006
Pin 10
Pin 5
Pin 1
Kinetix 6000 Connector Data
57
Auxiliary Feedback Connector Pinouts
For TTL devices, the position count will increase when A leads B. For
sinusoidal devices, the position count will increase when cosine leads
sine.
Stegmann Hiperface (SRS and SRM only)
AF Pin
Description
Signal
AF Pin
Description
Signal
1
Sine differential input+
SINE+
9
Reserved
—
2
Sine differential input-
SINE-
10
Hiperface data channel
DATA-
3
Cosine differential input+
COS+
11
Reserved
—
4
Cosine differential input-
COS-
12
Reserved
—
5
Hiperface data channel
DATA+
13
Reserved
—
6
Common
ECOM
14
Encoder power (+5V)
EPWR_5V
7
Encoder power (+9V)
EPWR_9V
15
Reserved
—
8
Reserved
—
TTL or Sine/Cosine with Index Pulse
AF Pin
Description
Signal
AF Pin
Description
Signal
1
A+ / Sine differential input+
A+ / SINE+
9
Reserved
—
2
A- / Sine differential input-
A- / SINE-
10
Index pulse-
I-
3
B+ / Cosine differential input+
B+ / COS+
11
Reserved
—
4
B- / Cosine differential input-
B- / COS-
12
Reserved
—
5
Index pulse+
I+
13
Reserved
—
6
Common
ECOM
14
Encoder power (+5V)
EPWR_5V
7
Encoder power (+9V)
EPWR_9V
15
Reserved
—
8
Reserved
—
Pin Orientation for 15-pin Auxiliary Feedback (AF) Connector
15-pin IAM/AM
Auxiliary Feedback Connector
Pin 6
Pin 11
Pin 1
Pin 15
Pin 5
Pin 10
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Kinetix 6000 Connector Data
IAM Input Connector Pinouts
Control Power Connector
CPD Pin
1
2
Description
Control power VAC input
Signal
CTRL 2
CTRL 1
DC Bus and Input Power Connector
IPD Pin
Description
Signal
1
DC-
2
An integral, unregulated power supply,
consisting of ac line input, three-phase
bridge rectifier, and filter capacitors.
3
Chassis ground.
4
5
DC+
L3
Three-phase input power.
6
L2
L1
Contactor Enable Connector
CED Pin
Description
Signal
1
Relay-driven dry contact used in the
safety string for a three-phase power
contactor.
CONT EN-
2
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CONT EN+
Kinetix 6000 Connector Data
59
IAM and AM Motor Power and Brake Connector Pinouts
Motor Power Connector
MP Pin
Description
4
Chassis ground
Signal
3
2
W
Three-phase motor power
V
1
U
IMPORTANT
To meet CE requirements, combined motor power cable length
for all axes on the same dc bus must not exceed 240 m (787 ft)
with 460V systems or 160 m (525 ft) with 230V systems.
Drive-to-motor power cables must not exceed 90 m (295.5 ft).
Motor Brake/Resistive Brake Connector
BC Pin
6
5
Description
Signal
MBRK-
Motor brake connections
MBRK+
4
Motor brake common
COM
3
+24V brake input power (from LIM or
customer supplied)
PWR
2
Resistive brake module (RBM)
connections (from RBM and safety
string)
DBRK-
1
DBRK+
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Kinetix 6000 Connector Data
Understanding IAM/AM
Signal Specifications
A description of the Kinetix 6000 IAM/AM input/output (IOD),
SERCOS, contactor enable (CED), brake (BC), and control power
(CPD) connectors is provided on the following pages.
Digital Inputs
Two fast registration inputs and four other inputs are available for the
machine interface on the integrated sxis module (IAM) and axis
module (AM). Each IAM and AM supplies 24V dc @ 500 mA 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 power and common connection is provided
for each input.
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.
Understanding Digital Inputs
IOD Pin
Signal
Description
Capture
Time
Edge/Level
Sensitive
IOD-2
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 each
axis.
20 ms
Level
IOD-5
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).
20 ms
Level
IOD-14
IOD-17
REG1
REG2
Fast registration inputs are required to inform the motor interface to
capture the positional information with less than 3 μs uncertainty. Optically
isolated, single-ended active high signal. Current loading is nominally
10 mA. A 24V dc input is applied to this terminal to enable each axis.
500 ns
Edge
IOD-8
IOD-11
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).
20 ms
Level
Min
Max
ENABLE, HOME, and OT+/OT-
10.8V
26.4V
REG1 and REG2
21.6V
26.4V
Digital Input Specifications
Parameter
Description
On-state voltage
Voltage applied to the input, with respect
to IOCOM, to guarantee an on-state.
On-state current
Current flow to guarantee an on-state.
3.0 mA
10.0 mA
Off-state voltage
Voltage applied to the input, with respect to IOCOM, to guarantee an
off-state.
-1.0V
3.0V
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Kinetix 6000 Connector Data
61
Enable, Home, and Overtravel Digital Input Circuits
24V dc (1)
I/O SUPPLY
IOD-1, -4, -7, -10
INPUT
IOD-2, -5, -8, -11
VCC
3k Ω
0.1 μF
IO_COM
CTRL_INPUT
511 Ω
IOD-3, -6, -9, -12
1k Ω
Customer-supplied Input Device
Kinetix 6000 IAM/AM
(1)
24V dc source (range) = 21.6V - 26.4V (supplied by drive, not to exceed 500 mA total).
Maximum current input = 10 mA
Registration Digital Input Circuits
+24V dc
IOD-13, -16
I/O SUPPLY
VCC
INPUT
IOD-14, -17
1k Ω
3k Ω
0.001 μF
IO_COM
511 Ω
REG_INPUT
HCPL-0631
IOD-15, -18
Customer-supplied Registration
Input Device
Kinetix 6000 IAM/AM
SERCOS Connections
Two fiber-optic connectors (transmit and receive) are provided on the
integrated axis module (IAM) and axis module (AM).
SERCOS Communications Specifications
Specification
Description
Data Rates
2, 4, and 8 Mbps
Node Addresses
01...99 (1)
(1)
Node address assignments begin with the integrated axis module (IAM). Node addresses for additional axes on
the same power rail are assigned by incrementing from left to right (starting with the IAM address).
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Kinetix 6000 Connector Data
Analog Outputs
The integrated axis module (IAM) and axis module (AM) include two
analog outputs (IOD-23 and -25) that can be configured through
software to represent drive variables.
Analog Output Circuit
Oscilloscope
2.5V = 0 ref
Kinetix 6000 IAM/AM
2.5V
CH1
CH2
DAC
(second channel not shown)
IMPORTANT
Output values can vary during power-up until the specified
power supply voltage is reached.
Analog Output Specifications
Parameter
Description
Min
Max
Resolution
Number of states that the output signal is divided
into, which is 2 (to the number of bits).
—
±11 bits
Output
current
Current capability of the output.
0
+2 mA
Output signal
range
Range of the output voltage.
0
+5V
Offset error
Deviation when the output should be at 0V.
—
1 mV
Bandwidth
Frequency response of the analog output
dc
7.2k Hz (3 db)
For configuration/setup of the analog outputs, refer to Supplemental
Troubleshooting Information beginning on page 160.
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Kinetix 6000 Connector Data
63
Contactor Enable Relay
Contactor enable is a relay-driven contact used in the safety control
string to protect the drive electronics during certain fault conditions. It
is capable of handling 120V ac or 24V dc at 1 A or less. Contactor
enable is a function of the converter and is not available in the axis
modules. An active state indicates the drive is operational and does
not have a fault.
ATTENTION
Wiring the contactor enable relay is required. To avoid personal
injury or damage to the drive, wire the contactor enable relay
into your safety control string so that:
• three-phase power is removed from the drive in the event of
shutdown fault conditions.
• drive operation is prevented when the Power Rail is not fully
populated.
• control power is applied to the drive prior to three-phase
power.
Refer to IAM Wiring Example (without LIM) on page 196 for a
wiring example.
IMPORTANT
All power rail slots must have a module installed or the
contactor enable relay will not close.
Contactor Enable Relay Circuit
CONT EN+
Normally
Open
Relay
CONT EN-
Kinetix 6000 IAM
Contactor Enable Relay Output Specifications
Parameter
Description
Min
Max
On-state
current
Current flow when the relay is closed
—
1A
On-state
resistance
Contact resistance when the relay is closed
—
1Ω
Off-state
voltage
Voltage across the contacts when the relay is open
—
120V ac or
24V dc
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Kinetix 6000 Connector Data
Motor/Resistive Brake Relay
Two connections are required for the (customer-supplied) motor/
resistive brake input power (BC-3 and -4) and two connections each
for the motor and resistive brake output, as shown in the figure
below. Connections are rated for +24V and current as shown in the
table below.
An active signal releases the motor brake (BC-5 and -6). The brake
signal is the same as the contactor enable signal, with the addition of
the turn-on and turn-off delays specified by the brake active delay and
brake inactive delay (configurable in RSLogix 5000 software). Refer to
Axis Module/Motor Wiring Examples beginning on page 204 and
Controlling a Brake Example on page 210 for wiring examples.
The resistive brake relay (BC-1 and -2) controls the resistive brake
module (RBM) contactor. The RBM is wired between the drive and
motor, using an internal contactor to switch the motor between the
drive and a resistive load. The RBM contact delay is the time it takes
to fully close the contactor across the motor power input lines, and
must be configured in RSLogix 5000 software. Refer to Integrating
Resistive Brake Modules with Kinetix 6000 Drives beginning on page
239 for wiring examples.
Brake Relay Circuit
Kinetix 6000 IAM/AM
1
COM
(BC-4)
(1)
DBRK(BC-2)
1
DBRK+
(BC-1)
MBRK(BC-6)
MBRK+
(BC-5)
PWR
(BC-3)
Noise suppression device.
Brake Relay Output Specifications
Parameter
Description
IAM/AM
2094-AC05-Mxx, -AC09-Mxx,
2094-AMP5, -AM01, -AM02
On-state current (1)
1.0 A
2094-AC16-Mxx, -AC32-Mxx,
2094-AM03, -AM05
1.3 A
2094-BC04-Mxx, -BC07-Mxx,
2094-BM03, -BM05
3.0 A
On-state resistance
Contact resistance when the relay is closed
1Ω
Off-state voltage
Voltage across the contacts when the relay is open
30V
(1)
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Current flow when the
relay is closed
2094-BC01-Mxx, -BC02-Mxx,
2094-BMP5, -BM01, -BM02
Max
For motors requiring more than the maximum current specified, a relay must be added.
Kinetix 6000 Connector Data
65
Control Power Input
The integrated axis module (IAM) requires ac input power for logic
circuitry.
IMPORTANT
The control power input requires an ac (EMC) line filter for CE
certification. For wiring examples, refer to Power Wiring
Examples beginning on page 193.
IMPORTANT
Source 2094-ACxx-Mxx (230V) IAM control power from the
three-phase input power (line-to-line). Supplying 230V control
power from any other source requires an isolation transformer.
If used, do not ground either leg of the isolation transformer
output. Control power isolation, via a step-down transformer, is
required for all 460V applications.
Refer to Transformer Specifications for Control Power Input on
page 179.
Control Power Current Specifications
Specification
Description
Input voltage
95...264V ac rms, single-phase
Input power frequency
47...63 Hz
Control Power Current Requirements
Number of Axis
Modules (1)
Current Requirements
(110/115V ac input)
Current Requirements
(220/230V ac input)
Input VA
0
750 mA
350 mA
150 VA
1
1.5 A
700 mA
200 VA
2
2.25 A
1A
275 VA
3
3A
1.35 A
350 VA
4
3.75 A
1.7 A
450 VA
5
4.5 A
2A
550 VA
6
5.25 A
2.4 A
650 VA
7
6A
3A
750 VA
(1)
This number does not include the axis module (inverter section) that resides inside the integrated axis module.
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Kinetix 6000 Connector Data
Understanding Feedback
Specifications
The integrated axis module (IAM) and axis module (AM) can accept
motor and auxiliary feedback signals from the following types of
encoders:
•
Stegmann Hiperface
•
TTL or Sine/Cosine with index pulse and Hall commutation
•
Resolver Transmitter TR = 0.25 (motor feedback only)
Auto-configuration in RSLogix 5000 software of intelligent
absolute, high-resolution, and incremental encoders is possible
only with Allen-Bradley motors.
TIP
Motor and Auxiliary Feedback Specifications
AM, BM, and IM input encoder signals are filtered using analog and
digital filtering. The inputs also include illegal state change detection.
AM, BM, and IM Motor Encoder Input Circuits
+5 V
1k Ω
10k Ω
+
1k Ω
56 pF
+
1k Ω
56 pF
1k Ω
56 pF
100 pF
1k Ω
1k Ω
10k Ω
1k Ω
56 pF
1k Ω
56 pF
10k Ω
1k Ω
56 pF
100 pF
10k Ω
Drive
Drive
AM and BM Channel Inputs
IM Channel Input
Motor Encoder Feedback Specifications
Specification
Description
Encoder types
Incremental, A quad B, sine/cosine, intelligent, resolver, and
absolute
Maximum input frequency
Commutation feedback
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5.0 MHz (TTL input) per channel
250 kHz (sine/cosine input)
Hall sensor
Kinetix 6000 Connector Data
67
AM, BM, and IM Input Specifications for TTL Encoders
Parameter
Description
Min
Max
AM, BM, and IM
On-state input voltage
Input voltage difference between the plus (+) input and
the minus (-) input that is detected as an on-state.
+1.0V
+7.0V
AM, BM, and IM
Off-state input voltage
Input voltage difference between the plus (+) input and
the minus (-) input that is detected as an off-state.
-1.0V
-7.0V
Common mode
input voltage
Potential difference between any encoder signal and
logic ground.
-7.0V
+12.0V
DC current draw
Current draw into the + or - input.
-30 mA
30 mA
AM, BM input
signal frequency
Frequency of the AM or BM signal inputs. The count
frequency is 4 times this frequency, since the circuitry
counts all four transitions.
—
5.0 MHz
IM pulse width
Pulse width of the index input signal. Since the index is
active for a percentage of a revolution, the speed will
determine the pulse width.
125 nS
—
AM, BM phase error
2.5 MHz line frequency
Amount that the phase relationship between the AM
and BM inputs can deviate from the nominal 90°.
-22.5°
+22.5°
AM, BM phase error
1 MHz line frequency
Amount that the phase relationship between the AM
and BM inputs can deviate from the nominal 90°.
-45°
+45°
AM, BM, and IM Input Specifications for Sine/Cosine Encoders
Parameter
Description
Min
Max
Sine/cosine
input signal
frequency
Frequency of the Sine or Cosine signal inputs.
—
250 kHz
Sine/cosine
input voltage
Peak-to-peak input voltages of the Sine or Cosine
inputs.
0.5V (p-p)
2.0V (p-p)
Feedback Power Supply
The IAM and AM power circuit board generates +5V and +9V dc for
motor and auxiliary feedback power. Short circuit protection and
separate common mode filtering for each channel is included.
Motor and Auxiliary Feedback Power Specifications
Supply
Reference
+5V dc
+9V dc
Voltage
Current mA
Min
Nominal
Max
Min
Max
EPWR_5V
5.13
5.4
5.67
10
400 (1) (3)
EPWR_9V
8.3
9.1
9.9
10
275 (2) (3)
(1)
400 mA on the 5V supply split in any manner between the channels with no load on the 5V supply.
(2)
275 mA on the 9V supply split in any manner between the channels with no load on the 9V supply.
(3)
300 mA on the 5V supply on one channel with 150 mA on the 9V supply on the second channel.
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Kinetix 6000 Connector Data
Locating Shunt Module
Connectors and Indicators
The Kinetix 6000 shunt module (2094-BSP2) is suitable for both 230V
and 460V applications.
Locating Shunt Module Connectors and Indicators
Shunt Module, Front View
(2094-BSP2)
TS2
TS1
External Shunt Resistor
(RC) Connector
Shunt Module, Front View
(2094-BSP2)
External Thermal Switch
(TS) Connector
1 2
COL
INT
DC+
1 2 3
Motor Cable
Shield Clamp
Shunt Fault LED
Over-Temp Fault LED
Bus Status LED
Mounting Screw
Shunt Module Connectors
Designator
Description
Connector
RC
External shunt resistor connector
Three-position connector housing
TS
Thermal switch connector
Two-position connector housing
External Shunt Resistor Three-pin (RC) Connector Pinout
RC Pin
Description
Signal
1
External shunt resistor connection
DC+
2
Internal shunt connection
INT
3
Shunt collector connection
COL
External Thermal Switch Two-pin (TS) Connector Pinout
TS Pin
Description
Signal
1
External passive shunt module thermal
switch connections
TS1
2
TS2
Refer to Understanding External Shunt Module Connections on page
113 when wiring the RC and TS connectors.
Publication 2094-UM001A-EN-P — September 2006
Chapter
5
Connecting the Kinetix 6000 Drive System
Introduction
Understanding Basic
Wiring Requirements
This chapter provides procedures for wiring your Kinetix 6000 system
components and making cable connections.
Topic
Page
Introduction
69
Understanding Basic Wiring Requirements
69
Determining Your Type of Input Power
71
Setting the Ground Jumper in Ungrounded Power Configurations
75
Grounding Your Kinetix 6000 System
78
Power Wiring Requirements
80
Wiring Guidelines
83
Wiring the LIM Connectors
84
Wiring the IAM/AM Connectors
90
Applying the Motor Cable Shield Clamp
103
Understanding Feedback and I/O Cable Connections
104
Understanding External Shunt Module Connections
113
Understanding Resistive Brake Module Connections
114
Connecting Your SERCOS Fiber-optic Cables
115
This section contains basic wiring information for the Kinetix 6000
drive.
ATTENTION
SHOCK HAZARD
69
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.
To avoid hazard of electrical shock, perform all mounting and
wiring of IAM, AM, SM, LIM, RBM, or power rail prior to
applying power. Once power is applied, connector terminals
may have voltage present even when not in use.
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Connecting the Kinetix 6000 Drive System
IMPORTANT
This section contains common PWM servo system wiring
configurations, size, and practices that can be used in a
majority of applications. National Electrical Code, local
electrical codes, special operating temperatures, duty cycles, or
system configurations take precedence over the values and
methods provided.
Building Your Own Cables
IMPORTANT
Factory-made cables are designed to minimize EMI and are
recommended over hand-built cables to optimize system
performance.
•
Connect the cable shield to the connector shells on both ends of
the cable with a complete 360° connection.
•
Use a twisted pair cable whenever possible. Twist differential
signals with each other and twist single-ended signals with the
appropriate ground return.
Refer to the Kinetix Motion Control Selection Guide, publication
GMC-SG001 for low profile connector kit, drive-end (mating)
connector kit, and motor-end connector kit catalog numbers.
Routing Power and Signal Wiring
Be aware that when you route power and signal wiring on a machine
or system, radiated noise from nearby relays, transformers, and other
electronic drives can be induced into motor or encoder feedback
signals, input/output communications, or other sensitive low voltage
signals. This can cause system faults and communication problems.
Refer to Minimizing Electrical Noise 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.
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
Determining Your Type of
Input Power
71
Before wiring input power to your Kinetix 6000 system, you must
determine the type of input power you are connecting to. The IAM is
designed to operate in both grounded and ungrounded environments.
ATTENTION
When using a LIM with your Kinetix 6000 drive, the VAC LINE
input power must come from a grounded configuration (refer to
the figure below).
When not using a LIM with your Kinetix 6000 drive, ungrounded
configurations are permitted, but you must set the jumper to
prevent high electrostatic build-up.
Refer to Setting the Ground Jumper in Ungrounded Power
Configurations on page 75 for more information.
Grounded Power Configurations
The grounded (WYE) power configuration lets you ground your
three-phase power at a neutral point. This type of grounded power
configuration is preferred.
Grounded Power Configuration (WYE Secondary)
L1
1 2
Three-phase
Input VAC
L3
L2
L1
CONT ENCONT EN+
W
V
U
1 2 3 4 5 6 7 8 9
L2
DCDC+
MBRK MBRK +
COM
PWR
1 2 3 4 5 6
Transformer
CTRL 2
CTRL 1
1 2 3 4 5 6
L3
1 2
Transformer (WYE) Secondary
1 2 3 4
Integrated Axis Module, Top View
(2094-ACxx-Mxx-S is shown)
DBRK DBRK +
RX
TX
DPI
Phase Ground
BAUD
RATE
Bonded Cabinet
Ground
Ground Grid or
Power Distribution Ground
Connect to power rail ground stud.
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72
Connecting the Kinetix 6000 Drive System
Grounded (B-Phase) Power Configuration (Delta Secondary)
DC-
W
DC+
L2
L1
1 2
CONT ENCONT EN+
L2
1 2 3 4 5 6 7 8 9
L3
V
U
MBRK -
1 2 3 4 5 6
L3
1 2 3 4 5 6
Transformer
1 2
Transformer (Delta) Secondary
CTRL 2
CTRL 1
1 2 3 4
Integrated Axis Module, Top View
(2094-BCxx-Mxx-S is shown)
MBRK +
COM
PWR
DBRK DBRK +
RX
TX
DPI
BAUD
RATE
L1
Bonded Cabinet
Ground
Connect to power rail ground stud.
Ground Grid or
Power Distribution Ground
The integrated axis module (IAM) has a factory-installed ground
jumper configured for grounded power distribution.
IMPORTANT
Publication 2094-UM001A-EN-P — September 2006
If you determine that you have grounded power distribution in
your plant, you do not need to modify your IAM.
Connecting the Kinetix 6000 Drive System
73
Ungrounded Power Configurations
Ungrounded power configurations are allowed, but you must jumper
across a 120 kΩ resistor (internal to the IAM) to prevent high
electrostatic build-up. The ungrounded power configuration (shown
below) does not provide a neutral ground point. The IAM has a
ground jumper set for grounded power distribution (default
configuration).
If you determine that you have ungrounded power distribution
in your facility, you need to move the default jumper (configured
for grounded power) to the ungrounded power position to
prevent electrostatic buildup inside the IAM.
IMPORTANT
Refer to Setting the Ground Jumper in Ungrounded Power
Configurations on page 75 for more information.
Ungrounded Power Configuration
CONT ENCONT EN+
MBRK MBRK +
1 2 3 4 5 6
L3
L2
L1
W
V
U
1 2 3 4 5 6 7 8 9
DCDC+
1 2
L1
1 2 3 4 5 6
L2
Three-phase
Input VAC
1 2
L3
Transformer
CTRL 2
CTRL 1
1 2 3 4
Integrated Axis Module, Top View
(2094-BCxx-Mxx-S is shown)
COM
PWR
DBRK DBRK +
RX
TX
DPI
Chassis Ground
BAUD
RATE
Bonded Cabinet
Ground
Ground Grid or
Power Distribution Ground
ATTENTION
Connect to power rail ground stud.
Ungrounded systems do not reference each phase potential to a
power distribution ground. This can result in an unknown
potential to earth ground.
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74
Connecting the Kinetix 6000 Drive System
DC Common Bus
Configurations
When an integrated axis module (IAM) is used in a dc common bus
configuration, the IAM is known as a leader IAM or follower IAM. The
IAM (non-common bus) and leader IAM have identical three-phase
input power connections. The leader IAM is responsible for
discharging the dc bus, and for providing common bus follower drives
with dc bus pre-charge, bus regulation, phase-loss detection, and
ground fault detection. Follower IAMs do not have three-phase input
power connections, but have dc bus connections from a leader IAM.
IAM Terminology and Use
This IAM
Is Wired
And is
IAM
With three-phase input power.
Not wired in common bus mode.
Leader IAM
With three-phase input power, but has dc common
bus connections to a follower IAM.
Wired in common bus mode.
Follower IAM
Without three-phase input power, but has dc
common bus connections from a leader IAM.
Wired in common bus mode and
configured using RSLogix 5000 software.
Use Kinetix 6000 drive firmware v1.85 and RSLogix 5000
software v15 or later, for dc common bus power configurations.
IMPORTANT
The Kinetix 6000 leader IAM can operate with non-Kinetix 6000
follower drives, as can the Kinetix 6000 follower IAM operate with
non-Kinetix 6000 common bus leader drives. However, non-Kinetix
6000 leader and follower drives must meet the same functional
requirements as the Kinetix 6000 leader and follower IAMs.
Any non-Kinetix 6000 common bus leader that does not provide
pre-charge is required to add an additional external pre-charge
circuit before connecting to any Kinetix 6000 common bus
follower IAM.
IMPORTANT
Typical DC Common Bus Configuration
BAUD
RATE
RX
DBRK +
TX
L3
L2
L1
CONT ENCONT EN+
RX
BAUD
RATE
RX
TX
DPI
N.C.
N.C.
N.C.
BAUD
RATE
MBRK +
COM
PWR
DBRK DBRK +
TX
1 2 3 4
1 2 3 4
1 2 3 4
MBRK -
MBRK MBRK +
COM
PWR
DBRK DBRK +
MBRK -
BAUD
RATE
RX
1 2 3 4 5 6
PWR
W
V
U
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
TX
1 2 3 4
1 2 3 4
1 2 3 4
1 2 3 4 5 6
Publication 2094-UM001A-EN-P — September 2006
DBRK +
COM
DBRK -
W
V
U
1 2 3 4 5 6 7 8 9
DC Common Bus
Connections
MBRK MBRK +
Axis Module
(2094-xMxx-S)
1 2 3 4 5 6 7 8 9
BAUD
RATE
PWR
W
V
U
DC+
1 2 3 4 5 6 7 8 9
TX
DPI
COM
DBRK -
DC-
1 2
RX
RX
MBRK +
CTRL 2
CTRL 1
1 2 3 4 5 6
1 2
CONT ENCONT EN+
MBRK -
MBRK MBRK +
COM
PWR
DBRK DBRK +
W
V
U
1 2
L2
L1
W
V
U
1 2 3 4 5 6 7 8 9
L3
W
V
U
1 2 3 4 5 6 7 8 9
DCDC+
1 2 3 4 5 6 7 8 9
CTRL 2
CTRL 1
1 2 3 4 5 6
Three-phase
Input Power
1 2
Bonded Cabinet
Ground
Integrated Axis Module
(2094-xCxx-Mxx-S)
Common Bus Follower IAM
Axis Module
(2094-xMxx-S)
1 2 3 4 5 6
Integrated Axis Module
(2094-xCxx-Mxx-S)
Common Bus Leader IAM
MBRK +
COM
PWR
DBRK DBRK +
TX
BAUD
RATE
Connecting the Kinetix 6000 Drive System
75
Common Bus Fusing Requirements
When using a Kinetix 6000 leader IAM, dc bus fuses are only required
when wiring to more than one Kinetix 6000 follower IAM. When
wiring multiple follower IAMs, terminal blocks are required to extend
the dc common bus power to additional drives. Fuses should be
installed in both lines of the dc bus between the dc bus terminal block
and each follower IAM. These fuses should be rated based on the dc
input current of each follower IAM.
When using a non-Kinetix 6000 common bus leader, dc bus fuses are
required in both lines of the dc bus, between the common bus leader
and follower IAM. These fuses should be rated based on the leader’s
dc output current. When using more than one follower IAM, fuses
should be installed in both lines of the dc bus between the
non-Kinetix 6000 common bus leader and the terminal block as well
as between the dc bus terminal block and each follower IAM.
Refer to Circuit Breaker/Fuse Specifications on page 177 for
recommended fuse sizes. Refer to DC Common Bus Wiring Examples
on page 197 for interconnect diagrams.
Setting the Ground Jumper
in Ungrounded Power
Configurations
Setting the ground jumper is only necessary when using an
ungrounded power configuration. Setting the jumper involves
removing the IAM from the power rail, opening the IAM, and moving
the jumper.
Setting the ground jumper is best done when the integrated axis
module (IAM) is removed from the power rail and placed face-up on
a solid surface equipped as a grounded static safe workstation.
ATTENTION
To avoid personal injury and/or equipment damage, remove the
IAM from the power rail before setting the ground jumper.
To remove the IAM from the power rail, refer to Removing Power Rail
Modules on page 164.
IMPORTANT
If you have grounded power distribution, you do not need to set
the ground jumper. Go to Grounding Your Kinetix 6000 System
on page 78.
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76
Connecting the Kinetix 6000 Drive System
When using ungrounded input power in common bus configurations,
use the table below to determine where to set the ground jumper.
Ground Jumper to Set
When Leader Drive is
And Follower Drive is
Then Set the Jumper in This
Drive
Kinetix 6000 IAM
Kinetix 6000 IAM
Leader Drive.
Kinetix 6000 IAM
non-Kinetix 6000 IAM
Leader Drive.
non-Kinetix 6000 IAM
Kinetix 6000 IAM
Follower Drive (if no setting
exists in the leader drive).
Setting the Ground Jumper
Follow these steps to set the ground jumper.
1. Remove the top and bottom front panel screws.
Refer to the appropriate figure for your 230V or 460V IAM.
Setting the Ground Jumper (230V IAM)
Top Screw
P17
P16
Integrated Axis Module (230V)
2094-ACxx-Mxx-S
P15
Ground jumper set
for ungrounded configuration.
Ground jumper set
for grounded configuration
(default setting).
Front Panel (opened)
Publication 2094-UM001A-EN-P — September 2006
Bottom Screw
Connecting the Kinetix 6000 Drive System
77
Setting the Ground Jumper (460V IAM)
Top Screw
Integrated Axis Module (460V)
2094-BCxx-Mxx-S
P13
P14
P12
Ground jumper set
for ungrounded configuration.
Ground jumper set
for grounded configuration
(default setting)
Front Panel (opened)
Bottom Screw
2. Swing the front panel open to the right, as shown, and locate the
ground jumper.
IMPORTANT
Do not attempt to remove the front panel from the IAM.
The front panel LEDs and switches are also connected to
the IAM with a ribbon cable. The ribbon cable will act like
a hinge and allow you to swing the front panel open and
access the ground jumper.
3. Determine if you have a 230V system or 460V system.
For This IAM
Move the Ground Jumper From
2094-ACxx-Mxx-S (230V)
P16 to P17
2094-BCxx-Mxx-S (460V)
P14 to P12
4. Replace the IAM front panel and two screws.
Apply 1.6 Nm (14 lb-in) torque.
5. Mount the IAM back on the power rail.
Refer to Mounting the Modules on page 45 for instructions.
Publication 2094-UM001A-EN-P — September 2006
78
Connecting the Kinetix 6000 Drive System
Grounding Your
Kinetix 6000 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 16.
Grounding Your System to the Subpanel
The 2094 power rail (2094-PRx or 2094-PRSx) ships with a braided
ground strap, 100 mm (3.9 in.), that connects to the bonded cabinet
ground bus. Connect the other end to either the power rail ground
stud or mounting bracket ground stud, if mounting brackets are used.
Connecting the Braided Ground Strap Examples
Braided
Ground Strap
2094 Power Rail
(2094-PRSx shown)
PRS
PR
PR
Bonded Cabinet
Ground Bus
LIM
Ground Grid or Power
Distribution Ground
Line Interface Module
on 2094 Mounting Brackets
(2094-ALxxS shown)
Ground Stud
2094 Mounting Bracket
(2094-XNBRKT-1)
2094 Mounting Bracket
(2094-XNBRKT-1)
LIM
Ground Stud
PR
LIM
Braided
Ground Strap
LIM
Bonded Cabinet
Ground Bus
Braided
Ground Strap
PRS
Ground Stud
PRS
PR/PRS
PR
PR
2094 Power Rail
on 2094 Mounting Brackets
(2094-PRSx shown)
Bonded Cabinet
Ground Bus
Ground Grid or Power
Distribution Ground
Publication 2094-UM001A-EN-P — September 2006
Ground Grid or Power
Distribution Ground
Connecting the Kinetix 6000 Drive System
79
For power rail dimensions, refer to the Kinetix 6000 Power Rail
Installation Instructions, publication 2094-IN003.
For mounting bracket dimensions, refer to the 2094 Mounting
Brackets Installation Instructions, publication 2094-IN008.
IMPORTANT
When 2094 mounting brackets are used to mount the power rail
or LIM over the ac line filter, the braided ground strap must be
removed from the power rail and attached to a mounting
bracket ground stud.
Grounding Multiple Subpanels
Extending the chassis ground to multiple subpanels is illustrated in the
figure below. High-frequency (HF) bonding is not illustrated.
Subpanels Connected to a Single Ground Point
Follow NEC and
applicable local codes.
Bonded Ground Bus
Ground Grid or Power
Distribution Ground
For HF bonding information, refer to Bonding Multiple Subpanels on
page 29.
Publication 2094-UM001A-EN-P — September 2006
80
Connecting the Kinetix 6000 Drive System
Wire should be copper with 75 ° C (167 ° F) minimum rating. Phasing
of main ac power is arbitrary and earth ground connection is required
for safe and proper operation.
Power Wiring
Requirements
IMPORTANT
The National Electrical Code and local electrical codes take
precedence over the values and methods provided.
IAM Power Wiring Requirements
Connects to Terminals
Module
IAM
(230V)
Catalog Number
2094-AC16-Mxx-S
2094-BC01-Mxx-S
2094-BC02-Mxx-S
DC bus (1)
and
VAC input power
(2)
IPD-1
IPD-2
IPD-3
IPD-4
IPD-5
IPD-6
DCDC+
L3
L2
L1
Torque Value
Nm (lb-in)
2.5 (14)
10 (0.38)
0.5 - 0.6
(4.4 - 5.3)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
10 (0.38)
1.2 - 1.5
(10.6 - 13.2)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
10 (8)
25 (4)
4.0 (12)
10 (8)
2094-BC07-Mxx-S
25 (4)
2094-xCxx-Mxx-S
Contactor Enable
(1)
Signal
Recommended
Wire Size
Strip Length
mm2 (AWG)
mm (in.)
2094-BC04-Mxx-S
Control input power
IAM
(230V or 460V)
Pin
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-AC32-Mxx-S
IAM
(460V)
Description
CPD-1
CTRL 2
CPD-2
CTRL 1
CED-1
CONT EN-
CED-2
CONT EN+
0.5 - 0.6
(4.4 - 5.3)
2.5 (14)
10 (0.38)
2.5 (14) (2)
0.5 - 0.6
(4.4 - 5.3)
DC common bus connections (leader IAM to follower IAM) should be kept as short as possible.
The actual gauge of the contactor enable wiring depends on the system configuration. Consult your machine builder, the NEC, and applicable local codes.
ATTENTION
To avoid personal injury and/or equipment damage, make sure
installation complies with specifications regarding wire types,
conductor sizes, branch circuit protection, and disconnect
devices. The National Electrical Code (NEC) and local codes
outline provisions for safely installing electrical equipment.
To avoid personal injury and/or equipment damage, make sure
motor power connectors are used for connection purposes only.
Do not use them to turn the unit on and off.
To avoid personal injury and/or equipment damage, make sure
shielded power cables are grounded to prevent potentially high
voltages on the shield.
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
81
IAM/AM Power Wiring Requirements
Connects to Terminals
Module
Catalog Number
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-AMP5-S, -AM01-S,
-AM02-S, -BMP5-S,
-BM01-S, and -BM02-S
Description
Motor power
2094-AC16-Mxx-S
2094-AC32-Mxx-S
2094-AM03-S, -AM05-S
Pin
Signal
MP-4
MP-3
MP-2
MP-1
W
V
U
2094-BC04-Mxx-S
2094-BC07-Mxx-S
2094-BM03-S, -BM05-S
IAM or AM
IAM or AM
(230 or 460V)
2094-xCxx-Mxx-S and
2094-xMxx-S
IAM or AM
(230 or 460V)
2094-xCxx-Mxx-S and
2094-xMxx-S
Brake power
BC-6
BC-5
BC-4
BC-3
BC-2
BC-1
MBRKMBRK+
COM
PWR
DBRKDBRK+
Safe-off
SO-1
SO-2
SO-3
SO-4
SO-5
SO-6
SO-7
SO-8
SO-9
FDBK2+
FDBK2FDBK1+
FDBK1SAFETY
ENABLE2+
SAFETY
ENABLESAFETY
ENABLE1+
24V +
24V_COM
Recommended
Wire Size
Strip Length
mm2 (AWG)
mm (in.)
Motor power
cable depends
on motor/drive
combination.
Torque Value
Nm (lb-in)
10 (0.38)
0.5 - 0.6
(4.4 - 5.3)
10 (0.38)
1.2 - 1.5
(10.6 - 13.2)
25 (4) max
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
0.75 (18)
10 (0.38)
0.22 - 0.25
(1.9 - 2.2)
7.0 (0.275)
0.235 (2.0)
6 (10) max
0.75 (18)
(stranded wire
with ferrule)
1.5 (16)
(solid wire)
Shunt Module Power Wiring Requirements
Connects to Terminals
Module
SM (230/460V)
2094-BSP2
Description
1394-SR-xxxx
External passive
shunt module
Thermal switch
(1)
Pin
Signal
RC-1
DC+
RC-2
INT
RC-3
COL
TS-1
TS1
TS-2
TS2
Recommended
Wire Size
mm2 (AWG)
Torque Value
Nm (lb-in)
10 (8) (1)
1.2 - 1.5
(10.6 - 13.2)
0.75 (18)
0.22 - 0.25
(1.9 - 2.2)
105 °C (221 °F), 600V.
Publication 2094-UM001A-EN-P — September 2006
82
Connecting the Kinetix 6000 Drive System
Refer to Power Specifications on page 170 for additional information.
Refer to Power Wiring Examples on page 193 for interconnect
diagrams.
ATTENTION
ATTENTION
This drive contains ESD (Electrostatic Discharge) 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 Allen-Bradley publication
8000-4.5.2, Guarding Against Electrostatic Damage or any other
applicable ESD Protection Handbook.
To avoid personal injury and/or equipment damage, ensure
installation complies with specifications regarding wire types,
conductor sizes, branch circuit protection, and disconnect
devices. The National Electrical Code (NEC) and local codes
outline provisions for safely installing electrical equipment.
To avoid personal injury and/or equipment damage, ensure
motor power connectors are used for connection purposes only.
Do not use them to turn the unit on and off.
To avoid personal injury and/or equipment damage, ensure
shielded power cables are grounded to prevent potentially high
voltages on the shield.
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
Wiring Guidelines
83
Use these guidelines as a reference when wiring the connectors on
your Kinetix 6000 drive modules or line interface module (LIM).
IMPORTANT
Refer to page 50 for the connector locations of the Kinetix 6000
drive modules.
When tightening screws to secure the wires, refer to the tables
beginning on page 80 for torque values.
When removing insulation from wires, refer to the tables
beginning on page 80 for strip lengths.
IMPORTANT
To ensure system performance, run wires and cables in the
wireways as established in Establishing Noise Zones on page
30.
Refer to the Line Interface Module Installation Instructions, publication
2094-IN005, for LIM power wiring requirements and connector
locations. Refer to Wiring Examples beginning on page 192 for
interconnect diagrams including the LIM.
Follow these steps when wiring the connectors on your Kinetix 6000
drive modules or line interface module (LIM).
1. Prepare the wires for attachment to each connector plug by
removing insulation equal to the recommended strip length.
IMPORTANT
Use caution not to nick, cut, or otherwise damage strands
as you remove the insulation.
2. Route the cable/wires to your Kinetix 6000 drive module or LIM.
3. Insert wires into connector plugs.
Refer to connector pinout tables in Chapter 4 or the interconnect
diagrams in Appendix B.
4. Tighten the connector screws.
5. Gently pull on each wire to make sure it does not come out of its
terminal. Re-insert and tighten any loose wires.
6. Insert the connector plug into the module connector.
Publication 2094-UM001A-EN-P — September 2006
84
Connecting the Kinetix 6000 Drive System
Wiring the LIM Connectors
This section provides examples and wiring tables to assist you in
making connections to the line interface module (LIM) connectors.
Wiring the Auxiliary Input Power (APL) Connector
The Auxiliary Input Power (APL) connector is present only on the
2094-XL75S-Cx models.
Line Interface Module (APL connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
N
1
L2/
2
L1
Auxiliary Input Power (APL) Connector
Single-phase Supply APL Pin
Signal
L1
1
L1
L2
2
L2/N
Publication 2094-UM001A-EN-P — September 2006
Recommended
Wire Size
Strip Length
mm (in.)
mm2 (AWG)
Torque Value
Nm (lb-in)
0.2-4.0
(24-10)
0.5 - 0.6
(4.4 - 5.3)
7.0
(0.28)
Connecting the Kinetix 6000 Drive System
85
Wiring the VAC LINE (IPL) Connector
Line Interface Module (IPL connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
1
2
3
L3
4
L2
L1
VAC LINE (IPL) Connector
2094-AL09, -ALxxS, -BLxxS, and -XL75S-Cx
Three-phase Supply
IPL Pin
Signal
L1
4
L1
L2
3
L2
L3
2
L3
Recommended
Wire Size
Strip Length
mm (in.)
mm2 (AWG)
Torque Value
Nm (lb-in)
2.5-25
(14-4)
2.7
(24)
16.0
(0.63)
1
VAC LINE (IPL) Connector
2094-BL02
Three-phase Supply
IPL Pin
Signal
L1
1
L1
L2
2
L2
L3
3
L3
Recommended
Wire Size
Strip Length
mm (in.)
mm2 (AWG)
Torque Value
Nm (lb-in)
4.0
(12)
1.5 - 1.8
(13.2 - 15.9)
10.0
(0.38)
4
Publication 2094-UM001A-EN-P — September 2006
86
Connecting the Kinetix 6000 Drive System
Wiring the VAC LOAD (OPL) Connector
Line Interface Module (OPL connector)
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
1
2
3
L3
4
L2
L1
IMPORTANT
Line interface modules (2094-ALxxS, -BLxxS, and -XL75S-Cx)
are capable of connecting to two IAMs, providing each IAM has
its own line filter and the maximum current specification is not
exceeded.
Refer to Power Wiring Examples on page 194 for an example of
the LIM wired to two IAMs.
VAC LOAD (OPL) Connector (2094-ALxxS, -BLxxS, or -XL75S-Cx)
Three-phase Supply
OPL Pin
Signal
L1
4
L1’
L2
3
L2’
L3
2
L3’
Recommended Wire Size Strip Length
mm (in.)
mm2 (AWG)
Torque Value
Nm (lb-in)
2.5-25
(14-4)
2.7
(24)
16.0
(0.63)
1
VAC LOAD (OPL) Connector (2094-AL09)
Three-phase Supply
OPL Pin
Signal
L1
1
L1’
L2
2
L2’
L3
3
L3’
Recommended Wire Size Strip Length
mm2 (AWG)
mm (in.)
Torque Value
Nm (lb-in)
2.5-25
(14-4)
2.7
(24)
16.0
(0.63)
4
VAC LOAD (OPL) Connector (2094-BL02)
Three-phase Supply
OPL Pin
Signal
L1
4
L1’
L2
3
L2’
L3
2
L3’
1
Publication 2094-UM001A-EN-P — September 2006
Recommended Wire Size Strip Length
mm (in.)
mm2 (AWG)
Torque Value
Nm (lb-in)
4.0
(12)
1.5 - 1.8
(13.2 - 15.9)
10.0
(0.38)
Connecting the Kinetix 6000 Drive System
87
Wiring the Control Power Output (CPL) Connector
Line Interface Module (CPL connector)
L2
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
CTR
L1
1
2
CTR
Control Power Output (CPL) Connector
2094-ALxxS, -BLxxS, -XL75S-Cx
CPL Pin
Signal
1
CTRL 1
2
CTRL 2
Recommended
Wire Size
mm2 (AWG)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
0.2-4.0
(24-10)
7.0
(0.28)
0.5 - 0.6
(4.4 - 5.3)
Recommended
Wire Size
mm2 (AWG)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
2.5
(14)
10.0
(0.38)
0.5 - 0.6
(4.4 - 5.3)
Control Power Output (CPL) Connector
2094-AL09 and -BL02
CPL Pin
Signal
2
L1
1
L2/N
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Connecting the Kinetix 6000 Drive System
Wiring the Auxiliary Power Output (P2L) Connector
4
Line Interface Module (P2L connector)
1
2
3
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
L2
X2_
AU
L1
X2_
AU
L2
X1_
AU
L1
X1_
AU
Auxiliary Power Output (P2L) Connector
2094-ALxxS, -BLxxS, -XL75S-Cx
Publication 2094-UM001A-EN-P — September 2006
P2L Pin
Signal
1
AUX1_L1
2
AUX1_L2
3
AUX2_L1
4
AUX2_L2
Recommended
Wire Size
mm2 (AWG)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
0.2-4.0
(24-10)
7.0
(0.28)
0.5 - 0.6
(4.4 - 5.3)
Connecting the Kinetix 6000 Drive System
89
Wiring the Brake Power Output (24V dc) Connector
Line Interface Module (24V connector)
1
2
3
4
5
6
Line Interface Module, Top View
(2094-XL75S-Cx is shown)
R2
PW
IO_ OM2
C
IO_ WR2
P
O
I _ OM2
C
IO_ WR2
P
IO_ OM2
C
IO_
Brake Power Output (24V dc) Connector
2094-ALxxS, -BLxxS, -XL75S-Cx
P1L Pin
Signal
1
IO_PWR2
2
IO_COM2
3
IO_PWR2
4
IO_COM2
5
IO_PWR2
6
IO_COM2
Recommended
Wire Size
mm2 (AWG)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
0.08-1.5
(28-16)
7.0
(0.28)
0.22-0.25 (1.9-2.2)
Recommended
Wire Size
mm2 (AWG)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
2.5
(14)
10.0
(0.38)
0.5 - 0.6
(4.4 - 5.3)
Brake Power Output (24V dc) Connector
2094-AL09 and -BL02
PSL Pin
Signal
1
MBRK PWR
2
MBRK COM
3
MBRK PWR
4
MBRK COM
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90
Connecting the Kinetix 6000 Drive System
Wiring the IAM/AM
Connectors
This section provides examples and wiring tables to assist you in
making connections to the integrated axis module (IAM) connectors.
Wiring the Control Power (CPD) Connector
This example applies to an integrated axis module (IAM), leader IAM,
or follower IAM.
Integrated Axis Module (CPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
L2
1
CTR
L1
2
CTR
IMPORTANT
LIM models (2094-AL75S and BL75S) will supply up to eight
axes. LIM models (2094-XL75S-Cx) will supply up to sixteen
axes.
IMPORTANT
Source the 230V IAM control power from the three-phase input
power (line-to-line). Supplying 230V control power from any
other source requires an isolation transformer. If used, do not
ground either output leg of the isolation transformer.
Refer to Control Power Input on page 65 for more information
and IAM Wiring Example (without LIM) on page 196 for the
interconnect drawing.
Control Power (CPD) Connector
CPL Connector (LIM) or Other Single-phase Input
2094-ALxxS, -BLxxS,
-XL75S-Cx
CPD Connector (IAM)
2094-AL09 and -BL02
CPL Pin
Signal
CPL Pin
Signal
CPD Pin
Signal
1
CTRL 1
2
L1
1
CTRL 2
2
CTRL 2
1
L2/N
2
CTRL 1
Publication 2094-UM001A-EN-P — September 2006
Recommended
Strip Length
Wire Size
mm (in.)
mm2 (AWG)
Torque Value
Nm (lb-in)
2.5 (14)
0.5 - 0.6
(4.4 - 5.3)
10 (0.38)
Connecting the Kinetix 6000 Drive System
91
Wiring the Input Power (IPD) Connector
This example applies to an integrated axis module (IAM) or leader
IAM (dc common bus).
Integrated Axis Module (IPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
56
34
12
DC
+
DC
L3
L2
L1
Input Power (IPD) Connections
OPL Connector (LIM) or Other Three-phase Input
IPD Connector
(IAM or leader IAM)
2094-BL02, -ALxxS, -BLxxS,
or -XL75S-Cx
2094-AL09
OPL Pin
Signal
OPL Pin
Signal
IPD Pin
Signal
1
L1’
4
L1’
6
L1
2
L2’
3
L2’
5
L2
3
L3’
2
L3’
4
L3
4
1
3
N/A
2
DC+
1
DC-
Termination Specifications
Integrated Axis Module
Cat. No.
Input VAC
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-AC16-Mxx-S
Recommended
Wire Size
Strip Length
mm2 (AWG)
mm (in.)
2.5 (14)
230V ac
10 (8)
2094-AC32-Mxx-S
25 (4)
2094-BC01-Mxx-S
2094-BC02-Mxx-S
4.0 (12)
2094-BC04-Mxx-S
2094-BC07-Mxx-S
460V ac
10 (8)
25 (4)
Torque Value
Nm (lb-in)
10 (0.38)
0.5 - 0.6
(4.4 - 5.3)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
10 (0.38)
1.2 - 1.5
(10.6 - 13.2)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
Publication 2094-UM001A-EN-P — September 2006
92
Connecting the Kinetix 6000 Drive System
This example applies to a follower IAM (dc common bus).
Integrated Axis Module (IPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
56
34
12
DC
+
DC
L3
L2
L1
Input Power (IPD) Connections
IPD Connector
(IAM or follower IAM)
IPD Pin
Signal
6
N.C.
5
N.C.
4
N.C.
3
2
DC+
1
DC-
IMPORTANT
Do not connect three-phase input power to the follower IAM.
Termination Specifications
Integrated Axis Module
Cat. No.
Input VAC
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-AC16-Mxx-S
2.5 (14)
230V ac
10 (8)
2094-AC32-Mxx-S
25 (4)
2094-BC01-Mxx-S
2094-BC02-Mxx-S
4.0 (12)
2094-BC04-Mxx-S
2094-BC07-Mxx-S
Publication 2094-UM001A-EN-P — September 2006
Recommended
Wire Size
Strip Length
mm2 (AWG)
mm (in.)
460V ac
10 (8)
25 (4)
Torque Value
Nm (lb-in)
10 (0.38)
0.5 - 0.6
(4.4 - 5.3)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
10 (0.38)
1.2 - 1.5
(10.6 - 13.2)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
Connecting the Kinetix 6000 Drive System
93
Wiring the Contactor Enable (CED) Connector
This example applies to any integrated axis module (IAM), leader
IAM, or follower IAM.
Integrated Axis Module (CPD connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
NT
1
CO
-
EN
NT
2
ATTENTION
CO
+
EN
Wiring the contactor enable relay is required. To avoid personal
injury or damage to the drive, wire the contactor enable relay
into your safety control string.
Refer to Contactor Enable Relay on page 63.
In common bus configurations, the contactor enable (CED)
connections for leader and follower drives must be wired in
series to the safety control string.
For interconnect diagrams, refer to Wiring Examples beginning
on page 192.
Contactor Enable (CED) Connector
LIM I/O (IOL) Connector or
Other Control String
CED Pin
Signal
IO_COM
1
CONT EN-
COIL_A2
2
CONT EN+
2094-ALxxS, -BLxxS,
-XL75S-Cx
2094-AL09 and -BL02
IO_COM1
COIL_E2
(1)
Recommended
Wire Size
Strip Length
mm2 (AWG)
mm (in.)
2.5 (14) (1)
10 (0.38)
Torque Value
Nm (lb-in)
0.5 - 0.6
(4.4 - 5.3)
The actual gauge of the contactor enable wiring depends on the system configuration. Consult your machine builder, the NEC, and applicable local codes.
Publication 2094-UM001A-EN-P — September 2006
94
Connecting the Kinetix 6000 Drive System
Wiring the Safe-off (SO) Connector
This example applies to any integrated axis module (IAM) or axis
module (AM) equipped with the safe-off (SO) connector.
Integrated Axis Module (CED connector)
Kinetix 6000 IAM/AM
(Kinetix 6000 AM is shown)
1
1 2
3 4
5 6
7 8
9
Safe-off
(SO) Connector
Motion Allowed Jumper
Wiring Plug Header
Each IAM and AM ships with the (9-pin) wiring plug header and
motion allowed jumper installed in the safe-off connector. With the
motion allowed jumper installed, the safe-off feature is not used.
Pinouts for the safe-off (SO) connector are shown on page 52.
IMPORTANT
Pins SO-8 and -9 (24V+) are only used by the motion allowed
jumper. When wiring to the wiring plug header, the 24V supply
must come from an external source.
Safe-off (SO) Connector
CED Pin
Signal
1
FDBK2+
2
FDBK2-
3
FDBK1+
4
FDBK1-
5
SAFETY ENABLE2+
6
SAFETY ENABLE-
7
SAFETY ENABLE1+
8
24V +
9
24V_COM
Recommended
Wire Size
mm2 (AWG)
0.75 (18)
(stranded wire
with ferrule)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
7.0 (0.275)
0.235 (2.0)
1.5 (16)
(solid wire)
To wire the safe-off connector in single axis or multi-axis
configurations, refer to the Kinetix Safe-off Feature Safety Reference
Manual, publication GMC-RM002.
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
95
Wiring the Motor Power (MP) Connector
This example applies to axis modules (AM) and the inverter section of
integrated axis modules (IAM).
Integrated Axis Module/Axis Module (MP connector)
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
4
W
U
1
2
3
V
Cable Shield Clamp
Cable Shield Terminations
Factory supplied motor power cables for MP-Series, TL-Series,
1326AB, F-, and Y-Series motors are shielded, and the braided cable
shield must terminate at the drive during installation. A small portion
of the cable jacket must be removed to expose the shield braid. The
exposed area must be clamped (using the clamp provided) on top of
the IAM or AM and the power wires terminated in the motor power
(MP) connector plug.
SHOCK HAZARD
IMPORTANT
To avoid hazard of electrical shock, ensure shielded power
cables are grounded at a minimum of one point for safety.
For TL- and Y-Series motors, also connect the 152 mm (6.0 in.)
termination wire to the closest earth ground.
Refer to Pigtail Terminations on page 100 for more information.
Publication 2094-UM001A-EN-P — September 2006
96
Connecting the Kinetix 6000 Drive System
Motor Power Cables with Three-phase Wires Only
Motor
Motor Catalog Number
MP-Series Low Inertia
MPL-A/B3xxx, -A/B4xxx, -A/B45xxx,
-A/B5xxx, -B6xxx, -B8xxx, -B9xxx, S/M
MP-Series Integrated Gear
MPG-A/BxxxxS/M
1326AB (M2L/S2L)
1326AB-Bxxxx-M2L/S2L
Motor Power Cable
Catalog Number
2090-XXNPMP-xxSxx
TL-Series
TL-Axxxx-H
2090-XXNPT-16Sxx
F-Series
F-xxxx
2090-XXNPHF-xxSxx
These cables only contain the three-phase wires and the motors have
a separate connector for brake connections. Thermal switch wires are
included in the feedback cable.
No drive-end preparation is required for these cables.
IMPORTANT
Motor Power Terminations (three-phase wires only)
Motor Cable
Shield Clamp
Cable Clamp
(with tie wrap)
Motor Power (MP) Connector Plug
L3
L2
L1
2
W
V
U
1
DCDC+
3
4
CTRL 2
CTRL 1
MBRK MBRK +
COM
PWR
DBRK DBRK +
CONT ENCONT EN+
RX
TX
DPI
BAUD
RATE
The cable shield clamp shown above is mounted to an IAM. Cables
attach to the clamp on each AM in the same way.
IMPORTANT
Publication 2094-UM001A-EN-P — September 2006
Securing the cable shield in the clamp with a tie wrap is
recommended to improve stress relief.
Connecting the Kinetix 6000 Drive System
97
Motor Power Cables with Three-phase and Brake Wires
Motor Power Cable
Catalog Number
Motor
Motor Catalog Number
MP-Series Low Inertia
MPL-A/B15xxx and MPL-A/B2xxx V/E
MP-Series Food Grade
MPF-A/BxxxxS/M
MP-Series Stainless Steel
MPS-A/BxxxxS/M
Y-Series
Y-xxxx
2090-XXNPMF-xxSxx
2090-XXNPY-16Sxx
These MP-Series brake wires have a shield braid (shown below as
gray) that folds back under the cable clamp before the conductors are
attached to the motor brake (BC) connector. Y-Series brake wires are
not shielded and do not require routing under the cable clamp.
The thermal switch wires for the MP-Series motors are included in the
feedback cable.
Refer to Axis Module/Motor Wiring Examples beginning on page 204
for interconnect diagrams.
No drive-end preparation is required for these cables.
IMPORTANT
Refer to page 99 for drive-end cable pinouts.
Motor Power Terminations (three-phase and brake wires)
Motor Cable
Shield Clamp
(with tie wrap)
MP-Series Cable Brake Wires
DC-
W
V
DC+
U
L3
L2
1 2 3 4
CTRL 2
CTRL 1
MBRK MBRK +
COM
PWR
DBRK DBRK +
L1
CONT ENCONT EN+
RX
TX
DPI
Motor Power
(MP) Connector
1 2 3 4 5 6
Y-Series brake wires are not
shielded and do not require
routing under the cable clamp.
Resistive/Motor Brake
(BC) Connector
BAUD
RATE
The cable shield clamp shown above is mounted to an IAM. Cables
attach to the clamp on each AM in the same way.
IMPORTANT
Securing the cable shield in the clamp with a tie wrap is
recommended to improve stress relief.
Publication 2094-UM001A-EN-P — September 2006
98
Connecting the Kinetix 6000 Drive System
Motor Power Cables with Three-phase, Brake, and Thermal Switch Wires
Motor
Motor Catalog Number
Motor Power Cable
Catalog Number
1326AB (resolver)
1326AB-Bxxxx-21
1326-CPx1-xxx
The 1326AB (resolver) power cable contains the three-phase wires,
brake wires, and thermal switch wires. To improve the EMC
performance of your system, route the wires as shown.
IMPORTANT
Drive-end preparation is required for these cables.
Refer to page 99 for drive-end pinouts and cable preparation.
Motor Power Terminations (three-phase, brake, and thermal switch wires)
Low-profile motor feedback connector
(2090-K6CK-D15MF) pins 16, 17, and S
provide filtering for 1326-CPx1-xxx cables
(refer to page 111 for an illustration).
MF-16
MF-17
Thermal Switch
Wires
MF-S
Terminal Block (mounted on DIN rail)
Refer to page 28 for treatment of painted panels.
Cable Clamp
(with tie wrap)
Thermal Switch Wires
DCDC+
W
V
U
L3
L2
L1
RX
TX
DPI
Motor Power
(MP) Connector
1 2 3 4 5 6
MBRK MBRK +
COM
PWR
DBRK DBRK +
CONT ENCONT EN+
Keep wires separated
as much as possible.
1 2 3 4
CTRL 1
CTRL 2
Resistive/Motor Brake
(BC) Connector
BAUD
RATE
The cable shield clamp shown above is mounted to an IAM. Cables
attach to the clamp on each AM in the same way.
IMPORTANT
Publication 2094-UM001A-EN-P — September 2006
Securing the cable shield in the clamp with a tie wrap is
recommended to improve stress relief.
Connecting the Kinetix 6000 Drive System
99
Shield Clamp Cable Preparation (1326-CPx1-xxx)
Cable Pinouts (2090-XXNPY-16Sxx, and 2090-XXNPMF-xxSxx)
Strip Length 10 mm (0.375 in.)
1326AB (resolver) Motors
(1326-CPx1-xxx cable)
9
Black
5 Black
4
6
Black
Black
Y-Series Motors
(2090-XXNPY-xxSxx cable)
Thermal
switch
wires
Brake
wires
3 Black
MPL-A/B15xx, MPL-A/B2xx,
MPF-A/B and MPS-A/B Motors
(2090-XXNPMF-xxSxx cable)
1
White
2
Red
N/A
7
Black
9
Black
3
Black
2
Black
1
Black
Brake
wires
BR+ White
Spare
wire
set
Brake
wires
BR- Black
U
Brown
V
Black
Outer Insulation
2
Black
1
Black
Motor
Power
Wires
Motor
Power
Wires
W Blue
Motor
Power
Wires
Motor Power Cable
Grn/Yel
Exposed Braid
25.4 mm (1.0 in.)
Grn/Yel
Grn/Yel
105 mm (4.1 in.)
130 mm (5.1 in.)
Refer to Axis Module/Motor Wiring Examples beginning on page 204
for interconnect diagrams.
Motor Power (MP) Connector
Servo Motor
MP Connector (IAM/AM)
1326AB (resolver)
and Y-Series
1326AB (M2L/S2L), F-, TL-,
and MP-Series
MP Pin
Signal
1 / Black
U / Brown
1
U
2 / Black
V / Black
2
V
3 / Black
W / Blue
3
W
Green/Yellow
Green/Yellow
4
Termination Specifications
IAM/AM
Cat. No.
Recommended
Wire Size
mm2 (AWG)
2094-AC05-Mxx-S
2094-AC09-Mxx-S
2094-BC01-Mxx-S
2094-BC02-Mxx-S
2094-AMP5-S, -AM01-S, -AM02-S,
-BMP5-S, -BM01-S, and -BM02-S
Motor power
cable depends on
motor/drive
combination.
2094-AC16-Mxx-S
2094-AC32-Mxx-S
2094-AM03-S, -AM05-S
2094-BC04-Mxx-S
2094-BC07-Mxx-S
2094-BM03-S, -BM05-S
6 (10) max
25 (4) max
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
10 (0.38)
0.5 - 0.6
(4.4 - 5.3)
10 (0.38)
1.2 - 1.5
(10.6 - 13.2)
16 (0.63)
2.4 - 3.0
(21.6 - 26.5)
Publication 2094-UM001A-EN-P — September 2006
100
Connecting the Kinetix 6000 Drive System
Pigtail Terminations
TL- and Y-Series motors have a short pigtail cable which connects to
the motor, but is not shielded. The preferred method for grounding
the TL- and Y-Series motor power cable on the motor side is to
expose a section of the cable shield and clamp it directly to the
machine frame. The motor power cable also has a 150 mm (6.0 in.)
shield termination wire with a ring lug that connects to the closest
earth ground. Use this method in addition to the cable clamp. The
termination wire may be extended to the full length of the motor
pigtail if necessary, but it is best to connect the supplied wire directly
to ground without lengthening.
Pigtail Terminations
Cable Braid Clamped
to Machine Frame. (1)
Motor Power Cable
Machine Frame
(1)
(1)
Publication 2094-UM001A-EN-P — September 2006
Connectors
Pigtail Cable
150 mm (6.0) Termination
TL-Series or
Y-Series
Motor
(1)
Remove paint from machine frame to ensure proper HF-bond between machine frame and motor case, shield
clamp, and ground stud.
Connecting the Kinetix 6000 Drive System
101
Wiring the Motor/Resistive Brake (BC) Connector
This example applies to axis modules (AM) and the inverter section of
integrated axis modules (IAM).
Integrated Axis Module/Axis Module (BC connector)
RKMB K+
R
MB
M
O
C
R
PW KR
DB K+
R
DB
1
2
3
4
5
6
Integrated Axis Module, Top View
(2094-BC02-M02-S is shown)
Motor/Resistive Brake
(BC) Connector
Wiring 24V dc Brake Input Power Connections
IMPORTANT
If your system includes a line interface module (LIM), you can
source the 24V dc from the LIM (P1L or PSL connector).
Motor/Resistive Brake (BC) Connector
2094-ALxxS, -BLxxS,
-XL75S-Cx
2094-AL09 and -BL02
BC Connector (IAM/AM)
P1L Pin
Signal
PSL Pin
Signal
BC Pin
Signal
1
IO_PWR2
1
MBRK PWR
3
PWR
2
IO_COM2
2
MBRK COM
4
COM
Wiring the Resistive Brake Module (RBM) Connections
Motor/Resistive Brake (BC) Connector
RBM I/O Connections
BC Connector (IAM/AM)
TB3 Pin
Signal
MP Pin
Signal (1)
6
COIL_A1
1
DBRK+
7
COIL_A2
2
DBRK-
(1)
Firmware version 1.071 or later, is required to use the DBRK outputs on the Kinetix 6000 IAM/AM.
Publication 2094-UM001A-EN-P — September 2006
102
Connecting the Kinetix 6000 Drive System
Wiring the Motor Brake Connections
The procedure for wiring your motor brake varies slightly, depending
on the motor series you are using. Refer to the table below to
determine where the brake wires for your servo motor are located and
for the appropriate brake cable or connector kit catalog number.
Motor Series
Brake Wires
MPL-A/B3xxx, MPL-A/B4xxx,
MPL-A/B45xxx, MPL-A/B5xxx,
MPL-B6xxx, MPL-B8xxx,
MPL-B9xxx, and MPG-A/B
1326AB (M2L/S2L)
Cable Catalog Number
The motor has a brake
connector. Brake wires
are in the brake cable.
2090-UXNBMP-18Sxx brake cable
TL-Axxxx-H
2090-DANBT-18Sxx brake cable
F-Series
Straight brake connector kit 9101-0330
MPL-A/B15xxx, MPL-A/B2xxx,
MPF-A/B and MPS-A/B
1326AB (resolver)
Y-Series
IMPORTANT
The motor does not have
a brake connector. Brake
wires are included in the
power cable.
2090-XXNPMF-xxSxx power cable
1326-CPx1-xxx power cable
2090-XXNPY-16Sxx power cable
Use surge suppression when controlling a brake coil. Refer to
Controlling a Brake Example on page 210.
Brake Cable Preparation
Outer Insulation
Strip Length 10 mm (0.375 in.)
BR+
Brake Cable
BR-
105 mm (4.1 in.)
Motor/Resistive Brake (BC) Connector
Motor Brake Wires
BC Connector (IAM/AM)
2090-UXNBMP-18Sxx
Brake Cable
2090-DANBT-18Sxxx 2090-XXNPMF-xxSxx 1326-CPx1-xxx
Brake Cable
Power Cable
Power Cable
2090-XXNPY-16Sxx
Power Cable
BC Pin
Signal
A / BR+
1 / BR+
F/+ / BR+
6 / B1
7 / BR+
5
MBRK+
C / BR-
2 / BR-
G/- / BR-
4 / B2
9 / BR-
6
MBRK-
Termination Specifications
BC Connector (IAM/AM)
Publication 2094-UM001A-EN-P — September 2006
BC Pin
Signal
BC-6
BC-5
BC-4
BC-3
BC-2
BC-1
MBRKMBRK+
COM
PWR
DBRKDBRK+
Recommended
Wire Size
mm2 (AWG)
Strip Length
mm (in.)
Torque Value
Nm (lb-in)
0.75 (18)
10 (0.38)
0.22 - 0.25
(1.9 - 2.2)
Connecting the Kinetix 6000 Drive System
Applying the Motor Cable
Shield Clamp
103
This procedure assumes you have completed wiring your motor
power (MP) connector and are ready to apply the motor cable shield
clamp.
Follow these steps to apply the motor cable shield clamp.
1. Use a small flat blade screwdriver to depress the spring loaded
clamping plate.
Flat Blade Screwdriver
3.5 mm (0.14 in.) tip
Cable Clamp
Screwdriver
tip in slot
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.
4. Attach tie wrap around cable and clamp for additional strain relief.
Exposed Braid
(under clamp)
Motor
Cable
Outer Insulation
Horizontal Cable Clamp Orientation Example
Cable Clamp
Outer Insulation
Tie Wrap
Cable Clamp
Exposed Braid
(under clamp)
Vertical Cable Clamp
Orientation Example
Motor Cable
Vent holes on top of IAM/AM
5. Repeat Steps 1...4 for each AM and IAM.
Publication 2094-UM001A-EN-P — September 2006
104
Connecting the Kinetix 6000 Drive System
Understanding Feedback
and I/O Cable Connections
Factory made cables with premolded connectors are designed to
minimize EMI and are recommended over hand-built cables to
improve system performance. However, other options are available
for building your own feedback and I/O cables.
Options for Connecting Motor Feedback and I/O
Connection Option
Connector Kit
Catalog Number
Cable
Using this Type of Cable
Premolded connectors
N/A
Motor feedback
Refer to the table below for the premolded
motor feedback cable available for your motor.
Motor feedback
Refer to the table below for the flying-lead
cable available for your motor.
2090-K6CK-D15M
Low-profile connector
Panel-mounted breakout
board kits
(1)
2090-K6CK-D15MF
1326-CCUx-xxx.
2090-K6CK-D15F
Auxiliary feedback
User-supplied flying-lead cable.
2090-K6CK-D26M
I/O interface
User-supplied flying-lead cable.
2090-UXBK-D15xx (1)
Motor feedback
Refer to the table below for the flying-lead
cable available for your motor.
Not compatible with 1326-CCUx-xxx cable.
Motor Feedback Cables for Specific Motor/Feedback Combinations
Motor Series
Feedback Type
MPL-AxxxxS/M
MPL-BxxxxS/M
High-resolution encoder
MPL-A3xxx-H
MPL-A4xxx-H
MPL-A45xxx-H
MPL-A5xxx-H
Incremental encoder
MPG-Axxxx-S/M
MPG-Bxxxx-S/M
High-resolution encoder
MPL-Bxxxx-R
Motor resolver
MPL-A15xxx-H
MPL-A2xxx-H
MPL-B15xxx-H
MPL-B2xxx-H
Incremental encoder
MPL-Axxxx-V/E
MPL-Bxxxx-V/E
MPF-Axxxx-S/M
MPF-Bxxxx-S/M
Feedback Cable
Pinout
Premolded
Flying-Lead
2090-UXNFBMP-Sxx
2090-XXNFMP-Sxx
page 105
N/A
2090-CDNFDMP-Sxx
page 105
N/A
2090-XXNFMF-Sxx
page 106
High-resolution encoder
MPS-Axxxx-S/M
MPS-Bxxxx-S/M
TL-Axxxx-H
Incremental encoder
2090-XXNFT-Sxx
N/A
page 106
1326AB-Bxxxx-M2L/S2L
High-resolution encoder
2090-UXNFBMP-Sxx
2090-XXNFMP-Sxx
page 105
1326AB-Bxxxx-21
Motor resolver
N/A
1326-CCUx-xxx
page 107
2090-UXNFBHF-Sxx
2090-XXNFHF-Sxx
page 107
2090-UXNFBY-Sxx
2090-XXNFY-Sxx
page 107
F-Series
Y-Series
Publication 2094-UM001A-EN-P — September 2006
Incremental encoder
Connecting the Kinetix 6000 Drive System
105
Flying-lead Feedback Cable Pin-outs
2090-XXNFMP-Sxx Feedback Cable
Motors with Incremental
Encoder Feedback
Motors with High Resolution Feedback
Motor
Connector
Pin
Drive MF
Connector
Pin
MPL-Bxxx-M/-S
MPL-A5xxx-M/-S
1326AB-Bxxx-M2L/-S2L
MPL-A3xxx-M/-S
MPL-A4xxx-M/-S
MPL-A45xxx-M/-S
MPG-A/Bxxx-M/-S
MPL-A3xxx-H
MPL-A4xxx-H
MPL-A45xxx-H
MPL-A5xxx-H
A
Sine+
Sine+
AM+
1
B
Sine-
Sine-
AM-
2
C
Cos+
Cos+
BM+
3
D
Cos-
Cos-
BM-
4
E
Data+
Data+
IM+
5
F
Data-
Data-
IM-
10
K
Reserved
EPWR_5V
EPWR_5V
14
L
Reserved
ECOM
ECOM
6
N
EPWR_9V
Reserved
Reserved
7
P
ECOM
Reserved
Reserved
6
R
TS+
TS+
TS+
11
S
TS-
TS-
TS-
–
T
Reserved
Reserved
S1
12
U
Reserved
Reserved
S2
13
V
Reserved
Reserved
S3
8
2090-CDNFDMP-Sxx Feedback Cable
Motor
Connector
Pin
Resolver Feedback
MPL-Bxxxx-R Motors
Drive MF
Connector
Pin
A
S2
1
B
S4
2
C
S1
3
D
S3
4
G
R1
5
H
R2
10
R
TS+
11
S
TS-
6
Publication 2094-UM001A-EN-P — September 2006
106
Connecting the Kinetix 6000 Drive System
2090-XXNFMF-Sxx Feedback Cable
Motors with High Resolution Feedback
Motors with Incremental
Encoder Feedback
MPL-B15xxx-V/-E
MPL-B2xxx-V/-E
MPF/MPS-Bxxx-M/-S
MPF-A5xx-M/-S
MPL-A15xxx-V/-E
MPL-A2xxx-V/-E
MPF/MPS-A3xx-M/-S
MPF/MPS-A4xx-M/-S
MPF/MPS-A45xx-M/-S
MPS-A5xx-M/-S
MPL-A15xxx-H
MPL-A2xxx-H
MPL-B15xxx-H
MPL-B2xxx-H
1
Sine+
Sine+
AM+
1
2
Sine-
Sine-
AM-
2
3
Cos+
Cos+
BM+
3
4
Cos-
Cos-
BM-
4
5
Data+
Data+
IM+
5
6
Data-
Data-
IM-
10
9
Reserved
EPWR_5V
EPWR_5V
14
10
Reserved
ECOM
ECOM
6
11
EPWR_9V
Reserved
Reserved
7
Motor
Connector
Pin
Drive MF
Connector
Pin
12
ECOM
Reserved
Reserved
6
13
TS+
TS+
TS+
11
14
TS-
TS-
TS-
–
15
Reserved
Reserved
S1
12
16
Reserved
Reserved
S2
13
17
Reserved
Reserved
S3
8
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
2090-XXNFHF-Sxx Feedback Cable
2090-XXNFY-Sxx Feedback Cable
F-Series Motors
Drive MF
Connector
Pin
Incremental Encoder
Motor
Connector Feedback
Pin
Y-Series Motors
Drive MF
Connector
Pin
A
AM+
1
9
AM+
1
B
AM-
2
10
AM-
2
C
BM+
3
11
BM+
3
D
BM-
4
12
BM-
4
E
IM+
5
13
IM+
5
F
IM-
10
14
IM-
10
G
Reserved
–
15
S1
12
H
Reserved
–
17
S2
13
J
EPWR_5VM
14
19
S3
8
K
EPWR_5VM
14
22
EPWR_5VM
14
L
ECOMM
6
23
ECOMM
6
M
ECOMM
6
N
S2
13
24
Drain
Connector
Housing
P
S3
8
Reserved
Reserved
7
R
TS+
11
Reserved
Reserved
9
S
TS-
6
Reserved
Reserved
11
T
S1
12
Reserved
Reserved
15
Motor
Connector
Pin
Incremental Encoder
Feedback
107
1326-CCU-xxx Feedback Cable
1326-CPx1-xxx Power Cable
Motor
Connector
Pin
Resolver Feedback
1326AB-Bxxxx-21
Drive MF
Connector
Pin (1)
Motor
Connector
Pin
Thermal Switch
Connections
1326AB-Bxxxx-21
Drive MF
Connector
Pin (2)
A
R1
5
5
TS+
16
B
R2
10
9
TS-
17
C
–
–
–
Shield
S
D
S1
3
E
S3
4
F
–
–
G
S2
1
H
S4
2
(1)
(2)
For termination of individual drain wires, use Low Profile connector kit (2090-K6CK-D15MF) and reference figure on page 111.
Thermal switch wires (5 and 9) are in the motor power cable (1326-CPx1-xxx). Use Low Profile connector kit (2090-K6CK-D15MF) and reference figure
on page 111.
Publication 2094-UM001A-EN-P — September 2006
108
Connecting the Kinetix 6000 Drive System
Wiring Feedback and I/O
Connectors
These procedures assume you have mounted your Kinetix 6000
system, completed all power wiring, and are ready to connect your
feedback and I/O cables.
For This Connection
Go to
Premolded cable
Connecting Premolded Motor Feedback Cables on page 108.
Panel-mounted breakout board
Wiring Panel-mounted Breakout Board Kits on page 109.
Low-profile connector
Wiring Low-profile Connector Kits on page 110.
Connecting Premolded Motor Feedback Cables
Motor feedback cables with premolded connectors plug directly into
15-pin motor feedback (MF) connectors on either the IAM or AM (no
wiring is necessary).
IMPORTANT
When using Bulletin 2090 cables with premolded connectors,
tighten the mounting screws (finger tight) to improve system
performance.
Integrated Axis Module/Axis Module (MF connector)
Integrated Axis Module, Side View
(2094-BC02-M02-S is shown)
Integrated Axis Module, Front View
(2094-BC02-M02-S is shown)
Premolded Connector
(2090-UXNFBMP-Sxx cable)
Motor Feedback (MF) Connector
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
109
Wiring Panel-mounted Breakout Board Kits
The panel-mounted breakout board kit (catalog number
2090-UXBK-D15xx) includes a (DIN rail) breakout board and cable.
The cable connects between the breakout board and the motor
feedback (MF) connector. Wires from your flying-lead motor feedback
cable connect to the terminals.
Integrated Axis Module/Axis Module (MF connector)
Integrated Axis Module, Side View
(2094-BC02-M02-S is shown)
Integrated Axis Module, Front View
(2094-BC02-M02-S is shown)
2090-UXBC-D15xx
Breakout Cable
Motor Feedback (MF) Connector
2090-UXBB-D15
Panel-mounted Breakout Board
Wire Terminations
IMPORTANT
The panel-mounted breakout board kit (2090-UXBK-D15xx) is
not compatible with 1326-CCUx-xxx cable.
Publication 2094-UM001A-EN-P — September 2006
110
Connecting the Kinetix 6000 Drive System
Wiring Low-profile Connector Kits
Low-profile connector kits (2090-K6CK-Dxxx) are suitable for motor
feedback (MF), auxiliary feedback (AF), and I/O connections (IOD)
on any IAM or AM. They also apply to I/O connections (IOL) on the
2094-AL09 and 2094-BL02 line interface module (LIM).
Integrated Axis Module/Axis Module (MF connector)
Integrated Axis Module, Side View
(2094-BC02-M02-S is shown)
Integrated Axis Module, Front View
(2094-BC02-M02-S is shown)
2090-XXNFMP-Sxx (flying-lead)
Feedback Cable with
K6CK-D15Mxx
Low-profile Connector Kit
Motor Feedback (MF) Connector
IMPORTANT
Tightening the mounting screws is essential to ensure shield
integrity of the low-profile connector covers with the drive
feedback connector D-shells. Use 0.4 Nm (3.5 lb-in) torque.
Wiring (15-Pin) Flying-lead Feedback Cable Connections
2090-XXNFxx-Sxx or 2090-CDNFDMP-Sxx Feedback Cable
15-pin (male) Motor Feedback
Low-profile Connector
Bare Wires
Wire Insulation
Foil Shield
Pin 10
Pin 5
Mounting
Screws
Braided Shield
Pin 1
2090-XXNFxx-Sxx
Shield Clamp
Exposed Braid under clamp
Turn clamp over to hold
small wires secure.
Publication 2094-UM001A-EN-P — September 2006
0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Outer Insulation
Tie
Wrap
15-pin (female) Auxiliary Feedback
Low-profile Connector
Pin 15
Pin 1
Pin 11
Pin 6
Pin 5
Pin 10
Refer to Chapter 4 for feedback
signal descriptions.
Refer to Wiring Examples beginning on
page 192 for the motor feedback
interconnect drawing for your application.
2090-XXNFxx-Sxx or
2090-CDNFDMP-Sxx Feedback Cable
Pin 6
Pin 11
Pin 15
Connecting the Kinetix 6000 Drive System
111
Wiring (15-Pin) Flying-lead Feedback Cable Connections
1326-CCUx-xxx Motor Feedback Cable
15-pin (male) Motor Feedback
Low-profile Connector
Bare Wires
Drain Wire
Wire Insulation
Foil Shield
Braided Shield
Drain wire (only with 1326-CCUx-xxx
cable) folded back under clamp.
Shield Clamp
1326-CCUx-xxx Feedback Cable
IMPORTANT
Pin 15
Pin 1
Pin 11
Pin 6
Pin 5
Pin 10
Pin 6
Pin 11
Pin 15
Refer to Chapter 4 for feedback
signal descriptions.
Tie
Wrap
17 16 S
Exposed Braid under clamp
Turn clamp over to hold
small wires secure.
Pin 1
1326-CCUx-xxx
0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Outer Insulation
Pin 10
Pin 5
Mounting
Screws
15-pin (female) Auxiliary Feedback
Low-profile Connector
Refer to Wiring Examples beginning on
page 192 for the motor feedback
interconnect drawing for your application.
Pins S, 16, and 17 are only included on
2090-K6CK-D15MF Low Profile connectors and
used for thermal switch connections to 1326AB
(resolver-based) motors. After filtering, these pins
connect to MF-11 and -6.
Thermal Switch Wires
The purpose of the cable shield clamp is to provide a proper
ground and improve system performance, not stress relief.
Clamping the exposed braid under the shield clamp is critical.
Turn clamp over, if necessary, to ensure a proper ground.
Publication 2094-UM001A-EN-P — September 2006
112
Connecting the Kinetix 6000 Drive System
Wiring (26-Pin) I/O Cable Connections
Pin 18
Pin 9
Pin 26
Mounting
Screws
Pin 19
Pin 10
12 11 10
9 8 7 6 5 4 3 2 1
S 26 25 24 S 23 22 21 20 19 18 17 16 15 14 13
Pin 1
26-pin (male) I/O
Low Profile Connector
Tie Wrap
Slot
Turn clamp over to hold
small wires secure.
Three Conductor
I/O Cables
IMPORTANT
Publication 2094-UM001A-EN-P — September 2006
Discrete I/O Wire
Clamping the exposed braid under the shield clamp is critical.
Turn clamp over, if necessary, to ensure a proper ground.
Connecting the Kinetix 6000 Drive System
Understanding External
Shunt Module Connections
113
Follow these guidelines when wiring your external active or passive
shunt resistor kit.
IMPORTANT
When tightening screws to secure the wires, refer to the tables
beginning on page 80 for torque values.
IMPORTANT
To ensure system performance, run wires and cables in the
wireways as established in Chapter 2.
Shunt Module Wiring
This Shunt Module
Power rail mounted
shunt module.
Cat. No.
2094-BSP2
With This Module
Do This
• Verify the internal shunt jumper is in place between RC-2 and RC-3, as
shown in the figure below.
N/A
• Verify the thermal switch jumper is in place between TS-1 and TS-2, as
shown in the figure below.
• Remove the internal shunt jumper between RC-2 and RC-3.
External passive shunt
connected to the
power rail shunt
module.
• Remove the thermal switch jumper between TS-1 and TS-2
(if your shunt module includes a thermal switch).
1394-SRxxxx
SM
2094-BSP2
• Refer to External Shunt Resistor on page 40 and Mounting the External
Shunt Module on page 48.
• Refer to Locating Shunt Module Connectors and Indicators on page 68.
• Refer to Shunt Module Wiring Examples on page 201.
• Refer to External Shunt Resistor on page 40.
IAM
2094-xCxx-Mxx
• Refer to Shunt Module Wiring Examples on page 201.
• Refer to the installation instructions provided with your Bulletin 1336 shunt
module, publication 1336-5.64.
External Shunt Resistor
(RC) Connector
External Thermal Switch
(TS) Connector
(1)
Cable Shield
Clamp
COL
INT
DC+
TS2
TS1
COL
INT
DC+
TS2
TS1
Jumper (1)
1 2
Shunt Module, Top View
(2094-BSP2)
1 2 3
Shunt Module Jumper Settings
1 2 3
1336-MOD-Kxxxx
1 2
External active shunt
connected to the dc
bus.
These are the default jumper settings.
Publication 2094-UM001A-EN-P — September 2006
114
Connecting the Kinetix 6000 Drive System
Understanding Resistive
Brake Module Connections
Follow these guidelines when wiring your Bulletin 2090 Resistive
Brake Module (RBM).
IMPORTANT
To ensure system performance, run wires and cables in the
wireways as established in Chapter 2.
If your application requires an RBM and you are wiring to a Kinetix
6000 IAM/AM drive, then refer to the following:
•
Resistive Brake Modules on page 42.
•
Resistive brake module to Kinetix 6000 drive interface cable
(catalog number 2090-XXNRB-xxFxPx).
•
The The example diagram below shows Kinetix 6000 IAM, AM,
and LIM (2094-ALxxS, -BLxxS, and -XL75S) wired with the Bulletin
2090 RBM in a category 2 configuration. in Appendix E.
•
The installation instructions provided with your RBM, publication
2090-IN009.
Resistive Brake Module Connections
I/O
(TB3) Connections
2094-xCxx-Mxx IAM or
2094-xMxx AM (top view)
Motor Power
Cable Clamp
(exposed shield
braid under clamp)
2090-XBxx-xx
Resistive Brake Module
(front view)
Tie Wrap
DCDC+
W
V
U
L3
L2
L1
Drive Connection
(TB1) Connector
1 2 3 4
CTRL 2
CTRL 1
Contactor Status LED
Motor Connection
(TB2) Connector
MBRK MBRK +
COM
PWR
DBRK -
CONT ENCONT EN+
DBRK +
RX
TX
DPI
BAUD
RATE
Exposed Shield Braid
Under Clamp
Motor Cable
Shield Clamps
2090-XXNRB-xxFvPx
RBM/Kinetix 6000 Interface Cable
Bulletin 2090 Motor Power Cable
To Motor
Publication 2094-UM001A-EN-P — September 2006
Connecting the Kinetix 6000 Drive System
Connecting Your SERCOS
Fiber-optic Cables
115
This procedure assumes you have your Logix SERCOS interface
module/PCI card and Kinetix 6000 IAM/AM modules mounted and are
ready to connect the fiber-optic cables.
The SERCOS fiber-optic ring is connected using the SERCOS receive
(Rx) and transmit (Tx) connectors. Refer to page 50 to locate the
SERCOS connectors on your Kinetix 6000 IAM/AM. Refer to the figure
below to locate the connectors on your SERCOS interface module or
PCI card.
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).
CompactLogix, ControlLogix, and SoftLogix SERCOS Connector Locations
SERCOS interfaceTM
OK
RSLogix 5000 Software
F 1
45
23 6 7
ABCDE
CP
ControlLogix Platform
1756-MxxSE SERCOS
interface Module
0
CompactLogix Platform
1768-M04SE SERCOS
interface Module
SoftLogix Platform
1756-PM16SE SERCOS interface PCI Card
(as viewed from the back of your PC)
89
OK
CP
Front View
TX
Tx (rear)
Rx (front)
SERCOS Transmit Connector, Tx
Tx (rear)
Front View
RX
Rx (front)
SERCOS Receive Connector, Rx
SERCOS Receive Connector, Rx (front)
SERCOS Transmit Connector, Tx (rear)
Connect the cable from transmit on the Logix module to receive on
the IAM, then transmit to receive (drive to drive), and from transmit
on the last drive back to receive on the Logix module.
SoftLogix and ControlLogix platforms are used in the examples
beginning below, however, all platforms connect in the same manner.
3456 72
ABCDE
Fiber-optic Cable Example 1 (basic SERCOS ring connections)
0
F 1
89
Bottom View
OK
CP
TX
Transmit
Receive
SoftLogix Platform
1784-PM16SE SERCOS
interface PCI Card
RX
SERCOS fiber-optic ring
Receive
Kinetix 6000
System
Transmit
Receive
Transmit
Kinetix 6000
System
Publication 2094-UM001A-EN-P — September 2006
116
Connecting the Kinetix 6000 Drive System
The CompactLogix platform (1768-M04SE) is limited to four
axes per module.
IMPORTANT
In this example, two Logix modules are installed in separate Logix
chassis.
Fiber-optic Cable Example 2 (two Logix chassis)
1756-MxxSE SERCOS interface Modules
SERCOS interfaceTM
SERCOS interfaceTM
CP
Transmit
OK
Logix Platform
(ControlLogix is shown)
CP
OK
Tx (rear)
Tx (rear)
Rx (front)
Rx (front)
Receive
Transmit
Receive
Transmit
Receive
SERCOS Fiber-optic Ring
Receive
Transmit
Kinetix 6000
System
SERCOS Fiber-optic Ring
When connecting 2094-BM03 and -BM05 (double-wide) axis modules,
use 2090-SCEP0-2, 0.2 m (7.0 in.) cables. When connecting
2094-AMxx, -BMP5, -BM01 and -BM02 (single-wide) axis modules, use
2090-SCEP0-1, 0.1 m (5.1 in.) cables.
Fiber-optic Cable Example 3 (double-wide modules)
1756-M16SE SERCOS
Interface Module
Logix Platform
(ControlLogix is shown)
SERCOS Fiber-optic Ring
SERCOS interfaceTM
CP
OK
0.2 m 0.1 m
(7.0 in.) (5.1 in.)
Tx (rear)
Rx (front)
Kinetix 6000 System
(5-axis power rail)
IMPORTANT
Publication 2094-UM001A-EN-P — September 2006
Clean the fiber-optic cable connectors prior to installation. Dust
in the connectors can reduce signal strength. For more
information, refer to Fiber-optic Cable Installation and Handling
Instructions, publication 2090-IN010.
Connecting the Kinetix 6000 Drive System
117
In this example, the second Kinetix 6000 system is located in a
separate cabinet and connected with bulkhead adapters.
IMPORTANT
To avoid signal loss, do not use bulkhead adapters to connect
glass cables. Only use bulkhead adapters for making
plastic-to-plastic cable connections.
Fiber-optic Cable Example 4 (bulkhead adapters)
1756-MxxSE SERCOS
Interface Module
Cabinet
SERCOS int erfac eTM
CP
Logix Platform
(ControlLogix is shown)
OK
SERCOS Fiber-optic
Bulkhead Adapter
Tx (rear )
Rx (fron t)
Transmit
Receive
SERCOS Fiber-optic Ring
Receive
SERCOS Ring
Transmit
Receive
Transmit
SERCOS Fiber-optic
Bulkhead Adapter
Kinetix 6000
System
Kinetix 6000
System
Publication 2094-UM001A-EN-P — September 2006
118
Connecting the Kinetix 6000 Drive System
Publication 2094-UM001A-EN-P — September 2006
Chapter
6
Configure and Startup the
Kinetix 6000 Drive System
Introduction
119
This chapter provides procedures for configuring your Kinetix 6000
system components with your Logix SERCOS module.
Topic
Page
Introduction
119
Configure the IAM/AM
120
Configure the Logix SERCOS interface Module
125
Apply Power to the Kinetix 6000 Drive
135
Test and Tune the Axes
138
Publication 2094-UM001A-EN-P — September 2006
120
Configure and Startup the Kinetix 6000 Drive System
Configure the IAM/AM
Follow these steps to configure the IAM/AM.
1. Verify that there is no power applied to the IAM/AM and that the
SERCOS fiber-optic cables are plugged into the Tx and Rx
connectors.
To verify your fiber-optic cable connections, refer to Connecting
Your SERCOS Fiber-optic Cables on page 115.
To Configure
Begin With
The integrated axis module (IAM)
Step 2
An axis module (AM)
Step 4
2. Set the base node address for the IAM by setting the SERCOS
Node Address switch.
Valid node addresses are 01...99. The left hand switch sets the
most significant digit (MSD) and the right hand switch sets the
least significant digit (LSD).
To
Press
Increment the (MSD/LSD) node address
The plus (+) switch.
Decrement the (MSD/LSD) node address
The minus (-) switch.
Decrements MSD
MSD
Increments MSD
Decrements LSD
LSD
Increments LSD
Setting the base node address on the IAM determines the node
address for the IAM inverter. Node addressing for all slot locations
on the same power rail increment (from the IAM inverter) left to
right.
3. Cycle control power to initialize the IAM.
IMPORTANT
The base node address setting only takes effect after the
IAM is initialized.
IMPORTANT
When two or more IAMs are connected to the same
SERCOS interface module, each node address must be
unique.
Refer to the node addressing examples on pages 122 and
124.
Publication 2094-UM001A-EN-P — September 2006
Configure and Startup the Kinetix 6000 Drive System
121
4. Set the SERCOS baud rate using DIP switches 2 and 3.
For This Baud Rate
Set Switch 2
Set Switch 3
4 Mbps
OFF
ON
8 Mbps
ON
OFF
5. Set the SERCOS optical power level to High using DIP switch 1.
For This Optical Power Level
Set Switch 1
Low
OFF
High
ON
DIP Switches Set for
8 Mbps Applications
(high power setting)
2
3
1
2
3
ON
OFF
1
DIP Switches Set for
4 Mbps Applications
(high power setting)
Integrated Axis Module, Top View
(2094-ACxx-Mxx)
ON
OFF
Switch in OFF Position
Note: Switch numbers as seen on the IAM
are upside down in this orientation.
SERCOS Baud Rate
and Optical Power Switches
Switch numbers shown above
are in ON Position
Switch
turned around for clarity.
6. Repeat Steps 4 and 5 for each 2094-xMxx axis module.
Publication 2094-UM001A-EN-P — September 2006
122
Configure and Startup the Kinetix 6000 Drive System
Node Addressing Example 1
1756-MxxSE SERCOS
interface Module
SERCOS interfaceTM
CP
OK
Logix Platform
(ControlLogix is shown)
Tx (rear)
Rx (front)
Transmit
Receive
SERCOS Fiber-optic Ring
Receive
Receive
Transmit
Transmit
Kinetix 6000
System 2
(2-axis power rail)
Kinetix 6000
System 1
(6-axis power rail)
17 = AM (axis 2) Node Address
16 = IAM (axis 1) Base Node Address
15 = Slot Filler Node Address
14 = Shunt Module Node Address
13 = AM (axis 4) Node Address
12 = AM (axis 3) Node Address
11 = AM (axis 2) Node Address
10 = IAM (axis 1) Base Node Address
In Example 1, the Kinetix 6000 (6-axis) System 1 power rail contains
one IAM, three AMs, one SM, and one slot filler module. The shunt
module and slot filler modules are assigned a node address, but they
do not use it.
Kinetix 6000 (2-axis) System 2 power rail contains one IAM and one
AM. The base node address of the IAM (system 2) must be set for an
address of ≥16 or ≤8.
IMPORTANT
The node address for each axis module is determined by the
base node-address switch setting on the IAM.
Do not position axis modules to the right of shunt or slot filler
modules. The added distance between non-adjacent axes can
increase electrical noise and impedance, and requires longer
fiber-optic cable lengths.
IMPORTANT
Publication 2094-UM001A-EN-P — September 2006
Slot filler modules must be used to fill any unoccupied slot on
the power rail. However, the slot fillers may also be removed
and replaced by an axis or shunt module in the future.
Configure and Startup the Kinetix 6000 Drive System
123
Node Addressing Example 2
1756-MxxSE SERCOS
interface Module 1
1756-MxxSE SERCOS
interface Module 2
SERCOS interfaceTM
CP
SERCOS interfaceTM
OK
CP
OK
ControlLogix Chassis
ControlLogix Chassis
Tx (rear)
Tx (rear)
Rx (front)
Transmit
Rx (front)
Receive
Transmit
Receive
SERCOS Fiber-Optic rings
Transmit
Receive
Transmit
Receive
Kinetix 6000
(8-axis power rail)
08 = Slot Filler node address
07 = AM (axis 7) node address
06 = AM (axis 6) node address
05 = AM (axis 5) node address
04 = AM (axis 4) node address
03 = AM (axis 3) node address
02 = AM (axis 2) node address
01 = IAM (axis 1) base node address
In the example above, SERCOS interface module 1 controls axes
1 to 4 and module 2 controls axes 5 to 7. The slot filler module is
assigned a node address, but does not use it.
You can mount the two SERCOS interface modules in two separate
ControlLogix chassis (as shown above) or you can mount them in the
same chassis.
Utilizing two SERCOS interface modules to control axes from a single
Kinetix 6000 power rail allows you to reduce the cycle times.
IMPORTANT
Slot Filler modules must be used to fill any unoccupied slot on
the power rail. However, the slot fillers may also be removed
and replaced by an axis or shunt module in the future.
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Node Addressing Example 3
1756-MxxSE SERCOS
interface Module
SERCOS interfaceTM
CP
OK
Logix Platform
(ControlLogix is shown)
Tx (rear)
Rx (front)
Transmit
Receive
SERCOS Fiber-optic Ring
Receive
Transmit
Kinetix 6000
(8-axis power rail)
08 = Slot Filler Node Address
07 = AM (axis 4) Node Address
06 = Not Used (AM Rightmost Slot)
05 = AM (axis 3) Node Address
04 = Not Used (AM Rightmost Slot)
03 = AM (axis 2) Node Address
02 = Not Used (IAM Rightmost Slot)
01 = IAM (axis 1) Base Node Address
In Example 2, the Kinetix 6000 (8-axis) power rail contains a
double-wide IAM, two double-wide AMs, one single-wide AM, and
one slot filler module. The slot filler module is assigned a node
address, but does not use it.
The leftmost slot of a double-wide module determines the node
address. So, in the example above, node addresses 02, 04, and 06 (the
rightmost slots of the double-wide modules) are not used.
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IMPORTANT
Slot filler modules must be used to fill any unoccupied slot on
the power rail. However, the slot fillers may also be removed
and replaced by an axis or shunt module in the future.
IMPORTANT
Do not position axis modules to the right of shunt or slot filler
modules. The added distance between non-adjacent axes can
increase electrical noise and impedance, and requires longer
fiber-optic cable lengths.
Configure and Startup the Kinetix 6000 Drive System
Configure the Logix
SERCOS interface Module
125
This procedure assumes that you have wired your Kinetix 6000 system
and have configured the baud rate and optical power switches.
IMPORTANT
In order for the Kinetix 6000 drive to communicate with the
SERCOS interface module (indicated by the three LED indicators
on the module going solid green), your RSLogix 5000 software
must be revision 11.0 or later.
For greater detail on the RSLogix 5000 software as it applies to
configuring the ControlLogix, CompactLogix, or SoftLogix SERCOS
modules, refer to Additional Resources on page 10.
Configure the Logix Controller
Follow these steps to configure the Logix controller.
1. Apply power to your Logix chassis/personal computer containing
the SERCOS interface module and open your RSLogix 5000
software.
2. From the File menu, choose New.
The New Controller dialog opens.
3. Configure the new controller.
a.
b.
c.
d.
e.
Select controller type.
Select RSLogix 5000 software revision.
Name the file.
Select the Logix chassis size.
Select the Logix processor slot.
4. Click OK.
5. From the Edit menu, choose Controller Properties.
The Controller Properties dialog opens.
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6. Select the Date and Time tab.
7. Check the box Make this controller the Coordinated System Time
master.
IMPORTANT
Only one ControlLogix processor can be assigned as the
Coordinated System Time master.
8. Click OK.
Configure the Logix Module
Follow these steps to configure the Logix module.
1. Right-click on I/O Configuration in the explorer dialog and select
New Module.
The Select Module dialog opens.
2. Expand the Motion category and select 1756-MxxSE, -L60M03SE,
1768-M04SE, or 1784-PM16SE as appropriate for your actual
hardware configuration.
3. Click OK.
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The New Module dialog opens. Your new module appears under
the I/O Configuration folder in the explorer dialog.
4. Configure the new module.
a. Name the module.
b. Select the slot where your module resides (leftmost slot = 0).
c. Select an Electronic Keying option (select Disable Keying if
unsure).
d. Check the box Open Module Properties.
5. Click OK.
The Module Properties dialog opens.
6. Select the SERCOS Interface tab and reference the table below.
Logix SERCOS Module
Number of Axes
1756-M03SE or
1756-L60M03SE
Up to 3
1756-M08SE
Up to 8
1756-M16SE or
1784-PM16SE
Up to 16
1768-M04SE
Up to 4
Data Rate
4 or 8 Mbps
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7. Verify that the Data Rate setting matches DIP switches 2 and 3
(baud rate) as set on the IAM and AMs, or use the Auto Detect
setting.
8. Set the Cycle Time according to the table below.
Data Rate
4 Mbps
Number of Axes
Cycle Time
up to 2
0.5 ms
up to 4
1 ms
up to 8
2 ms
No support for axes 9...16
8 Mbps
up to 4
0.5 ms
up to 8
1 ms
up to 16
2 ms
The number of axes/module is limited to the number of axes as
shown in Step 6.
9. Verify that the Optical Power setting (high or low) matches DIP
switch 1 as set on the IAM and AMs.
10. Set Transition to Phase.
Transition to Phase default setting is 4 (phase 4). The Transition to
Phase setting will stop the ring in the phase specified.
11. Click OK.
12. Repeat steps 1...11 for each Logix module.
Configure the Kinetix 6000 Modules
Follow these steps to configure the Kinetix 6000 modules.
1. Right-click the new Logix module you just created and select New
Module.
The Select Module dialog opens.
2. Expand the Drives category and select your 2094-xCxx-Mxx (IAM)
or 2094-xMxx (AM) as appropriate for your actual hardware
configuration.
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3. Click OK.
The New Module dialog opens.
a. Name the module.
b. Set the Node address.
Set the node address in the software to match the node setting on
the drive. Refer to Configure the IAM/AM, Step 2, on page 120.
c. Select an Electronic Keying option.
d. Check the box Open Module Properties.
4. Click OK.
5. Select the Associated Axes tab.
6. Click the New Axis button.
The New Tag dialog opens.
7. Add the axis.
a. Name the axis.
b. Select AXIS_SERVO_DRIVE as the Data Type.
8. Click OK.
The axis appears under the Ungrouped Axes folder in the explorer
dialog.
9. Assign your axis to the node address (as shown in the dialog
below).
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With drive firmware revision 1.80 or later, and RSLogix 5000
software revision 13 or later, it is possible to configure the
auxiliary axis feedback port as a Feedback Only axis. With this
feature, each IAM (inverter) or AM can be configured to appear as
two axes/nodes on the SERCOS ring. The base node is the servo
axis utilizing the motor feedback, and the base node (plus 128) is
a feedback only axis utilizing the auxiliary feedback port (as
shown below).
If an axis is associated to the auxiliary axis node, then the Axis
Configuration on the General tab of the Axis Properties dialog is
set to Feedback Only (as shown below).
10. Select the Power tab.
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11. Select the Bus Regulator Catalog Number or other as appropriate
for your actual hardware configuration.
If your IAM is
Configured as an IAM or
Leader IAM (common bus) (1)
Configured as a Follower IAM (2)
And your hardware configuration includes this shunt
option
Then select
Internal shunts only
Internal or <none>
Bulletin 2094 (rail mounted) shunt module
2094-BSP2
Bulletin 1394 passive shunt module (connected to the
2094-BSP2)
1394-SRxxxx
Bulletin 1336 active shunt module
Internal or <none>
N/A. Shunts are disabled on Follower IAM
CommonBus Follow
(1)
Drive will not accept Internal, <none>, 2094-BSP2, or 1394-SRxxxx selection if dc bus voltage is present without having three-phase power applied.
(2)
Drive will not accept CommonBus Follow selection if three-phase power is applied.
ATTENTION
To avoid damage to your Bulletin 1394 external shunt
module, verify that the proper 230V or 460V fuse is
installed prior to applying power.
Refer to Circuit Breaker/Fuse Specifications on page 177,
for more information.
IMPORTANT
When configured to use the Bulletin 1394 or 2094 shunt
modules, the IAM bus regulator capacity attribute displays
the shunt module or passive shunt module utilization
instead of the IAM internal shunt resistor utilization.
IMPORTANT
DC common bus applications must calculate Total Bus
Capacitance and Additional Bus Capacitance and set the
Add Bus Cap parameter (x:x:x599) using DriveExplorer
software.
Refer to the Appendix D beginning on page 231, for more
information.
12. Click OK.
13. Repeat steps 1...9 for each 2094-xMxx axis module.
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Configure the Motion Group
Follow these steps to configure the motion group.
1. Right-click Motion Groups in the explorer dialog and select New
Motion Group.
The New Tag dialog opens.
2. Name the new motion group.
3. Click OK.
New group appears under the Motion Groups folder.
4. Right-click the new motion group and select Properties.
The Motion Group Properties dialog opens.
5. Select the Axis Assignment tab and move your axes (created
earlier) from Unassigned to Assigned.
6. Select the Attribute tab and edit the default values as appropriate
for your application.
7. Click OK.
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Configure Axis Properties
Follow these steps to configure axis properties.
1. Right-click on an axis in the explorer dialog and select Properties.
The Axis Properties dialog opens.
2. Select the Drive/Motor tab and edit the default values as
appropriate for your application.
a. Set the Kinetix 6000 Amplifier (2094-xCxx-Mxx).
b. Set the Motor Catalog Number.
For amplifier and motor catalog numbers refer to the amplifier and
motor name plate.
c. Set Drive Enable Input Checking.
When checked (default), means a hard drive-enable input signal is
required. Uncheck to remove that requirement.
3. Select the Motor Feedback tab and verify the Feedback Type
shown is appropriate for your actual hardware configuration.
4. Select the Units tab and edit default values as appropriate for your
application.
5. Select the Conversion tab and edit default values as appropriate
for your application.
6. Select the Fault Actions tab and click the Set Custom Stop Action...
tab.
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The Custom Stop Action Attributes dialog opens.
The Custom Stop Action Attributes window lets you set delay
times for servo motors and resistive brake modules. For
recommended motor brake delay times, refer to the Kinetix
Motion Control Selection Guide, publication GMC-SG001.
7. Configure the delay times.
a. Set the Brake Engage Delay Time.
b. Set the Brake Release Delay Time.
c. Set the Resistive Brake Contact Delay time (0 - 1000 ms range).
TIP
The recommended delay time for 2090-XB33-xx and
-XB120-xx resistive brake modules is 71 ms.
If you are using RSLogix 5000 v12 or earlier, refer to
Setting the RBM Delay Time Using DriveExplorer on page
252.
d. Click Close.
8. Click OK.
9. Repeat steps 1...8 for each 2094-xMxx axis module.
10. 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.
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Apply Power to the
Kinetix 6000 Drive
135
This procedure assumes that you have wired and configured your
Kinetix 6000 system (with or without the LIM) and your SERCOS
interface module.
SHOCK HAZARD
To avoid hazard of electrical shock, perform all mounting and
wiring of IAM, AM, SM, LIM, RBM, or power rail prior to
applying power. Once power is applied, connector terminals
may have voltage present even when not in use.
Refer to the Line Interface Module Installation Instructions, publication
2094-IN005, when troubleshooting the LIM status indicators, and for
the location of LIM circuit breakers, connectors, and status indicators.
Follow these steps to apply power to the Kinetix 6000 system.
1. Disconnect the load to the motor.
ATTENTION
To avoid personal injury or damage to equipment,
disconnect the load to the motor. Make sure each motor is
free of all linkages when initially applying power to the
system.
2. Determine your source of control power.
If Your Control Power
Then
1. Verify that CB1, CB2, and CB3 are in the OFF position.
2. Apply three-phase input power to the LIM VAC Line connector.
Is sourced from a LIM
3. Set CB3 to the ON position.
4. Set CB2 to the ON position.
5. Go to main Step 3.
1. Apply (95...264V ac) control power to the IAM (CPD connector).
Is not sourced from a LIM
2. Go to main Step 3.
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3. Observe the IAM/AM logic power LED indicator.
Seven-segment
Fault Status LED Indicator
Logic Power
LED Indicator
If the Logic Power LED Indicator is Then
ON
Go to Step 4.
1. Check your control power connections.
Not ON
2. Go back to main Step 2.
4. Determine your source of three-phase input power.
If Your Three-phase
Power
Then
1. Set CB1 to the ON position.
Is sourced from a LIM
2. Verify the Hardware Enable Input signal (IOD pin 2) for each
axis is at 0 volts.
Remove the connection between IOD-1 and IOD-2 if one exists.
3. Go to main Step 5.
1. Apply 195...265V ac (230V) or 324...528V ac (460V) input power
to the IAM (IPD connector).
Is not sourced from a LIM
2. Verify the Hardware Enable Input signal (IOD pin 2) for each
axis is at 0 volts.
Remove the connection between IOD-1 and IOD-2 if one exists.
3. Go to main Step 5.
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5. Observe the IAM/AM fault status LED indicator.
The status LED indicator will first flash the SERCOS node address,
then cycle through phases until final configuration (phase 4) is
reached.
IAM/AM Fault Status LED Indicator
Status
Do This
Actively cycling (phase 0)
The drive is looking for a closed SERCOS ring. Wait for
phase 1 or take corrective action until you reach phase 1.
Check fiber-optic connections.
Displaying a fixed 1 (phase 1)
The drive is looking for active nodes. Wait for phase 2 or
take corrective action until you reach phase 2.
Check node addressing.
Displaying a fixed 2 (phase 2)
The drive is configuring nodes for communication. Wait for
phase 3 or take corrective action until you reach phase 3.
Check program motor and drive
configuration against installed hardware.
Displaying a fixed 3 (phase 3)
The drive is configuring device specific parameters. Wait for
phase 4 or take corrective action until you reach phase 4.
Check motor catalog number against
selection. (1)
Displaying a fixed 4 (phase 4)
The drive is configured and active.
Go to Step 6.
Flashing an E followed by two numbers
Drive is faulted.
Go to Error Codes on page 146.
(1)
You can get diagnostic information from the module by highlighting the module name in RSLogix 5000 software. A Pseudo Key Failure often indicates that the motor
selection does not match the motor installed.
6. Observe the three status LED indicators on the front of the IAM/
AM.
Status LED
Indicator
Drive
Comm
Condition
Status
Do This
Off
Normal condition
Observe the Comm Status LED indicator.
Steady red
Drive is faulted
Go to IAM/AM Status Indicators on page 152.
Flashing green
Establishing communication with network
Wait for steady green.
Steady green
Communication is ready
Observe the Bus Status LED indicator.
Off
No ring present
Go to IAM/AM Status Indicators on page 152.
1. Verify Hardware Enable Input (IOD-2) is open.
Steady green
Axis is enabled when status should be disabled
3. Return to Apply Power to the Kinetix 6000 Drive on page
135.
Bus
(1)
2. Verify MSO instruction is not commanded in RSLogix
5000 software.
Flashing green (1)
Bus is up, axis is disabled (normal status)
Go to Step 7.
Off
DC bus is not present
Go to IAM/AM Status Indicators on page 152.
The follower IAM has a 2.5 second delay after dc bus voltage is applied before the Bus Status LED begins flashing. This provides the common bus leader time to complete
pre-charge.
7. Observe the three SERCOS LED indicators on the SERCOS module.
Three SERCOS LED Indicators Status
Do This
Flashing green and red
Establishing communication
Wait for steady green on all three LED indicators.
Steady green
Communication ready
Go to Test and Tune the Axes.
Not flashing green and red/
not steady green
SERCOS module is faulted
Go to the appropriate Logix manual for specific instructions
and troubleshooting.
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Test and Tune the Axes
This procedure assumes that you have configured your Kinetix 6000
drive, your SERCOS interface module, and applied power to the
system.
IMPORTANT
Before proceeding with testing and tuning your axes, verify that
the IAM and AM seven-segment and status LED indicators are
as described in Step 6 on page 137.
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 10.
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 in the explorer
dialog and select Axis Properties.
The Axis Properties dialog appears.
3. Select the Hookup tab.
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4. Select 2.0 as the number of revolutions for the test (or another
number more appropriate for your application).
This Test
Performs this Test
Test Marker
Verifies marker detection capability as you rotate the
motor shaft.
Test Feedback
Verifies feedback connections are wired correctly as
you rotate the motor shaft.
Test Command & Feedback
Verifies motor power and feedback connections are
wired correctly as you command the motor to rotate.
Also, lets you define polarity.
5. Apply Hardware Enable Input signal (IOD-2) for the axis you are
testing.
ATTENTION
To avoid personal injury or damage to equipment, apply
24V ENABLE signal (IOD-2) only to the axis you are testing.
6. Select the Test (Marker/Feedback/Command & Feedback) button
to verify connections.
The Online Command dialog 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 opens (Feedback and
Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.
8. Click OK.
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9. Determine if your test completed successfully.
If
Then
Your test completes successfully, this dialog appears.
1. Click OK.
2. Remove Hardware Enable Input signal (IOD-2).
3. Go to Tune the Axes.
1. Click OK.
Your test failed, this dialog appears.
2. Verify the Bus Status LED turned solid green during
the test.
3. Verify that the Hardware Enable Input signal
(IOD-2) 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.
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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. Select the Tune tab.
3. Enter values for Travel Limit and Speed. In this example, Travel
Limit = 5 and Speed = 10.
Actual value of programmed units depend on your application.
4. Select setting for Direction (Forward Uni-directional is default).
5. Check Tune boxes as appropriate for your application.
6. Apply Hardware Enable Input signal (IOD-2) for the axis you are
tuning.
ATTENTION
To avoid personal injury or damage to equipment, apply
24V ENABLE signal (IOD-2) only to the axis you are tuning.
7. Select the Start Tuning button to auto-tune your axis.
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The Online Command - Tune Servo dialog opens. When the test
completes, the Command Status changes from Executing to
Command Complete.
8. Click OK.
The Tune Bandwidth dialog opens.
Actual bandwidth values (Hz) depend on your application and
may require adjustment once motor and load are connected.
Record your bandwidth data for future reference.
9. Click OK.
The Online Command - Apply Tune dialog opens. When the test
completes, the Command Status changes from Executing to
Command Complete.
10. Click OK.
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11. Determine if your test completed successfully.
If
Then
Your test completes successfully, this dialog appears.
1. Click OK.
2. Remove the Hardware Enable Input signal (IOD-2)
applied earlier.
3. Go to Step 12.
Your test failed, this dialog appears.
1. Click OK.
2. Make an adjustment to motor velocity.
3. Refer to appropriate Logix motion module setup
and configuration manual for more information.
4. Return to Step 7 and run the test again.
12. Repeat Test and Tune the Axes for each axis.
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Chapter
7
Troubleshooting the Kinetix 6000 Drive
System
Introduction
Safety Precautions
This chapter provides troubleshooting tables and for your
Kinetix 6000 system components.
Topic
Page
Introduction
145
Safety Precautions
145
Interpreting Status Indicators
146
Supplemental Troubleshooting Information
160
Observe the following safety precautions when troubleshooting your
Kinetix 6000 drive.
ATTENTION
ATTENTION
ATTENTION
145
Capacitors on the dc bus may retain hazardous voltages after
input power has been removed. Before working on the drive,
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.
Do not attempt to defeat or override the drive 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.
Provide an earth ground for test equipment (oscilloscope) used
in troubleshooting. Failure to ground the test equipment could
result in personal injury.
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Troubleshooting the Kinetix 6000 Drive System
Interpreting Status
Indicators
Refer to these troubleshooting tables to identify faults, potential
causes, and the appropriate actions to resolve the fault. If the fault
persists after attempting to troubleshoot the system, please contact
your Rockwell Automation sales representative for further assistance.
Error Codes
The following list of problematic symptoms (no error code shown)
and faults with assigned error codes is designed to help you resolve
anomalies.
When a fault is detected, the seven-segment LED indicator will display
an E followed by the flashing of the two-digit error code, one digit at
a time. This is repeated until the error code is cleared.
Seven-segment LED Indicator Error Codes
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom
Power (PWR) indicator not
ON
Potential Cause
Possible Resolution
No ac power or auxiliary logic power.
Verify ac control power is applied to the
Kinetix 6000 system.
Internal power supply malfunction.
Call your Rockwell Automation sales
representative to return module for repair.
• Check motor wiring.
Motor wiring error.
• Run Hookup test in RSLogix 5000
software.
Incorrect motor chosen.
Verify the proper motor is selected.
Digital I/O not working
correctly
I/O power supply disconnected.
Verify connections and I/O power source.
A blown fuse was detected
on the inverter PCB
Blown fuse.
Call your Rockwell Automation sales
representative to return module for repair.
• High motor ambient temperature
and/or
• Operate within (not above) the
continuous torque rating for the
ambient temperature
40 °C (104 °F) maximum.
Motor jumps when first
enabled
E00
E04
BusUndervoltage
Fault
(Blown fuse)
MotorOvertemp
Fault
(Motor Overtemp)
Motor thermal switch
tripped
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• Excessive current
• Lower ambient temperature, increase
motor cooling.
Motor wiring error.
Check motor wiring at MF connector on the
IAM/AM.
Incorrect motor selection.
Verify the proper motor has been selected.
Troubleshooting the Kinetix 6000 Drive System
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom
Potential Cause
Possible Resolution
Motor cables shorted.
Verify continuity of motor power cable and
connector.
Motor winding shorted internally.
Disconnect motor power cables from the
motor. If the motor is difficult to turn by
hand, it may need to be replaced.
• Check for clogged vents or defective
fan.
Kinetix 6000 temperature too high.
E05
DriveOvercurrent
Fault
(Power Fault)
Self-protection of the
Intelligent Power Module
(IPM) is indicating a major
power related fault
condition.
147
• Make sure cooling is not restricted by
insufficient space around the unit.
• Verify ambient temperature is not too
high.
Operation above continuous power rating
and/or product environmental ratings.
• Operate within the continuous power
rating.
• Reduce acceleration rates.
Remove all power and motor connections,
and preform a continuity check from the dc
bus to the U, V, and W motor outputs. If a
continuity exists, check for wire fibers
between terminals, or send drive in for
repair.
Kinetix 6000 has a short circuit,
overcurrent, or failed component.
E06
E07
HardOvertravel
Fault
(+/- Hard Overtravel)
Axis moved beyond the
physical travel limits in the Dedicated overtravel input is inactive.
positive/negative direction.
MotFeedbackFault
(Motor Feedback Loss)
The feedback wiring is open, shorted, or missing.
• Check wiring.
• Verify motion profile.
• Verify axis configuration in software.
• Check motor encoder wiring.
• Run Hookup test in RSLogix 5000
software.
• Verify voltage level of the incoming ac
power.
E09
BusUndervoltage
Fault
(Bus Undervoltage)
With three-phase power
present, the dc bus voltage
is below limits.
DC bus voltage fell below
the undervoltage limit
while an axis on the
follower power rail was
enabled.
• DC bus voltage for 460V system is
below 275V
• DC bus voltage for 230V system is
below 137V
E10
The dc bus voltage is
above limits.
When the motor is driven by an external
mechanical power source, it may
regenerate too much peak energy
through the drive power supply. The
system faults to save itself from an
overload.
• DC bus voltage for 460V system is
over 820V
• DC bus voltage for 230V system is
over 410V
E11
MotFeedbackFault
(Illegal Hall State)
State of Hall feedback
inputs is incorrect.
• Install an uninterruptible power supply
(UPS) on your ac input.
Disable follower axis before removing
power.
Excessive regeneration of power.
DriveOvervoltage
Fault
(Bus Overvoltage)
• Check ac power source for glitches or
line drop.
Bad connections.
• Change the deceleration or motion
profile.
• Use a larger system (motor and Kinetix
6000 drive).
• Install shunt module.
Verify input is within specifications.
• Verify the Hall wiring at the MF
connector on the IAM/AM.
• Verify 5V power supply to the encoder.
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148
Troubleshooting the Kinetix 6000 Drive System
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom
E16
Softovertravel
Fault
(+/- Software
Overtravel)
Axis position exceeded maximum software setting.
• Verify overtravel settings are
appropriate.
E18
OverSpeedFault
(Overspeed Fault)
Motor speed has exceeded 150% of maximum rated speed. The 100%
trip point is dictated by the lesser of the user velocity limits or the
motor rated base speed.
• Check cables for noise.
Potential Cause
Possible Resolution
• Verify motion profile.
• Check tuning.
• Increase the feed forward gain.
• Increase following error limit or time.
E19
PositionErrorFault
(Follow Error)
Position error limit was exceeded.
• Check position loop tuning.
• Verify sizing of system.
• Verify mechanical integrity of system
within specification limits.
• Use shielded cables with twisted pair
wires.
E20
MotFeedbackFault
(Mtr Fdbk AQB)
Motor Encoder State Error
The motor encoder encountered an
illegal transition.
• Route the feedback away from
potential noise sources.
• Check the system grounds.
• Replace the motor/encoder.
E21
AuxFeedbackFault
(Aux Feedback Comm)
E30
MotFeedbackFault
(Motor Feedback Comm)
Communication was not established with an intelligent encoder.
Verify auxiliary encoder wiring.
• Verify motor selection.
Communication was not established with an intelligent encoder.
• Verify the motor supports automatic
identification.
• Verify motor encoder wiring.
Wiring error.
E34
GroundShortFault
(Ground Fault)
Excessive ground current in
the converter was
detected.
• Check motor power wiring.
• Check input power wiring.
Motor internal ground short.
Replace motor.
Internal malfunction.
Disconnect motor power cable from drive
and enable drive with current limit set to 0.
If fault clears, then a wiring error or motor
internal problem exists. If fault remains,
call your sales representative.
• Remove ground from control power
input.
Grounded control power terminal
(applies to 230V systems only)
• Source control power from three-phase
input power (refer to page 196).
• Add isolation transformer for control
power.
E35
DriveUndervoltage
Fault
(Pre-charge Fault)
Converter pre-charge cycle
failed.
Low ac input voltage.
Check input ac voltage on all phases.
Internal malfunction.
Call your sales representative.
• Reduce acceleration rates.
• Reduce duty cycle (ON/OFF) of
commanded motion.
E36
DriveOvertemp
Fault
(System
Overtemperature)
Converter thermal switch
tripped.
Excessive heat exists in the power
circuitry.
• Increase time permitted for motion.
• Use larger Kinetix 6000 converter.
• Check for clogged vents or defective
fan.
• Make sure cooling is not restricted by
insufficient space around the unit.
Publication 2094-UM001A-EN-P — September 2006
Troubleshooting the Kinetix 6000 Drive System
Error
Code
Fault Message
RSLogix (HIM)
E37
PowerPhaseLoss
Fault
(Phase Loss Flt)
E38
SERCOSFault
(SERCOS Ring Flt)
Problem or Symptom
Potential Cause
Possible Resolution
• One or more phases of the input ac power is missing.
• Axis was enabled when main (three-phase) power was removed.
• Common bus follower axis was enabled when dc bus power was
removed.
The SERCOS ring is not
active after being active
and operational.
149
• Check input ac voltage on all phases.
• Disable axis before removing power.
Check that fiber-optic cable is present and
connected properly.
Cable disconnected.
• Verify that there are no impediments to
motion at startup, such as hard limits.
E39
DriveHardFault
(Self Sense Flt)
Self-sensing Commutation
Startup Error
Motion required for self-sensing startup
commutation was obstructed.
• Increase self-sensing current if high
friction or load conditions exist.
• Check motor or encoder wiring using
wiring diagnostics.
E43
DriveEnableInput
Fault
(Drive Enable Flt)
Missing Drive Enable Input
Signal
• An attempt was made to enable the
axis through software while the Drive
Enable hardware input was inactive.
• The Drive Enable input transitioned
from active to inactive while the axis
was enabled.
• Loose wiring at SO connector.
• Cable/header not seated properly in
SO connector.
• Disable the Drive Enable Input fault.
• Verify that Drive Enable hardware input
is active whenever the drive is enabled
through software.
• Verify wire terminations, cable/header
connections, and +24V.
DriveHardFault
(Safe-off HW Flt)
Safe-off function
mismatch. Drive will not
allow motion.
E50
SERCOSFault
(SERCOS Same ADDR)
Duplicate node address detected on SERCOS ring.
Verify that each SERCOS drive is assigned
a unique node address.
E54
DriveHardFault
(Ifbk HW Fault)
Current feedback hardware fault detected.
Replace the module
E60
DriveHardFault
(Unknown Axis)
Illegal ID bits detected
Replace the module
E49
• Safe-off circuit missing +24V dc.
• Reset error and run proof test.
• If error persists, return the drive to
Rockwell Automation.
• Use shielded cables with twisted pair
wires.
E61
AuxFeedbackFault
(Aux Fdbk AQB)
Auxiliary Encoder State
Error
The auxiliary encoder encountered an
illegal transition.
• Route the feedback away from
potential noise sources.
• Check the system grounds.
• Replace the motor/encoder.
E62
AuxFeedbackFault
(Aux Fdbk Loss)
The feedback wiring is open, shorted, or missing.
E63
AuxFeedbackNoise
(Aux Fdbk Noise)
Noise on auxiliary
feedback cable.
E64
MotorFeedbackNoise
(Mtr Fdbk Noise)
Noise on motor feedback
cable.
E65
No Fault Message
(condition indicated
by on-screen
message)
(Hookup Fault)
Hookup procedure failed
Check the motor feedback cable
connectors/wiring to the IAM/AM and
motor.
• Verify grounding.
Recommended grounding, per
installation instructions, has not been
followed.
• Route feedback cable away from noise
sources.
• Refer to System Design for Control of
Electrical Noise Reference Manual,
publication GMC-RM001.
• Check motor power/feedback wiring.
Motor or feedback device malfunction.
• Refer to on-screen message for
resolution.
Publication 2094-UM001A-EN-P — September 2006
150
Error
Code
Troubleshooting the Kinetix 6000 Drive System
Fault Message
RSLogix (HIM)
Problem or Symptom
Potential Cause
Possible Resolution
• Check motor power/feedback wiring.
No Fault Message
(condition indicated
by on-screen
message)
(Atune Flt)
Autotune procedure failed
E67
DriveHardFault
(Task init)
Operating system failed
Software initialization fault detected due
to hardware failure.
E68
DriveHardFault
(SCANport Comm)
DPI communication failed
The DPI device or cable is faulty.
E69
DriveHardFault
(Objects Init)
Non-volatile memory is corrupt due to control board hardware failure.
Load default parameters, save to
non-volatile memory, and recycle power or
reset the drive.
E70
DriveHardFault
(NV Mem Init)
Non-volatile memory is corrupt due to control board software error.
Load default parameters, save to
non-volatile memory, and recycle power or
reset the drive.
E71
DriveHardFault
(Memory Init)
RAM or Flash memory validation failure
E66
E72
E73
DriveOvertemp
Fault
(Drive Overtemp)
Communicate
(Backplane Comm)
Motor or feedback device malfunction.
• Refer to on-screen message for
resolution.
• Perform Hookup in RSLogix 5000
software.
• Consult RSLogix 5000 help screen.
Inverter thermal switch
tripped
• Cycle power.
• If fault persists, replace module.
Check DPI connections.
• Cycle power.
• If fault persists, replace module.
The fan on the IAM or an AM failed.
Replace the failed module.
The cabinet ambient temperature is
above rating.
Check the cabinet temperature.
The machine duty cycle requires an RMS
current exceeding the continuous rating
of the controller.
Change the command profile to reduce
speed or increase time.
The airflow access to the Kinetix 6000
system is limited or blocked.
Check airflow and re-route cables away
from the Kinetix 6000 system.
Power rail CAN communications failed.
Check module for proper mount.
Power rail connection shorted or open.
Check power rail and module for foreign
objects.
• Check for proper motor sizing.
E74
DriveOvercurrent
Fault
(Bus OverCurrent)
Motor or transmission malfunction.
DC link current exceeds
rating.
• Check/replace transmission device.
• Check/replace motor.
IAM not properly sized.
• Check for proper IAM sizing.
• Install larger kW rated IAM.
• Use a properly sized shunt or modify
duty cycle of the application.
E75
DriveOvervoltage
Fault
(Shunt Time Out)
E76
DriveHardFault
(CAN Init)
DPI hardware initialization
fault detected.
E77
DriveHardFault
(Module Mismatch)
Either 230V AM is installed on power rail with 460V IAM, or 460V AM
is installed on power rail with 230V IAM.
E78
DriveHardFault
(SERCOS Init)
Control hardware fault detected.
The IAM, AM, or SM has exceeded its shunt resistor continuous rating. • System uses internal shunt and
requires external shunt for additional
capacity.
Publication 2094-UM001A-EN-P — September 2006
Control board hardware failure.
• Reset System.
• If fault persists, replace system
module.
Replace mismatched module.
• Cycle power.
• If fault persists, replace module.
Troubleshooting the Kinetix 6000 Drive System
Error
Code
E79
Fault Message
RSLogix (HIM)
DriveOvervoltage
Fault
(Shunt Module Flt)
Problem or Symptom
Potential Cause
151
Possible Resolution
Shunt module temperature fault LED indicator is steady red.
Refer to Temperature Fault LED Indicator
on page 154.
Shunt module shunt fault LED indicator is steady red.
Refer to Shunt Fault LED Indicator on page
154.
Module missing from power rail.
• Install missing module on power rail.
• Fill empty slot with slot filler module.
E80
DriveHardFault
(CPLD Flt)
Control hardware fault detected.
Replace module.
E81
DriveHardFault
(Common Bus Flt)
Follower IAM detected ac input power being applied.
Remove ac input power connections from
follower IAM.
E90
DriveHardFault
(Pre-charge Timeout Flt)
Pre-charge resistor power exceeds the resistor rating.
Allow resistor to cool.
All
RESERVED
others
Call your local Rockwell Automation sales
representative.
Publication 2094-UM001A-EN-P — September 2006
152
Troubleshooting the Kinetix 6000 Drive System
IAM/AM Status Indicators
Drive Status LED Indicator
Drive Status LED
Indicator
Status
Potential Cause
Possible Resolution
Off
Normal, no faults
N/A
N/A
Steady Red
Drive faulted
Seven-segment LED displays error code
Refer to seven-segment error code and Error
Codes section beginning on page 146.
Comm Status LED Indicator
Comm Status LED
Indicator
Status
Potential Cause
Possible Resolution
Steady Green
Communication ready
No faults or failures.
N/A
System is still in the process of establishing
SERCOS communication.
Wait for steady green LED indicator.
Node address setting on the drive module
does not match SERCOS controller
configuration.
Verify proper node switch setting.
Loose fiber-optic connection.
Verify proper fiber-optic cable connections.
Broken fiber-optic cable.
Replace fiber-optic cable.
Receive fiber-optic cable connected to
SERCOS transmit connector and vice versa.
Check proper SERCOS fiber-optic cable
connections.
Flashing Green
Off
(1)
Establishing
communication
No communication (1)
Refer to Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010, for more information.
Bus Status LED Indicator
Bus Status LED
Indicator
Status
Steady Green
Bus power is present, axis enabled.
No faults or failures.
Flashing Green
Bus power is present, axis disabled.
No faults or failures.
Condition
Normal when:
• 24V is applied to Hardware Enable Input (IOD-2).
• MSO instruction is commanded in RSLogix 5000 software.
Normal when:
• 24V is not applied to Hardware Enable Input (IOD-2).
• MSO instruction is not commanded in RSLogix 5000 software.
• Normal when bus power is not applied.
Bus power not present.
• Fault exists, refer to seven segment error code and Error Codes section
beginning on page 146.
• Follower IAM is not configured as CommonBus Follow in RSLogix 5000
software.
Off
Bus power is present in follower IAM.
Publication 2094-UM001A-EN-P — September 2006
• After dc bus voltage is applied, a 2.5 second delay before the LED indicator
begins flashing green is normal operation to provide common bus leader time to
complete pre-charge.
Troubleshooting the Kinetix 6000 Drive System
153
SM Status Indicators
Each of the shunt module LED indicators provide specific
troubleshooting information.
General Shunt Module Troubleshooting
Module
Status
Under These Conditions
Fault is latched
Until fault condition is corrected and cleared.
• Using RSLogix MASR, MAFR, MGSR commands or the HIM (red
stop button).
SM
• Only after the dc bus is discharged (SM Bus Status LED is
flashing).
Fault is cleared
• Drive must be configured with 2094-BSP2 or Bulletin 1394 external
shunt module.
• When the 2094-BSP2 shunt module is used on a 230V system.
• When either 230V or 460V system is configured with a Bulletin
1394 external shunt module.
Disabled (for dc bus
regulation)
• When configured in common bus follower mode.
IAM/AM
Enabled to discharge the dc
bus
Drive (IAM or leader IAM) three-phase power is removed.
Disabled from discharging
the dc bus
When configured in common bus follower mode.
IMPORTANT
Under some fault conditions, two reset commands may be
required to clear drive and SM faults.
Publication 2094-UM001A-EN-P — September 2006
154
Troubleshooting the Kinetix 6000 Drive System
Bus Status LED Indicator
Bus Status LED
Status
Potential Cause
Flashing
Normal condition when control power is applied and bus voltage is less than
60V dc.
N/A
Steady Green
Normal condition when control power is applied and bus voltage is greater
than 60V dc.
N/A
Off
Control power is not present
Replace shunt module.
Internal power supply failure
Possible Resolution
Temperature Fault LED Indicator
Temp Fault LED
Status
Off
Normal condition
Potential Cause
Possible Resolution
N/A
SM internal temperature
exceeds operating
temperature specification
Shunt module fan failed
Replace shunt module.
Shunt module temperature exceeds rating
• Allow shunt module to cool.
• Reset faults.
• Verify IAM bus regulator configuration.
External temperature switch is open
• Allow shunt module to cool.
• Reset faults.
• Verify IAM bus regulator configuration.
TS jumper is not present
Install jumper.
Steady Red
External over temperature
condition
Shunt Fault LED Indicator
Shunt Fault LED
Status
Potential Cause
Off
Normal condition
Steady Red
Shorted internal or external
shunt resistor
Possible Resolution
N/A
Mis-wired shunt jumper or other short on RC
connector
Mis-wired (shorted) external shunt wiring
• Correct mis-wire (shorted) condition.
• If problem persists, replace shunt module.
All SM Status LED Indicators
SM Status LED
Status
Potential Cause
Possible Resolution
• Bus Status
• Temperature Fault
• Shunt Fault
All three SM status LED
indicators flash
simultaneously
Shunt module hardware failure
• Cycle power.
• If problem persists, replace shunt module.
Publication 2094-UM001A-EN-P — September 2006
Troubleshooting the Kinetix 6000 Drive System
Troubleshooting General
System Problems
Condition
Axis or system is unstable.
Use the tables below for troubleshooting general system faults.
Potential Cause
Possible Resolution
The position feedback device is incorrect or open.
Check wiring.
Unintentionally in torque mode.
Check to see what primary operation mode was
programmed.
Motor tuning limits are set too high.
Run Tune in RSLogix 5000 software.
Position loop gain or position controller accel/decel rate is
improperly set.
Run Tune in RSLogix 5000 software.
Improper grounding or shielding techniques are causing noise to be
transmitted into the position feedback or velocity command lines,
causing erratic axis movement.
Check wiring and ground.
Motor Select limit is incorrectly set (servo motor is not matched to
axis module).
• Run Tune in RSLogix 5000 software.
Notch filter or output filter may be required
(refer to Axis Properties dialog, Output tab in
RSLogix 5000 software).
Torque Limit limits are set too low.
Verify that current limits are set properly.
Incorrect motor selected in configuration.
Select the correct motor and run Tune in
RSLogix 5000 software again.
• Check motor size vs. application need.
• Review servo system sizing.
The system friction torque is excessive.
Check motor size vs. application need.
• Check motor size vs. application need.
Available current is insufficient to supply the correct accel/decel
rate.
• Review servo system sizing.
Acceleration limit is incorrect.
Verify limit settings and correct them, as
necessary.
Velocity Limit limits are incorrect.
Verify limit settings and correct them, as
necessary.
The axis cannot be enabled for 1.5 seconds after disabling.
Disable the axis, wait for 1.5 seconds, and
enable the axis.
Enable signal has not been applied or the enable wiring is incorrect.
The motor wiring is open.
Motor does not respond to a
velocity command.
• Check setups.
Mechanical resonance
The system inertia is excessive.
You cannot obtain the motor
acceleration/deceleration that
you want.
155
The motor thermal switch has tripped.
• Check the controller.
• Check the wiring.
Check the wiring.
• Check for a fault.
• Check the wiring.
The motor has malfunctioned.
Repair or replace the motor.
The coupling between motor and machine has broken (i.e., the
motor moves, but the load/machine doesn’t).
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.
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156
Troubleshooting the Kinetix 6000 Drive System
Condition
Potential Cause
Possible Resolution
• Verify grounding.
Recommended grounding per installation instructions have not
been followed.
Presence of noise on command
or motor feedback signal wires.
Line frequency may be present.
Variable frequency may be velocity feedback ripple or a disturbance
caused by gear teeth or ballscrew balls etc. The frequency may be a
multiple of the motor power transmission components or ballscrew
speeds resulting in velocity disturbance.
No rotation
• Refer to System Design for Control of
Electrical Noise, publication GMC-RM001.
• Verify grounding.
• Route wire away from noise sources.
• Decouple the motor for verification.
• Check and improve mechanical performance
of the gearbox, ballscrew, etc.
The motor connections are loose or open.
Check motor wiring and connections.
Foreign matter is lodged in the motor.
Remove foreign matter.
The motor load is excessive.
Verify the servo system sizing.
The bearings are worn.
Return the motor for repair.
The motor brake is engaged (if supplied).
Motor overheating
• Route wire away from noise sources.
• Check brake wiring and function.
• Return the motor for repair.
The motor is not connect to the load.
Check coupling.
The duty cycle is excessive.
Change the command profile to reduce accel/
decel or increase time.
The rotor is partially demagnetized causing excessive motor
current.
Return the motor for repair.
Motor tuning limits are set too high.
Run Tune in RSLogix 5000 software again.
• Remove the loose parts.
Loose parts are present in the motor.
• Return motor for repair.
Through bolts or coupling is loose.
Tighten bolts.
The bearings are worn.
Return motor for repair.
Mechanical resonance
Notch filter may be required (refer to Axis
Properties dialog, Output tab in RSLogix 5000
software).
Motor power phases U and V, U and W, or V and W reversed.
Check and correct motor power wiring.
Sine, Cosine or Rotor leads are reversed in the feedback cable
connector.
Check and correct motor feedback wiring.
Sine, Cosine, Rotor lead sets of resolver feedback are reversed.
Check and correct motor feedback wiring.
• Replace motor.
Abnormal noise
Erratic operation - Motor
locks into position, runs
without control or with
reduced torque.
Publication 2094-UM001A-EN-P — September 2006
Troubleshooting the Kinetix 6000 Drive System
157
Understanding Logix/Drive Fault Behavior
This section provides the drive fault actions and indicates whether the
fault action is programmable.
Drive Fault Action Definitions
Drive Fault Action
Definition
Shutdown
The drive disables and the contactor enable relay opens. Uncontrolled
stop, motor coasts to a stop.
Disable Drive
The drive is disabled. Uncontrolled Stop, motor coasts to a stop.
Stop Motion
Logix configuration for velocity loop Kp/Ki is followed. When zero speed is
reached or stopping time is exceeded, the drive is disabled. Stopping time
and stopping torque are configurable parameters in RSLogix 5000.
Status Only
Drive continues to operate. Status is provided by seven-segment Fault
Status LED Indicator, Drive Status LED Indicator, and DPI (if used).
Logix/Drive Fault Behavior
Fault Message RSLogix
(HIM)
Error
Code
Description
Drive Fault
Action
RSLogix
Programmable
Fault Action?
BusUndervoltageFault
(Blown fuse)
E00
A blown fuse was detected in the inverter pcb.
SHUTDOWN
N
MotorOvertempFault
(Motor Overtemp)
E04
The motor thermal switch was tripped.
Firmware I2t protection does not generate a fault, rather it
dynamically folds back current when 110% of motor rating is
reached. Setting the Motor Thermal fault action to Status Only will
bypass this function.
STOP
Y
DriveOvercurrentFault
(Power Fault)
E05
An instantaneous over-current was detected in the inverter power
section.
SHUTDOWN
N
HardOvertravelFault
(+/- Hard Overtravel)
E06
Axis moved beyond the physical travel limits in the positive/negative
direction. This fault can be configured for status only.
STOP
Y
MotFeedbackFault
(Motor Feedback Loss)
E07
The feedback wiring is open, shorted or missing.
DISABLE
N
SHUTDOWN
N
With 3 phase present, the dc bus voltage is below limits. The trip
point is 275V and 137V dc for 460V/230V drives respectively.
BusUndervoltageFault
(Bus Under Voltage)
E09
DriveOvervoltageFault
(Bus Overvoltage)
E10
The dc bus voltage is above limits. The trip point is 820V and 410V dc
for 460V/230V drives respectively.
SHUTDOWN
N
MotFeedbackFault
(Illegal Hall State)
E11
State of Hall feedback inputs in incorrect.
DISABLE
N
SoftovertravelFault
(+/- Software Overtravel)
E16
Axis position exceeded maximum software setting in the positive/
negative direction. This fault can be configured for status only.
STOP
Y
OverSpeedFault
(Overspeed Fault)
E18
Axis speed has reached 150% of the maximum rated setting. The
100% trip point is dictated by the lesser of the user velocity limits or
the motor rated base speed.
DISABLE
N
PositionErrorFault
(Follow Error)
E19
Axis position error limit has been exceeded. This fault can be
configured for status only.
STOP
Y
DC bus voltage is below limits when any axis on common bus
follower power rail was enabled.
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158
Troubleshooting the Kinetix 6000 Drive System
Fault Message RSLogix
(HIM)
Error
Code
Description
Drive Fault
Action
RSLogix
Programmable
Fault Action?
MotFeedbackFault
(Mtr Fdbk AQB)
E20
Motor encoder has encountered an illegal state transition.
DISABLE
N
AuxFeedbackFault
(Aux Feedback Comm)
E21
Communication was not established with an intelligent (Stegmann)
encoder on the Auxiliary feedback port.
STOP
N
MotFeedbackFault
(Motor Feedback Comm)
E30
Communication was not established with an intelligent (Stegmann)
encoder on the Motor feedback port.
STOP
N
GroundShortFault
(Ground Fault)
E34
Excessive ground current in the converter was detected.
SHUTDOWN
N
DriveUndervoltageFault
(Precharge Fault)
E35
The converter pre-charge cycle has failed.
SHUTDOWN
N
DriveOvertempFault
(System Overtemperature)
E36
Converter internal temperature limit exceeded.
SHUTDOWN
N
• One or more phases of the input AC power is missing.
PowerPhaseLossFault
(Phase Loss Flt)
E37
• Axis was enabled when main (three-phase) power was removed.
SERCOSFault
(SERCOS Ring Flt)
E38
The SERCOS ring is not active after being active and operational.
STOP
N
DriveHardFault
(Self Sense Flt)
E39
Self-sensing commutation fault detected.
DISABLE
N
DriveEnableInputFault
(Drive Enable Flt)
E43
Generated when Enable input switches off when drive is enabled.
STOP
Y
DriveHardFault
(Safe-Off HW Flt)
E49
Safe-off function mismatch. Drive will not allow motion. Refer to the
Kinetix Safe-off Feature Safety Reference Manual, publication
GMC-RM002, for more information. Applies to IAM
(2094-xCxx-Mxx-S) and AM (2094-xMxx-S) with safe-off feature.
SHUTDOWN
N
SERCOSFault
(SERCOS Same ADDR)
E50
Duplicate node address detected on SERCOS ring.
STOP
N
DriveHardFault
(Ifbk HW Fault)
E54
Current feedback hardware fault detected.
SHUTDOWN
N
DriveHardFault
(Unknown Axis)
E60
Invalid module type identified by firmware when applying power.
SHUTDOWN
N
AuxFeedbackFault
(Aux Fdbk AQB)
E61
Auxiliary encoder has encountered an illegal state transition.
DISABLE
N
AuxFeedbackFault
(Aux Fdbk Loss)
E62
The feedback wiring is open, shorted or missing.
DISABLE
N
AuxFeedbackNoise
(Aux Fdbk Noise)
E63
Presence of noise on auxiliary feedback cable.
MotorFeedbackNoise
(Mtr Fdbk Noise)
DISABLE
Y
E64
Presence of noise on motor feedback cable.
No Fault Message
(condition indicated by
on-screen message)
(Hookup Fault)
E65
Hookup procedure failed.
DISABLE
N
• Common bus follower axis was enabled when dc bus power was
removed.
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SHUTDOWN/ STOP N
Troubleshooting the Kinetix 6000 Drive System
159
Fault Message RSLogix
(HIM)
Error
Code
Description
Drive Fault
Action
RSLogix
Programmable
Fault Action?
No Fault Message
(condition indicated by
on-screen message)
(Atune Flt)
E66
Autotune procedure failed.
DISABLE
N
DriveHardFault
(Task init)
E67
Operating system failed.
SHUTDOWN
N
DriveHardFault
(SCANport Comm)
E68
DPI communication failed.
STOP
N
DriveHardFault
(Objects Init)
E69
Non-volatile memory attribute out of range.
SHUTDOWN
N
DriveHardFault
(NV Mem Init)
E70
Non-volatile memory corrupted.
SHUTDOWN
N
DriveHardFault
(Memory Init)
E71
RAM or flash memory validation failure.
SHUTDOWN
N
DriveOvertempFault
(Drive Overtemp)
E72
Inverter temperature limit exceeded.
SHUTDOWN
Firmware I2t protection does not generate a fault, rather it
dynamically folds back current when 110% of drive rating is reached.
Y
Communicate
(Backplane Comm)
E73
Power rail backplane CAN communications failed.
STOP
N
DriveOvercurrentFault
(Bus OverCurrent)
E74
The converter has exceeded its converter rating.
SHUTDOWN
N
DriveOvervoltageFault
(Shunt Time Out)
E75
The IAM, AM, or SM has exceeded its shunt resistor continuous
rating. SHUTDOWN for IAM, DISABLE for AM. IAM also provides
fault handling for shunt module.
SHUTDOWN
N
DriveHardFault
(Can Init)
E76
Either DPI or backplane CAN initialization failure.
SHUTDOWN
N
DriveHardFault
(Module Mismatch)
E77
Generated by IAM if the power rating of an AM on the same power
rail does not match with IAM input power rating.
SHUTDOWN
N
DriveHardFault
SERCOS Init
E78
Control hardware fault detected.
SHUTDOWN
N
DriveOvervoltageFault
(Shunt Module Flt)
E79
Power rail mounted shunt module fault. Displayed on IAM
seven-segment fault status LED indicator.
SHUTDOWN
N
HardwareFault
(CPLD Flt)
E80
Control hardware fault detected.
SHUTDOWN
N
HardwareFault
(Common Bus Flt)
E81
Common bus follower IAM detected ac input power being applied.
SHUTDOWN
N
HardwareFault
(Pre-charge Timeout Flt)
E90
Pre-charge resistor power exceeds the resistor rating.
SHUTDOWN
N
RESERVED
All
Others
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Troubleshooting the Kinetix 6000 Drive System
Supplemental
Troubleshooting
Information
This section provides information for accessing and changing
parameters not accessible through RSLogix 5000 software.
Tools for Changing Parameters
Most parameters are accessible through RSLogix 5000 software.
Alternatives include the DPI compatible Human Interface Module
(HIM) and DriveExplorer software.
Method
DriveExplorer
HIM
(1)
(2)
Description
Catalog Number
Firmware Revision
DriveExplorer software (1)
9306-4EXP02ENE
2.01 or later
Serial to SCANport adapter
1203-SSS (Series B)
3.004 or later
Full numeric LCD HIM
20-HIM-A3 (2)
N/A
Refer to DriveExplorer Getting Results Manual, publication 9306-GR001, for instructions.
Compatible catalog numbers include all 20-HIM-Ax.
Changing Parameters Using DriveExplorer
To navigate using DriveExplorer, refer to the example dialog below.
In this example, the I/O Interface group folder is open, the Analog
Outputs parameter is selected, and the parameter elements are
displayed in the box to the right.
IMPORTANT
Parameters are read-only when the SERCOS ring is active. You
must break the SERCOS ring to change parameters.
To save changes, perform a non-volatile save (NVS) prior to
cycling power.
DriveExplorer Example
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161
Changing Parameters Using the HIM
When using the HIM to monitor or change parameters, use the up and
down arrows (∧ and ∨ ) to arrive at selections. Refer to the
instructions that came with your HIM for more information.
Follow these steps to monitor or change parameters using the HIM.
1. Select parameter. Press ↵ .
2. Select I/O AM1 Group (for IAM). Press ↵ .
3. Select Analog Outputs. Press ↵ .
a. Analog Output 1 is displayed. Press ↵ .
b. For Analog Output 2 use arrows to select. Press ↵ .
4. Press Sel.
5. Enter parameter number. Press ↵ .
Using Analog Test Points to Monitor System Variables
There are two analog output test points accessible from the IOD
26-pin connector on the IAM and AM.
IAM/AM I/O 26-pin (IOD) Connector
IOD Pin
Description
Signal
23
Analog output 0
DAC0
24
Analog output common
DAC_COM
25
Analog output 1
DAC1
26
Analog output common
DAC_COM
Pin Orientation for 26-pin I/O (IOD) Connector
26-pin IAM/AM
I/O Connector
Pin 26
Pin 19
Pin 18
Pin 9
Pin 1
Pin 10
Refer to Analog Outputs on page 62 for signal specifications.
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Troubleshooting the Kinetix 6000 Drive System
Parameters begin with a variable to identify a specific axis by slot
number, as follows:
•
IAM = 0 for parameters 0...999
•
1st AM = 1 for parameters 1000...1999
•
2nd AM = 2 for parameters 2000...2999 and so on...
•
7th AM = 7 for parameter 7000...7999
Monitor System Variables
Controlling Parameter
Analog
Output
Parameter Number (1)
Default Value
1
x681
2
x683
(1)
Scale Parameter
(1)
Parameter Number (1)
Default Value
xx40
x682
0.0060
xx84
x684
0.1000
x = slot number
The value entered in Scale Parameter will scale the analog output so
that you can get a full scale reading of the specific parameter for the
dynamic range or values you are testing.
Monitor Dynamic System Variables
Publication 2094-UM001A-EN-P — September 2006
Attribute
Parameter Number (1)
Velocity feedback (2)
xx40
Velocity commanded (2)
xx36
Torque feedback (3))
xx84
Torque commanded (3)
xx80
Following error (4))
x189
(1)
x = slot number.
(2)
Velocity Command and Feedback scaling value is 0.25V = 1000 rpm (using default scaling).
(3)
Torque Command and Feedback scaling value is 0.25V = 100% rated motor current or amplifier rating
(whichever is less) using default scaling.
(4)
Output scaling is dependant on feedback device and drive resolution.
Chapter
8
Removing and Replacing the Kinetix 6000
Drive Modules
Introduction
This chapter provides remove and replace procedures for your
Kinetix 6000 system components.
Topic
Page
Introduction
163
Before You Begin
163
Removing Power Rail Modules
164
Replacing Power Rail Modules
165
Removing the Power Rail
166
Replacing the Power Rail
167
ATTENTION
Before You Begin
163
This drive contains ESD (Electrostatic Discharge) 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 Allen-Bradley publication
8000-4.5.2, Guarding Against Electrostatic Damage or any other
applicable ESD Protection Handbook.
You will need the following tools available before you begin removal
and replacement procedures:
•
A flat blade screw driver
•
A small flat blade screw driver, 3.5 mm (0.14 in.)
•
Voltmeter
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Removing and Replacing the Kinetix 6000 Drive Modules
Removing Power Rail
Modules
Follow these steps to remove modules from the 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. Allow five minutes for the dc bus to completely discharge 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 only attempt
the procedures in this document 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 module (IAM, AM, or
SM) you are removing.
To identify each connector, refer to page 50 (IAM/AM) or page 68
(SM). The slot filler module has no connectors aside from the
connections to the power rail.
4. Remove the motor cable from the cable shield clamp, as shown in
the examples below.
Vertical Cable Clamp
Orientation Example
Use flat blade screwdriver with
3.5 mm (0.14 in.) tip to depress
spring and remove cable.
Motor
Cable
Horizontal Cable Clamp
Orientation Example
Cable Clamp
Cable Clamp
Screwdriver Tip in Slot
Vent Holes on Top of IAM/AM
5. Loosen the mounting screw (bottom center of each module).
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165
6. Grasp 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).
7. Lift the bracket out of the power rail slot and remove module from
the power rail.
Guide Pins
Integrated Axis Module
(side view)
Power Rail
(side view)
Replacing Power Rail
Modules
Follow these steps to replace the power rail modules.
1. Determine your power rail replacement.
If you are
Then
Replacing a power rail module on the existing power rail
Go to Step 3.
Replacing a power rail module on a new power rail
Go to Step 2.
2. Prepare to mount your replacement module by removing the
protective boots from the power rail connector.
3. Hang the mounting bracket from the slot on the power rail.
IMPORTANT
Power rail must be in vertical orientation before replacing
modules or pins may not seat properly.
4. Align the guide pins on the power rail with the guide pin holes in
the back of the module (refer to the figure above).
TIP
The IAM can have two or three power rail connectors and
guide pins, the AM can have one or two, all other modules
have only one connector and one guide pin.
5. Use 2.26 Nm (20 lb-in) torque to tighten the mounting screw.
6. Re-connect the module connectors.
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Removing and Replacing the Kinetix 6000 Drive Modules
7. Re-apply power to the system.
8. Verify that the system is operating properly.
TIP
Removing the Power Rail
Because IAM and AM parameters reside in the RSLogix
5000 software, you do not need to perform any tuning or
setup procedures.
This procedure assumes you have removed all modules from the
power rail.
Follow these steps to remove the power rail.
1. Disconnect the braided grounding strap from the grounding stud
located on the right side of the power rail.
Braided Ground Strap
100 mm (3.9 in.)
Bonded Cabinet Ground
Power Rail
2094-PRx
Power Rail
2094-PRSx
Braided Ground Strap
100 mm (3.9 in.)
Bonded Cabinet Ground
2. Loosen the mounting bolts (removing the bolts is not necessary).
3. Lift the power rail up and off of the mounting bolts.
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Removing and Replacing the Kinetix 6000 Drive Modules
Replacing the Power Rail
167
This procedure assumes you do not need to change the location of
the power rail on the panel and you intend to reuse the mounting
bolts of the power rail you just removed.
IMPORTANT
ATTENTION
If you need to change the location of the power rail, or if you
are installing a power rail designed for additional or fewer
modules than you removed, refer to Kinetix 6000 Power Rail
Installation Instructions, publication 2094-IN003.
To avoid damage to the power rail during installation, do not
remove the protective boots until the module for each slot is
ready for mounting.
Follow these steps to replace the power rail.
1. Align the replacement power rail over the existing mounting bolts.
IMPORTANT
To improve the bond between the power rail and subpanel,
construct your subpanel out of zinc plated (paint-free)
steel.
2. Tighten the mounting bolts.
3. Re-attach the braided grounding strap to the power rail grounding
stud (refer to page 166).
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Removing and Replacing the Kinetix 6000 Drive Modules
Publication 2094-UM001A-EN-P — September 2006
Appendix
A
Specifications and Dimensions
Introduction
169
This appendix provides product specifications and mounting
dimensions for your Kinetix 6000 system components.
Topic
Page
Introduction
169
Power Specifications
170
Power Dissipation Specifications
180
General Specifications
181
AC Line Filter Specifications
183
External Shunt Module Specifications
184
Product Dimensions
185
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Specifications and Dimensions
Power Specifications
This section contains power specifications for your Kinetix 6000
system components.
Integrated Axis Module (converter) Power Specifications
IAM (230V) Power Specifications
Specification
Description
2094-AC05-MP5-S 2094-AC05-M01-S
AC input voltage
195...264V rms three-phase (230V nom)
AC input frequency
47...63 Hz
Main ac input current (1)
Nom (rms)
Max inrush (0-pk)
10 A
20 A
2094-AC09-M02-S
2094-AC16-M03-S
2094-AC32-M05-S
19 A
33 A
36 A
65 A
71 A
120 A
19 A
36 A
71 A
DC input voltage (common bus follower) 275...375V dc
DC input current (common bus follower)
10 A
Control power ac input voltage
95...264V rms single-phase (230V nom)
Control power ac input current
Nom (@ 220/230V ac) rms
Nom (@ 110/115V ac) rms
Max inrush (0-pk)
3A
6A
20 A
Nominal bus output voltage
325V dc
Line loss ride through
20 ms
Continuous output current
to bus (Adc)
10 A
19 A
36 A
71 A
Intermittent output current
to bus (Adc) (3)
20 A
38 A
72 A
142 A
Bus overvoltage
425V dc
Bus undervoltage
138V dc
Internal shunt
Continuous power
Peak power
N/A
N/A
50 W
8000 W
200 W
5600 W
200 W
5600 W
Internal shunt resistor
N/A
20 Ω
28.75 Ω
28.75 Ω
Shunt on
N/A
405V dc
Shunt off
N/A
375V dc
Continuous power output to bus
3 kW
6 kW
11.3 kW
22.5 kW
Peak power output
6 kW
12 kW
22.6 kW
45.0 kW
Efficiency
95%
Converter inductance
N/A
150 μH
75 μH
Converter capacitance
270 μF
1320 μF
1980 μF
(1)
3A
6A
83 A (2)
540 μF
All 2094-xCxx integrated axis modules are limited to 2 contactor cycles per minute (with up to 4 axis modules), or 1 contactor cycle per minute (with 5 to 8 axis modules).
Maximum inrush duration is less than 1/2 line cycle.
(3)
Intermittent output current duration equals 250 ms.
(2)
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171
IAM (460V) Power Specifications
Description
Specification
2094-BC01-MP5-S 2094-BC01-M01-S
AC input voltage
2094-BC02-M02-S
2094-BC04-M03-S
2094-BC07-M05-S
24 A
20 A
44 A
34 A
71 A
56 A
24 A
43 A
71 A
324...528V rms three-phase (360...480V nom)
AC input frequency
47...63 Hz
(1)
Main ac input current
Nom (rms)
Max inrush (0-pk)
10 A
10 A
DC input voltage (common bus follower)
458...747V dc
DC input current (common bus follower)
10 A
Control power ac input voltage
95...264V rms single-phase (230V nom)
Control power ac input current
Nom (@ 220/230V ac) rms
Nom (@ 110/115V ac) rms
Max inrush (0-pk)
3A
6A
25 A
Nominal bus output voltage
650V dc
Line loss ride through
20 ms
Continuous output current
to bus (Adc)
10 A
24 A
43 A
71 A
Intermittent output current
to bus (Adc) (2)
20 A
48 A
86 A
142 A
Bus overvoltage
825V dc
Bus undervoltage
275V dc
Internal shunt
Continuous power
Peak power
50 W
5600 W
200 W
22,300 W
Internal shunt resistor
115 Ω
28.75 Ω
Shunt on
805V dc
Shunt off
755V dc
Continuous power output to bus
6 kW
15 kW
27.6 kW
45 kW
Peak power output
12 kW
30 kW
55.2 kW
90 kW
Efficiency
95%
Converter inductance
250 μH
125 μH
75 μH
Converter capacitance
110 μF
940 μF
1410 μF
(1)
(2)
220 μF
All 2094-xCxx integrated axis modules are limited to 2 contactor cycles per minute (with up to 4 axis modules), or 1 contactor cycle per minute (with 5 to 8 axis modules).
Intermittent output current duration equals 250 ms.
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Specifications and Dimensions
Axis Module (inverter) Power Specifications
The following tables list power specifications for the Kinetix 6000 axis
modules. The specifications apply to the axis module specified in the
column heading by catalog number and the same axis module
(inverter section) that resides within an integrated axis module.
AM (inverter) 230V Power Specifications
Description
Specification
2094-AMP5-S
2094-AM01-S
(2094-AC05-MP5-S) (2094-AC05-M01-S)
2094-AM02-S
(2094-AC09-M02-S)
2094-AM03-S
2094-AM05-S
(2094-AC16-M03-S) (2094-AC32-M05-S)
Bandwidth (1)
Velocity loop
Current loop
500 Hz
1300 Hz
PWM frequency
8 kHz
Nominal input voltage
325V dc
Continuous current (rms)
3.7 A
6.0 A
10.6 A
17.3 A
34.6 A
Continuous current (0-pk)
5.2 A
8.5 A
15.0 A
24.5 A
48.9 A
Peak current (rms) (2)
7.4 A
12.0 A
21.2 A
34.6 A
51.9 A
Peak current (0-pk) (2)
10.5 A
17.0 A
30.0 A
48.9 A
73.4 A
Continuous power out (nom)
1.2 kW
1.9 kW
3.4 kW
5.5 kW
11.0 kW
Internal shunt
Continuous power
Peak power
N/A
N/A
50 W
1400 W
Internal shunt resistor
N/A
115 Ω
Shunt on
N/A
405V dc
Shunt off
N/A
375V dc
Efficiency
98%
Capacitance
390 μF
660 μF
780 μF
1320 μF
2640 μF
Capacitive energy absorption
15 J
25 J
29 J
50 J
99 J
(1)
(2)
4 kHz
Bandwidth values vary based on tuning parameters and mechanical components.
Peak current duration equals 2.5 seconds.
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173
AM (inverter) 460V Power Specifications
Description
Specification
2094-BMP5-S
2094-BM01-S
(2094-BC01-MP5-S) (2094-BC01-M01-S)
2094-BM02-S
(2094-BC02-M02-S)
2094-BM03-S
(2094-BC04-M03-S)
2094-BM05-S
(2094-BC07-M05-S)
Bandwidth (1)
Velocity loop
Current loop
500 Hz
1300 Hz
PWM frequency
8 kHz
Nominal input voltage
650V dc
Continuous current (rms)
2.8 A
6.1 A
10.3 A
21.2 A
34.6 A
Continuous current (sine)
0-pk
4 kHz
4.0 A
8.6 A
14.6 A
30.0 A
48.9 A
(2)
4.2 A
9.2 A
15.5 A
31.8 A
51.9 A
Peak current (0-pk) (2)
5.9 A
12.9 A
21.8 A
45.0 A
73.4 A
Continuous power out (nom)
1.8 kW
3.9 kW
6.6 kW
13.5 kW
22.0 kW
Internal shunt
Continuous power
Peak power
50 W
5600 W
200 W
22,300 W
Internal shunt resistor
115 Ω
28.75 Ω
Shunt on
805V dc
Shunt off
755V dc
Efficiency
97%
Capacitance
75 μF
150 μF
270 μF
840 μF
1175 μF
Capacitive energy absorption
10 J
19 J
35 J
108 J
152 J
Peak current (rms)
(1)
(2)
Bandwidth values vary based on tuning parameters and mechanical components.
Peak current duration equals 2.5 seconds.
Shunt Module Power Specifications
2094 (rail-mounted) Shunt Module Specifications
Specifications
Shunt Module
Kinetix 6000 Drives Catalog Number
Drive
Voltage
V ac
2094-ACxx-Mxx-S
or
2094-BCxx-Mxx-S
230
2094-BSP2
460
Peak
Resistance Power
Ω
kW
28.75
Peak
Current
A
5.7
14
22.5
28
Continuous Fuse Replacement
Power
W
200
N/A (no internal fuse)
For External Shunt Module Specifications, refer to page 184.
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Specifications and Dimensions
In the table below, the 230V system specifications are given for the
IAM internal shunt resistors, the Kinetix 6000 (2094-BSP2) SM, and the
Bulletin 1394 passive external shunt modules.
Shunt Module (230V) System Specifications
Kinetix 6000
(230V) IAM
2094-
Number of
Axis Modules
Quantity
Shunt Module Specifications
Catalog
Number
AC05-MP5-S
AC05-M01-S
AC09-M02-S
Peak
Power
kW
Continuous
Power
W
–
–
–
–
–
–
–
–
External Passive
Shunt Module (1)
System
Continuous
Shunt Power
W
0
0
50 (3)
–
–
–
AC16-M03-S
–
–
–
–
AC32-M05-S
–
–
–
–
28.75
14.1
5.7
200
N/A (2)
200 plus (5)
300
1394-SR9A
300 (6)
900
1394-SR9AF
900 (6)
1800
1394-SR36A
1800 (6)
3600
1394-SR36AF
3600 (6)
0 to 6
2094-BSP2
ACxx-Mxx-S
ACxx-Mxx-S
ACxx-Mxx-S
0 to 6
2094-BSP2
4
101.3
41
ACxx-Mxx-S
(1)
(2)
(3)
(4)
(5)
(6)
N/A
(2)
–
ACxx-Mxx-S
0 to 7
N/A (2)
Resistance
Ω
Peak
Current
A
200 plus (4)
Refer to page 184 for external shunt module specifications.
Module not part of system configuration.
50 or the sum of the AM internal shunt ratings.
200 plus the sum of the AM internal shunt ratings.
200 plus the sum of the IAM (2094-AC16-M03 and -AC32-M05 only) and AM internal shunt ratings.
Use of external shunt disables shunts internal to IAM and AM.
IMPORTANT
The Kinetix 6000 shunt module, catalog number 2094-BSP2,
used in combination with the 2094-AC09-M02 IAM, disables
the shunt resistor internal to that IAM. This situation is unique
to the 2094-AC09-M02 IAM. Shunt resistors internal to
adjacent AMs are not disabled.
Refer to the 2094-AC09-M02 example on page 175.
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Specifications and Dimensions
175
In the example below, the continuous shunt power is 300 W. The
50 W resistor in the IAM is disabled when used in combination with
the (2094-BSP2) SM. This example is unique to the 2094-AC09-M02
IAM.
230V Shunt Power Example (2094-AC09-M02)
Kinetix 6000 (230V) Shunt Power Example
300 W Continuous Shunt Power
SM (2094-BSP2) 200 W Shunt Module
AM (2094-AMP5) No Internal Shunt
AM (2094-AM03) 50 W Internal Shunt
AM (2094-AM03) 50 W Internal Shunt
IAM (2094-AC09-M02) 50 W Internal Shunt
In the table below, the 460V system specifications are given for the
IAM internal shunt resistors, the Kinetix 6000 (2094-BSP2) SM, and the
Bulletin 1394 passive external shunt modules.
Shunt Module (460V) System Specifications
Kinetix 6000
(460V) IAM
2094-
Number of
Axis Modules
Quantity
Shunt Module Specifications
System
External
Continuous
Passive
Shunt Power
Shunt Module (1) W
Resistance
Ω
Peak
Current
A
Peak
Power
kW
Continuous
Power
W
BC01-MP5-S
–
–
–
–
50 plus (3)
BC01-M01-S
–
–
–
–
50 plus (3)
–
–
–
–
BC04-M03-S
–
–
–
–
BC07-M05-S
–
–
–
–
28.75
28
22.5
200
N/A (2)
200 plus (5)
300
1394-SR9A
300 (6)
900
1394-SR9AF
900 (6)
1800
1394-SR36A
1800 (6)
3600
1394-SR36AF
3600 (6)
BC02-M02-S
BCxx-Mxx-S
0 to 7
1 to 6
Catalog
Number
N/A (2)
2094-BSP2
BCxx-Mxx-S
BCxx-Mxx-S
BCxx-Mxx-S
1 to 6
2094-BSP2
4
BCxx-Mxx-S
(1)
(2)
(3)
(4)
(5)
(6)
201.3
162
N/A (2)
50 plus (3)
200 plus (4)
Refer to page 184 for external shunt module specifications.
Module not part of system configuration.
50 plus the sum of the AM internal shunt ratings.
200 plus the sum of the AM internal shunt ratings.
200 plus the sum of the IAM and AM internal shunt ratings.
Use of external shunt disables shunts internal to IAM and AM.
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176
Specifications and Dimensions
In the example below, the sum of the IAM, AMs, and SM equal 500 W
of continuous shunt power.
TIP
Shunt power adds up the same way for 460V (IAM, AM, and
SM) systems too.
Shunt Power Example (without external shunt)
Kinetix 6000 (230V) Shunt Power Example
500 W Continuous Shunt Power
SM (2094-BSP2) 200 W Shunt Module
AM (2094-AM02) No Internal Shunt
AM (2094-AM03) 50 W Internal Shunt
AM (2094-AM03) 50 W Internal Shunt
IAM (2094-AC16-M03) 200 W Internal Shunt
In the example below, the system is identical to that shown in the
example above, except the Kinetix 6000 (2094-BSP2) shunt module is
wired to a Bulletin 1394 external shunt module. The IAM and AM
internal shunt power is disabled and the continuous shunt power is
equal to that of the external shunt module alone.
TIP
The external shunt disables the internal shunt capacity of 460V
(IAM, AM, and SM) systems too.
Shunt Power Example (with external shunt)
Kinetix 6000 (230V) Shunt Power Example
900 W Continuous Shunt Power
Shunt Module
ALLEN-BRADLEY
Bulletin 1394 External Shunt Module
(1394-SR9AF) 900 W External Shunt
R
BULLETIN 1394 300W SHUNT MODULE
CAT.
PART
SER.
INPUT DC
INPUT AC
FOR FUSE REPLACEMENT USE:
BUSSMAN CAT. NO.
FOR USE WITH 1394-SJT22-X SYSTEM MODULE
SM (2094-BSP2) 200 W Shunt Module
AM (2094-AM02) No Internal Shunt
AM (2094-AM03) 50 W Internal Shunt
AM (2094-AM03) 50 W Internal Shunt
IAM (2094-AC16-M03) 100 W Internal Shunt
Publication 2094-UM001A-EN-P — September 2006
Specifications and Dimensions
177
Circuit Breaker/Fuse Specifications
While circuit breakers offer some convenience, there are limitations
for their use. Circuit breakers do not handle high current inrush as
well as fuses. The Kinetix 6000 needs to be protected by a device
having a short circuit interrupt current rating of the service capacity
provided or a maximum of 100,000 A.
If an upstream circuit protection device is rated for the overload
current and short circuit rating, a supplementary circuit protection
device (such as the 1492 product) can be used as the only
Kinetix 6000 branch circuit protection device. The upstream fully rated
device let-through must be less than or equal to the 10 kA interrupt
rating of the 1492 circuit protection device.
The wiring interconnection in the figures below provide examples of
the needed protection and follows UL and NEC codes. Full
compliance is dependent on final wiring design and installation.
Circuit Protection under NEC 1999 110-10 (preferred fully rated devices)
Required Protection
under 110-10 of
NEC 1999
Preferred Fully
Rated Breakers
Required Protection
under 110-10 of
NEC 1999
Preferred Fully
Rated Breakers
Fully Rated
Fused
Disconnect
Fully Rated
Breaker
Fully Rated
Fused
Disconnect
Fully Rated
Breaker
Distribution
Blocks
Breakers Selected
for Device Protection
Fully Rated Short Circuit
Interrupt Capability
Fully Rated
Fused
Disconnect
Fully Rated
Breaker
Breakers Selected
for Device Protection
Fully Rated Short Circuit
Interrupt Capability
Drive
Drive
Drive
Circuit Protection under NEC 1999 110-10 (allowed but no longer preferred)
Required Protection
under 110-10 of
NEC 1999
Allowed But
No Longer Preferred
Distribution
Blocks
Distribution
Blocks
Breakers Selected
for Device Protection
With Limited Short
Circuit Interrupt
Capability
Drive
Drive
Traditional
Current Limit
Fused
Disconnect or
Breaker
Rated for
Short Circuit
Available
Limiting to
Short Circuit
Rating of Down
Stream Breaker
Required Protection
under 110-10 of
NEC 1999
Allowed But
No Longer Preferred
Breakers Selected
for Device Protection
With Limited Short
Circuit Interrupt
Capability
Traditional
Current Limit
Fused
Disconnect or
Breaker
Rated for
Short Circuit
Available
Limiting to
Short Circuit
Rating of Down
Stream Breaker
Drive
Publication 2094-UM001A-EN-P — September 2006
178
Specifications and Dimensions
Use class CC, J, L, or R fuses, with current rating as indicated in the
table below. The following fuse examples and Allen-Bradley circuit
breakers are recommended for use with integrated axis modules
(2094-xCxx-Mxx-S) when the Line Interface Module (LIM) is not used.
IMPORTANT
Line Interface Modules (2094-ALxxS, -BLxxS, and -XL75S-Cx)
provide branch circuit protection to the IAM. Follow all
applicable NEC and local codes.
Fuse Specifications
V ac Input Power
Catalog Number
2094-AC05-MP5-S
Bussmann
Fuse
Control Input Power
Allen-Bradley
Circuit Breaker (1)
KTK-R-20 (20 A) 1492-CB3H300
140M-F8E-C16
2094-AC09-M02-S KTK-R-30 (30 A) 1492-CB3H400
140M-F8E-C20
2094-AC16-M03-S LPJ-45SP (45 A) N/A
140U-H6C3-C50
2094-AC32-M05-S LPJ-80SP (80 A) N/A
140U-H6C3-C90
2094-AC05-M01-S
2094-BC01-MP5-S
Bussmann
Fuse
DC Common Bus Fuse
Allen-Bradley
Bussmann
Circuit Breaker (1) Fuse
1492-CB2H060
1492-SP2D200
FNQ-R-10 (10 A)
Ferraz
Shawmut Fuse
N/A
A50P20-1
FWH-35B
A50P35-4
FWH-60B
A50P60-4
FWH-125B
A50P125-4
N/A
A100P20-1
FWJ-40A
A100P40-1
KTK-R-20 (20 A) 1492-CB3H300
140M-F8E-C32
2094-BC02-M02-S
KTK-R-30 (30 A) 1492-CB3H400
140M-F8E-C45
2094-BC04-M03-S
LPJ-45SP (45 A)
140U-H6C3-C50
FWJ-70A
A100P70-1
2094-BC07-M05-S
LPJ-80SP (80 A)
140U-H6C3-C90
FWJ-125A
A100P125-1
2094-BC01-M01-S
(1)
N/A
1492-CB2H060
When using Bulletin 1492 circuit protection devices, the maximum short circuit current available from the source is limited to 5000 A.
ATTENTION
Publication 2094-UM001A-EN-P — September 2006
Bulletin 1492 and 140M circuit breakers should not be used on
the output of an ac drive as an isolating disconnect switch or
motor overload device. These devices are designed to operate
on sine wave voltage and the drive’s PWM waveform does not
allow it to operate properly. As a result, damage to the device
will occur.
Specifications and Dimensions
179
Contactor Ratings
The table below lists the recommended contactor ratings for
integrated axis modules installed without a line interface module.
Catalog Number
230V IAM
Contactor
Catalog Number
460V IAM
Contactor
2094-AC05-MP5-S
100-C23x10 (ac coil)
100-C23Zx10 (dc coil)
2094-BC01-MP5-S
100-C23x10 (ac coil)
100-C23Zx10 (dc coil)
2094-AC05-M01-S
2094-BC01-M01-S
2094-AC09-M02-S
100-C37x10 (ac coil)
100-C37Zx10 (dc coil)
2094-BC02-M02-S
100-C37x10 (ac coil)
100-C37Zx10 (dc coil)
2094-AC16-M03-S
100-C72x10 (ac coil)
100-C72Zx10 (dc coil)
2094-BC04-M03-S
100-C60x10 (ac coil)
100-C60Zx10 (dc coil)
2094-AC32-M05-S
100-C85x10 (ac coil)
100-C85Zx10 (dc coil)
2094-BC07-M05-S
100-C72x10 (ac coil)
100-C72Zx10 (dc coil)
Transformer Specifications for Control Power Input
Attribute
Value (460V system)
Input volt-amperes
750VA
Input voltage
460V ac
Output voltage
120...240V ac
Publication 2094-UM001A-EN-P — September 2006
180
Specifications and Dimensions
Power Dissipation
Specifications
Use the following table to size an enclosure and calculate required
ventilation for your Kinetix 6000 drive system.
Usage as % of Rated Power Output
(watts)
Kinetix 6000 Modules
20%
40%
60%
80%
100%
19
23
27
31
35
2094-AC09-M02-S
33
51
69
87
105
2094-AC16-M03-S
18
38
60
83
108
2094-AC32-M05-S
31
64
102
144
190
15
20
25
30
35
2094-BC02-M02-S
20
30
40
50
60
2094-BC04-M03-S
22
43
65
86
108
2094-BC07-M05-S
44
77
111
144
177
Integrated axis module (IAM converter) (1)
2094-AC05-MP5-S
2094-AC05-M01-S
2094-BC01-MP5-S
2094-BC01-M01-S
Integrated axis module (IAM Inverter) or axis module (AM) (1)
2094-AC05-MP5-S or -AMP5-S
60
65
70
75
80
2094-AC05-M01-S or -AM01-S
62
69
76
83
90
2094-AC09-M02-S or -AM02-S
64
73
82
91
100
2094-AC16-M03-S or -AM03-S
50
72
99
130
165
2094-AC32-M05-S or -AM05-S
106
160
220
285
356
2094-BC01-MP5-S or -BMP5-S
75.7
80.9
86
92
98
2094-BC01-M01-S or -BM01-S
95
120
145
170
195
2094-BC02-M02-S or -BM02-S
98
126
154
182
210
2094-BC04-M03-S or -BM03-S
95
132
171
212
256
2094-BC07-M05-S or -BM05-S
118
182
251
326
406
68
121
174
227
280
Shunt module (SM)
2094-BSP2
(1)
Internal shunt power is not included in the calculations and must be added based on utilization.
Publication 2094-UM001A-EN-P — September 2006
Specifications and Dimensions
General Specifications
181
This section contains general specifications for your Kinetix 6000
system components.
Maximum Feedback Cable Lengths
Although motor feedback cables are available in standard lengths up
to 90 m (295.3 ft), the drive/motor/feedback combination may limit
the maximum cable length, as shown in the tables below. These tables
assume the use of recommended 2090 series cables.
MP-Series (MPL and MPG) Motors
MPL-A (230V) Motors
MPL-B (460V) Motors
MPG-A
(230V) Motors
MPG-B
(460V) Motors
Absolute
High-resolution (1)
m (ft)
Incremental (2)
m (ft)
Absolute
High-resolution (1)
m (ft)
Incremental (2)
m (ft)
Resolver (3)
m (ft)
Absolute
High-resolution (4)
m (ft)
Absolute
High-resolution (4)
m (ft)
30 (98.4)
30 (98.4)
90 (295.3)
30 (98.4)
90 (295.3)
30 (98.4)
60 (196.8)
(1)
Refers to MPL-A/BxxxS/M (single-turn or multi-turn) low inertia motors with absolute high-resolution feedback.
Refers to MPL-A/BxxxH low inertia motors with 2000-line incremental feedback.
(3)
Refers to MPL-A/BxxxR low inertia motors with 2-pole resolver feedback.
(4)
Refers to MPG-A/BxxxS/M (single-turn or multi-turn) integrated gear motors with absolute high-resolution feedback.
(2)
MP-Series (MPF and MPS), 1326AB, and TL-, F-, and Y-Series Motors
MPF-A and MPS-A
(230V) Motors
MPF-B and MPS-B
(460V) Motors
1326AB (M2L/S2L)
(460V) Motors
1326AB
(460V) Motors
F- and Y-Series
(230V) Motors
TL-Series
(230V) Motors
Absolute
High-resolution (1) (2)
m (ft)
Absolute
High-resolution (1) (2)
m (ft)
Absolute
High-resolution (3)
m (ft)
Resolver (4)
m (ft)
Incremental (5)
m (ft)
Incremental (6)
m (ft)
30 (98.4)
90 (295.3)
90 (295.3)
90 (295.3)
30 (98.4)
30 (98.4)
(1)
(2)
(3)
(4)
(5)
(6)
Refers to MPF-A/BxxxxS/M (single-turn or multi-turn) food grade motors with absolute high-resolution feedback.
Refers to MPS-A/BxxxxS/M (single-turn or multi-turn) stainless steel motors with absolute high-resolution feedback.
Refers to 1326AB-Bxxxx-M2L/S2L (single-turn or multi-turn) motors with absolute high-resolution feedback.
Refers to 1326AB-Bxxxx-21 motors with resolver feedback.
Refers to F- and Y-Series motors with incremental (optical encoder) feedback.
Refers to TL-Axxxx-H low inertia motors with incremental feedback.
Environmental Specifications
Specification
Operational Range
Storage Range (non-operating)
Ambient Temperature
0...50 ° C (32...122 ° F)
-40...70 ° C (-40...158 ° F)
Relative Humidity
5...95% noncondensing
5...95% noncondensing
Altitude
1000 m (3281 ft)
3000 m (9843 ft) during transport
Vibration
5...55 Hz @ 0.35 mm (0.014 in.) double amplitude, continuous displacement; 55...500 Hz @ 2.0 g peak constant
acceleration
Shock
15 g, 11 ms half-sine pulse (3 pulses in each direction of 3 mutually perpendicular directions)
Publication 2094-UM001A-EN-P — September 2006
182
Specifications and Dimensions
Weight Specifications
Kinetix 6000
Module
IAM
(230V)
AM
(230V)
Power Rails
(Slim)
Value, Approx.
Catalog Number
Kinetix 6000
Module
kg (lb)
2094-AC05-MP5-S
2.23 (4.9)
2094-AC05-M01-S
2.27 (5.0)
2094-AC09-M02-S
2.31 (5.1)
2094-AC16-M03-S
2094-AC32-M05-S
Catalog Number
Value, Approx.
kg (lb)
2094-BC01-MP5-S
4.98 (11.0)
2094-BC01-M01-S
5.03 (11.1)
2094-BC02-M02-S
5.08 (11.2)
4.71 (10.4)
2094-BC04-M03-S
9.60 (21.1)
7.43 (16.4)
2094-BC07-M05-S
10.1 (22.3)
IAM
(460V)
2094-AMP5-S
1.46 (3.2)
2094-BMP5-S
2.44 (5.4)
2094-AM01-S
1.50 (3.3)
2094-BM01-S
2.49 (5.5)
2094-AM02-S
1.54 (3.4)
2094-BM02-S
2.54 (5.6)
2094-AM03-S
3.13 (6.9)
2094-BM03-S
4.58 (10.1)
2094-AM05-S
3.18 (7.0)
2094-BM05-S
4.98 (11.0)
2094-PRS1
1.05 (2.3)
2094-PR1
1.04 (2.3)
2094-PRS2
1.59 (3.5)
2094-PR2
1.41 (3.1)
2094-PRS3
2.14 (4.7)
2094-PR4
2.18 (4.8)
2094-PRS4
2.67 (5.9)
2094-PR6
2.90 (6.4)
2094-PRS5
3.11 (6.8)
2094-PR8
3.63 (8.0)
2094-PRS6
3.55 (7.8)
2094-PRS7
3.99 (8.8)
SM (460V)
2094-BSP2
3.10 (6.8)
2094-PRS8
4.43 (9.7)
Slot Filler Module
2094-PRF
0.45 (1.0)
AM
(460V)
Power Rails
Certifications
Certification (1)
(when product is marked)
Standards
c-UL-us
UL Listed to U.S. and Canadian safety standards (UL 508 C File E59272).
European Union 89/336/EEC EMC Directive compliant with EN 61800-3:2004:
Adjustable Speed Electrical Power Drive Systems - Part 3; EMC Product
Standard including specific test methods.
CE
European Union 73/23/EEC Low Voltage Directive compliant with:
• EN 60204-1:1997 - Safety of Machinery - Electrical Equipment of Machines.
• EN 50178:1997 - Electronic Equipment for use in Power Installations.
• EN 60204-1:1997 - Safety of Machinery - Electrical Equipment of Machines.
Functional Safety
• IEC 61508: Part 1-7:2000 - Functional Safety of Electrical/Electronic/
Programmable Electronic Safety-related Systems.
• EN954-1:1996 - Safety of machinery. Safety related parts of control systems.
Part 1: General principles for design.
(1)
Refer to http://www.rockwellautomation.com/products/certification for Declarations of Conformity Certificates.
Publication 2094-UM001A-EN-P — September 2006
Specifications and Dimensions
AC Line Filter
Specifications
183
The tables below contain specifications for ac line filters available for
Kinetix 6000 servo drive systems.
AC Line Filter Specifications
Specifications
AC Line Filter
Catalog Number
Voltage
Phase
2090-XXLF-X330B
2090-XXLF-375
2090-XXLF-375B
2090-XXLF-3100
500V ac
50/60 Hz
Three
Current
Power
Loss
W
Leakage
Current
mA
Weight
kg (lb)
30A @ 50° C
(122° F)
38
64
2.7
(5.9)
75A @ 50° C
(122° F)
57
100A @ 50° C
75
(122° F)
50
108
73
5.2
(11.4)
Humidity
Vibration
Operating
Temperature
90% RH
10-200 Hz
@ 1.8 g
-25 to 85° C
(-13 to 185 ° F)
9.5
(20.9)
AC Line Filter Selection
Drive Catalog Number
AC Line Filter
Catalog Number
2094-AC05-MP5-S
2094-AC05-M01-S
2090-XXLF-X330B
2094-AC09-M02-S
2094-AC16-M03-S
2090-XXLF-375
2094-AC32-M05-S
2090-XXLF-3100
2094-BC01-MP5-S
2094-BC01-M01-S
2090-XXLF-X330B
2094-BC02-M02-S
2094-BC04-M03-S
2090-XXLF-375B
2094-BC07-M05-S
2090-XXLF-3100
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184
Specifications and Dimensions
External Shunt Module
Specifications
External shunt modules are used with Kinetix 6000 drives when
regenerative loads exceed the capacity of the internal (IAM or AM)
shunt resistor.
Passive shunt modules wire to the Kinetix 6000 (rail mounted) shunt
module, catalog number 2094-BSP2.
External Passive Shunt Module Specifications
Specifications
External Shunt
Catalog Number
1394-SR9A
1394-SR9AF
1394-SR36A
1394-SR36AF
(1)
Drive
Voltage
V ac
Resistance
Ω
230 (1)
4
460
230
(1)
4
460
230 (1)
4
460
230 (1)
4
460
Peak
Power
kW
Peak
Current
A
41.0
101.25
160.0
20.0
41.0
101.25
160.0
20.0
41.0
101.25
160.0
20.0
41.0
101.25
160.0
20.0
Cont.
Power
W
Shipping
Weight
kg (lb)
300
3.63 (8)
900
3.63 (8)
1800
8.6 (19)
3600
9.0 (20)
Bussmann
Replacement Fuse
FNQ-R-20-R1 (1)
FWP50A14F
FNQ-R-20-R1(1)
FWP50A14F
FNQ-R-20-R1 (1)
FWP50A14F
FNQ-R-25-R1 (1)
FWP50A14F
Requires the use of an FNQ fuse with an adapter to allow the smaller body fuse to fit the larger FWP fuse holder.
Bulletin 1336 external active shunt modules wire directly to the dc
bus.
External Active Shunt Module Specifications
Specifications
Shunt Module
Kinetix 6000 Drives Catalog Number
2094-ACxx-Mxx
1336-MOD-KA005
1336-MOD-KA010
Drive
Voltage
V ac
230V
1336-MOD-KB005
2094-BCxx-Mxx
1336-MOD-KB010
460V
1336-MOD-KB050
Peak
Resistance Power
Ω
kW
Peak
Current
A
Continuous Shipping
Power
Weight
W
kg (lb)
Fuse Replacement
28.0
6
15
375
A50P10
13.2
12
30
750
104.0
6
7.5
375
52.0
12
15
750
10.0
60
76
3750
6.8 (15)
A50P20
A60Q
A60Q
33.8 (75)
A70QS35
Refer to the Common DC Bus Selection Guide, publication
DRIVES-SG001, for dimensions and catalog number information for
the Bulletin 1336 active shunt modules.
Publication 2094-UM001A-EN-P — September 2006
Specifications and Dimensions
Product Dimensions
185
This section contains product dimensions for your Kinetix 6000 system
components.
Integrated Axis Module Dimensions
2094-AC05-MP5-S, AC05-M01-S, and -AC09-M02-S (230V)
2094-BC01-MP5-S, -BC01-M01-S, and -BC02-M02-S (460V)
A
Dimensions are in millimeters (inches)
B
125
(4.9)
20
(0.8)
8.9
(0.35)
F
2094-AC05-M01-S (230V)
(shown)
E
D
2090-XXNFxx-Sxx (flying lead)
Feedback Cable with
2090-K6CK-D15Mxx
Low-profile Connector Kit
Power Rail
62
(2.45)
Important: Additional clearance below the connector
is necessary to provide the recommended cable-bend
radius.
This view illustrates the
additional clearance required for
premolded cable connectors.
2090-UXNFBxx-Sxx (premolded connector) Feedback Cable
Modules are shown mounted to the power rail and the dimensions
reflect that in the depth of the module.
IAM Dimensions
Kinetix 6000 IAM
A
mm (in.)
B
mm (in.)
D
mm (in.)
E
mm (in.)
F
mm (in.)
198 (7.8)
176 (7.0)
51 (2.0)
206 (8.2)
231 (9.1)
272 (10.7)
249 (9.8)
0 (0)
256 (10.1)
281 (11.0)
2094-AC05-MP5-S
2094-AC05-M01-S
2094-AC09-M02-S
2094-BC01-MP5-S
2094-BC01-M01-S
2094-BC02-M02-S
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186
Specifications and Dimensions
Integrated Axis Module Dimensions
2094-AC16-M03-S and -AC32-M05-S (230V)
2094-BC04-M03-S and -BC07-M05-S (460V)
Dimensions are in millimeters (inches)
A
C
B
8.9
(0.35)
F
2094-BC04-M03-S (460V) shown
E
2090-XXNFxx-Sxx (flying lead) Feedback Cable with
2090-K6CK-D15Mxx Low-profile Connector Kit
Power Rail
62
(2.45)
Important: Additional clearance below the connector
is necessary to provide the recommended cable-bend
radius.
This view illustrates the
additional clearance required for
premolded cable connectors.
2090-UXNFBxx-Sxx (premolded connector) Feedback Cable
Modules are shown mounted to the power rail and the dimensions
reflect that in the depth of the module.
IAM Dimensions
Kinetix 6000 IAM
2094-AC16-M03-S
2094-AC32-M05-S
2094-BC04-M03-S
2094-BC07-M05-S
Publication 2094-UM001A-EN-P — September 2006
A
mm (in.)
B
mm (in.)
198 (7.8)
176 (7.0)
272 (10.7)
249 (9.8)
C
mm (in.)
125 (4.9)
196 (7.7)
196 (7.7)
E
mm (in.)
F
mm (in.)
302 (11.9)
420 (16.5)
256 (10.1)
374 (14.7)
318 (12.5)
436 (17.2)
Specifications and Dimensions
187
Axis Module Dimensions
2094-AMP5-S, -AM01-S, and -AM02-S (230V)
2094-BMP5-S, -BM01-S, and -BM02-S (460V)
A
B
70
(2.76)
Dimensions are in millimeters (inches)
20
(0.8)
8.9
(0.35)
F
2094-AM01-S (230V) shown
E
D
2090-XXNFxx-Sxx (flying lead)
Feedback Cable with 2090-K6CK-D15Mxx
Low-profile Connector Kit
Power Rail
62
(2.45)
Important: Additional clearance below the connector
is necessary to provide the recommended cable-bend
radius.
This view illustrates the
additional clearance required for
premolded cable connectors.
2090-UXNFBxx-Sxx (premolded connector) Feedback Cable
Modules are shown mounted to the power rail and the dimensions
reflect that in the depth of the module.
AM Dimensions
Kinetix 6000 AM
A
mm (in.)
B
mm (in.)
D
mm (in.)
E
mm (in.)
F
mm (in.)
198 (7.8)
176 (7.0)
51 (2.0)
206 (8.2)
231 (9.1)
272 (10.7)
249 (9.8)
0 (0)
256 (10.1)
281 (11.0)
2094-AMP5-S
2094-AM01-S
2094-AM02-S
2094-BMP5-S
2094-BM01-S
2094-BM02-S
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188
Specifications and Dimensions
Axis Module Dimensions
2094-AM03-S and -AM05-S (230V)
2094-BM03-S and -BM05-S (460V)
Dimensions are in millimeters (inches)
A
C
B
8.9
(0.35)
F
2094-BM03-S (460V) shown
E
2090-XXNFxx-Sxx (flying lead) Feedback Cable with
2090-K6CK-D15Mxx Low-profile Connector Kit
Power Rail
62
(2.45)
Important: Additional clearance below the connector
is necessary to provide the recommended cable-bend
radius.
This view illustrates the
additional clearance required for
premolded cable connectors.
2090-UXNFBxx-Sxx (premolded connector) Feedback Cable
Modules are shown mounted to the power rail and the dimensions
reflect that in the depth of the module.
AM Dimensions
Kinetix 6000 AM
2094-AM03-S
2094-AM05-S
2094-BM03-S
2094-BM05-S
Publication 2094-UM001A-EN-P — September 2006
A
mm (in.)
B
mm (in.)
C
mm (in.)
E
mm (in.)
F
mm (in.)
198 (7.8)
176 (7.0)
70 (2.8)
302 (11.9)
420 (16.5)
272 (10.7)
249 (9.8)
141 (5.5)
256 (10.1)
374 (14.7)
318 (12.5)
436 (17.2)
Specifications and Dimensions
189
Shunt Module Dimensions
2094-BSP2
263
(10.3)
249
(9.8)
20
(0.8)
70
(2.76)
Dimensions are in millimeters (inches)
123
(4.8)
20
(0.8)
43
(1.7)
281
(11.0)
256
(10.1)
Power Rail
Modules are shown mounted to the power rail and the dimensions
reflect that in the depth of the module.
Publication 2094-UM001A-EN-P — September 2006
190
Specifications and Dimensions
Publication 2094-UM001A-EN-P — September 2006
Appendix
B
Interconnect Diagrams
Introduction
191
This appendix provides wiring examples and system block diagrams
for your Kinetix 6000 system components.
Topic
Page
Introduction
191
Wiring Examples
192
Power Wiring Examples
193
DC Common Bus Wiring Examples
197
Shunt Module Wiring Examples
201
Axis Module/Motor Wiring Examples
204
Controlling a Brake Example
210
System Block Diagrams
212
Publication 2094-UM001A-EN-P — September 2006
192
Interconnect Diagrams
Wiring Examples
This appendix provides wiring examples to assist you in wiring the
Kinetix 6000 system. The notes below apply to the wiring examples
on the pages that follow.
Note
Information
1
For power wiring specifications, refer to Power Wiring Requirements on page 80.
2
For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Specifications on page 177.
3
Place ac (EMC) line filters as close to the drive as possible and do not route very dirty wires in wireway. If routing in wireway is unavoidable, use
shielded cable with shields grounded to the drive chassis and filter case. For ac line filter specifications, refer to AC Line Filter Specifications on
page 183.
4
Terminal block is required to make connections.
5
2094-BCxx-Mxx (460V) IAM requires step down transformer for single-phase control power input. Source 2094-ACxx-Mxx (230V) IAM control
power from the three-phase input power (line-to-line). Supplying 230V control power from any other source requires an isolation transformer. If
used, do not ground either leg of the isolation transformer output.
6
LIM models 2094-ALxxS and -BLxxS can supply a maximum of eight axes. LIM models 2094-XL75S-Cx can supply a maximum of sixteen axes. For
common bus systems with more than sixteen axes, multiple LIMs (or control power transformers) are required.
7
LIM models 2094-ALxxS, -BLxxS, and -XL75S-Cx are capable of connecting to two IAMs, providing each IAM has its own line filter and the
maximum current specification is not exceeded.
8
Contactor coil (M1) needs integrated surge suppressors for ac coil operation. Refer to Contactor Ratings on page 179.
9
Drive Enable input must be opened when main power is removed, or a drive fault will occur. A delay of at least 1.0 second must be observed
before attempting to enable the drive after main power is restored.
10
Cable shield clamp must be used in order to meet CE requirements. No external connection to ground is required.
11
Default configuration for jumper is for grounded power at user site. Ungrounded sites must jumper the bleeder resistor to prevent high
electrostatic buildup. Refer to Determining Your Type of Input Power on page 71 for more information.
12
Leave jumper between PR2 and PR3 as shown to utilize the internal pre-charge resistor. Remove jumper when external pre-charge/circuit is
required. For more information, refer to the 8720MC Regenerative Power Supply Installation Manual, publication 8720MC-RM001.
13
14
ATTENTION
ATTENTION
Implementation of safety circuits and risk assessment is the responsibility of the machine
builder. Please reference international standards EN 1050 and EN 954 estimation and safety
performance categories. For more information refer to Understanding the Machinery Directive,
publication SHB-900.
Wiring the contactor enable relay is required. To avoid personal injury or damage to the drive,
wire the contactor enable relay into your safety control string. Refer to Contactor Enable Relay
on page 63, for more information. The recommended minimum wire size for wiring the safety
circuit to the contactor enable connector is 1.5 mm2 (16 AWG).
15
The Kinetix 6000 axis module referenced is either an individual axis module (2094-xMxx) or the same axis module that resides within an
integrated axis module (2094-xCxx-Mxx).
16
For motor cable specifications, refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001.
17
Wire colors are for flying lead cable (2090-XXNFxx-Sxx) and may vary from the premolded connector cable (2090-UXNFBxx-Sxx).
18
Y-Series feedback cables have a drain wire that must be folded back under the low-profile connector clamp.
19
Only the MPG-Bxxx encoder uses the +5V dc supply. MPL-B3xx, -B4xx, -B45xx, -B5xx, -B6xx, -B8xx, -B9xx, encoders use the +9V dc supply.
20
MPL-A3xx, -A4xx, -A45xx, and MPG-Axxx encoders use the +5V dc supply. Only the MPL-A5xx encoder uses the +9V dc supply.
21
MPL-A15xx, -A2xx, MPF-A3xx, -A4xx, -A45xx, and MPS-Axxx encoders use the +5V dc supply. MPL-B15xx, -B2xx, MPF -A5xx, -Bxxx, and
MPS-Bxxx encoders use +9V dc.
22
Brake wires on MPF-A/B5xx motors are labeled plus (+) and minus (-). All other MP-Series motor brake wires are labeled F and G.
23
Refer to 1336 Active Shunt Input Fuse Specifications for input fuse specifications. Current requirements are for master only shunt applications.
For master/slave applications, you must multiply the current requirement by the number of shunt units.
24
Refer to 1336 Active Shunt Fault Relay Specifications for fault relay specifications. This normally closed contact (TTL compatible) is closed when
115V ac is applied and opens when a shunt fault or loss of power occurs.
Publication 2094-UM001A-EN-P — September 2006
Interconnect Diagrams
193
Power Wiring Examples
Single IAM Wiring Example with LIM (2094-AL09 or -BL02)
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
Power Rail
Ground Stud
Bonded Cabinet
Ground Bus*
Note 10
Cable Shield
Clamp
4
Line Interface Module
2094-AL09 or -BL02
Single-phase (CPL) Output
195...264V ac RMS
Notes 1
Motor Power
(MP) Connector
L2
L1
1
1
2
2
1
2
VAC LINE Three-phase
(IPL) Input
195...264V ac RMS
or 324...528V ac RMS
Note 1
L3
L2
L1
Ground
VAC LOAD Three-phase
(OPL) Output
195...264V ac RMS
or 324...528V ac RMS
Note 1
3
4
L3'
5
L2'
6
L1'
Control Power
(CPD) Connector
CTRL 2
CTRL 1
W
V
U
Three-phase
Motor Power
Connections
Note 16
3
2
1
DCDC+
L3
L2
DC Bus
and
Three-phase
Input (IPD)
Connector
L1
Input Fusing *
MBRK_PWR
24V dc Output
(PSL) Connector
MBRK_COM
MBRK_PWR
MBRK_COM
1
2
3
4
MBRK MBRK +
COM
Motor/Resistive
Brake (BC) Connector
IO_PWR
I/O (IOL)
Connector
Note 13, 14
PWR
24-26
DBRK DBRK +
STOP *
COIL_A1
IO_COM
COIL_A2
6
BR-
5
BR+
Motor Brake
Connections
4
3
2
BR-
1
BR+
Resistive Brake
Connections
13
20-22
1
4
2
CONT ENCONT EN+
Contactor Enable
(CED) Connector
Note 14
* Indicates User Supplied Component
Publication 2094-UM001A-EN-P — September 2006
194
Interconnect Diagrams
Multiple IAM Wiring Example with LIM (2094-ALxxS, -BLxxS, or -XL75S)
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
(IAM_1)
Bonded Cabinet
Ground Bus*
Note 10
Power Rail
Ground Stud
Cable Shield
Clamp
Line Interface Module
2094-ALxxS, -BLxxS, or
-XL75S-Cx
4
W
V
Motor Power
(MP) Connector
Control Power CTRL 2 1
Single-phase (CPL) Output
2
195...264V ac RMS CTRL 1
Note 1
Note 4
1
2
U
Control Power
(CPD) Connector
CTRL 2
CTRL 1
Three-phase
Motor Power
Connections
Note 16
3
2
1
To CPD Connector
IAM_2
Note 6, 7
1
2
1
VAC LINE Three-phase
(IPL) Input
195...264V ac RMS
or 324...528V ac RMS
Note 1
2
3
4
VAC LOAD Three-phase
(OPL) Output
195...264V ac RMS
or 324...528V ac RMS
Note 1
L3
L2
L1
1
L3'
L2'
L1'
Note 4
2
3
Three-phase
AC Line Filter
Note 3
3
4
4
5
6
DCDC+
L3
DC Bus
and
Three-phase
Input (IPD)
Connector
L2
L1
To IPD Connector
IAM_2
Note 7
Auxiliary Power
Single-phase (APL) Input
93...121V ac RMS
or 196...253V ac RMS
(this connector is present
only on the 2094-XL75S-Cx)
Note 1
1
2
L1
L2/N
IO_PWR2
IO_COM2
24V dc (P1L) Output
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
1
2
3
To BC Connector
IAM_2
Note 7
4
5
6
Motor Brake
Connections
MBRK MBRK +
Motor/Resistive
Brake (BC) Connector
IO_PWR1
1, 3, 5
COM
PWR
DBRK DBRK +
I/O (IOL)
Connector
Note 13, 14
STOP *
COIL_E1
IO_COM1
COIL_E2
* Indicates User Supplied Component
Publication 2094-UM001A-EN-P — September 2006
6
BR-
5
BR+
4
3
2
BR-
1
BR+
Resistive Brake
Connections
7
2, 4, 6
1
8
2
CONT ENCONT EN+
Contactor Enable
(CED) Connector
Note 14
To CED Connector
IAM_2
Note 7
Interconnect Diagrams
195
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
(IAM_2)
Power Rail
Ground Stud
Bonded Cabinet
Ground Bus*
Note 10
Cable Shield
Clamp
4
Motor Power
(MP) Connector
1
From CPL connector, LIM
2
1
2
3
From OPL connector, LIM
Three-phase
AC Line Filter
Note 3
4
5
6
Control Power
(CPD) Connector
CTRL 2
CTRL 1
DCDC+
L3
L2
W
V
U
Motor/Resistive
Brake (BC) Connector
COM
PWR
DBRK DBRK +
2
1
L1
MBRK +
1
2
DC Bus
and
Three-phase
Input (IPD)
Connector
MBRK -
From IOL connector, LIM
and CED connector, IAM_1
Three-phase
Motor Power
Connections
Note 16
3
CONT ENCONT EN+
6
BR-
5
BR+
Motor Brake
Connections
4
3
From P1L connector, LIM
2
BR-
1
BR+
Resistive Brake
Connections
Contactor Enable
(CED) Connector
Note 14
Publication 2094-UM001A-EN-P — September 2006
196
Interconnect Diagrams
The configuration on this page does not include a LIM. You must
supply input power components. The single-phase and three-phase
line filters are wired downstream of fusing and the M1 contactor.
Wiring the contactor enable (CED) relay is required. To avoid
injury or damage to the drive, wire the contactor enable relay
into your safety control string.
ATTENTION
Refer to Contactor Enable Relay on page 63, for more
information.
IAM Wiring Example (without LIM)
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet Ground Bus *
Power Rail
Ground Stud
Chassis
Single-phase Input
95...264V ac RMS
Notes 1, 2
Single-phase
AC Line Filter
Note 3
Input Fusing *
1
2
Note 10
CTRL 2
CTRL 1
Control Power
(CPD) Connector
Cable Shield
Clamp
Isolation
Transformer *
Note 5
4
Motor Power
(MP) Connector
1
2
Note 4
DCDC+
3
Three-phase
AC Line Filter
Note 3
Three-phase Input
195...264V ac RMS
or 324...528V ac RMS
Notes 1, 2
4
5
6
Input Fusing *
L3
L2
M1 *
Notes 8, 9
MBRK MBRK +
Motor/Resistive
Brake (BC) Connector
COM
PWR
DBRK -
Notes 8, 14
1
2
24V ac/dc
or
120V ac
50/60 Hz
STOP *
START *
CR1 *
M1 *
CR1 *
CR1 *
Refer to Attention statement (Note 13).
Publication 2094-UM001A-EN-P — September 2006
CONT ENCONT EN+
Contactor Enable
(CED) Connector
Note 14
V
U
DC Bus
and
Three-phase
Input (IPD)
Connector
L1
W
DBRK +
Three-phase
Motor Power
Connections
Note 16
3
2
1
6
BR-
5
BR+
4
Motor Brake
Connections
User Supplied
24V dc (1.2A maxi)
3
2
BR-
1
BR+
Resistive Brake
Connections
Ground Jumper
Note 11
* Indicates User Supplied Component
Three-phase Input from LIM
or Input Power Contactor (M1)
195...264V ac RMS
or 324...528V ac RMS
Notes 1, 2, 7, 8
Single-phase Input
95...264V ac RMS
Notes 1, 2
Bonded Cabinet
Ground Bus*
2
1
6
5
4
3
2
1
2
1
Contactor Enable
(CED) Connector
Note 14
Motor/Resistive
Brake (BC) Connector
Note 10
W
V
U
1
2
6
5
4
1
N.C.
N.C.
N.C.
2
Three-phase
Motor Power
Connections
Note 16
3
2
1
2
1
3
4
5
6
1
2
3
4
Wire the leader and follower IAM
contactor enable terminals in series
with the safety control string or LIM I/O.
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
Kinetix 6000
Common Bus Leader IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus*
* Indicates User Supplied Component
Contactor Enable
(CED) Connector
Note 14
Motor/Resistive
Brake (BC) Connector
Note 10
W
V
U
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
Kinetix 6000
Common Bus Follower IAM
2094-ACxx-Mxx or -BCxx-Mxx
1
2
3
4
5
6
1
2
3
4
Three-phase
Motor Power
Connections
Note 16
Interconnect Diagrams
197
DC Common Bus Wiring Examples
Leader IAM Wiring Example with Single Follower IAM
Publication 2094-UM001A-EN-P — September 2006
198
Interconnect Diagrams
Leader IAM Wiring Example with Multiple Follower IAM
To Follower
DC Bus Connections
To Follower
Control Power
Connections
Kinetix 6000
Common Bus Leader IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
Power Rail
Ground Stud
Note 10
Cable Shield
Clamp
Single-phase Input
95...264V ac RMS
Notes 1, 2
1
2
Control Power
(CPD) Connector
CTRL 2
CTRL 1
4
Note 4
1
2
3
Three-phase Input from LIM
or Input Power Contactor (M1)
195...264V ac RMS
or 324...528V ac RMS
Notes 1, 2, 7, 8
4
5
6
DCDC+
L3
L2
DC Bus
and
Three-phase
Input (IPD)
Connector
Motor Power
(MP) Connector
W
V
U
L1
MBRK MBRK +
COM
Motor/Resistive
Brake (BC) Connector
PWR
DBRK DBRK +
1
2
CONT ENCONT EN+
3
2
1
Three-phase
Motor Power
Connections
Note 16
6
5
4
3
2
1
Contactor Enable
(CED) Connector
Note 14
To Follower
Control Circuit
Connections
Wire the leader and follower IAM
contactor enable terminals in series
with the safety control string or LIM I/O.
Publication 2094-UM001A-EN-P — September 2006
Interconnect Diagrams
199
Kinetix 6000
Common Bus Follower IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
Power Rail
Ground Stud
Note 10
Cable Shield
Clamp
Note 4
1
From Leader
Control Power
Connections
2
Control Power
(CPD) Connector
CTRL 2
CTRL 1
4
Note 4
1
From Leader
DC Bus Connections
2
3
DC Bus Fusing *
Note 2
N.C.
N.C.
N.C.
4
5
6
Motor Power
(MP) Connector
DCDC Bus
and
Three-phase
Input (IPD)
Connector
DC+
L3
L2
L1
W
V
U
MBRK MBRK +
6
5
2
DBRK +
2
1
Three-phase
Motor Power
Connections
Note 16
3
PWR
DBRK -
1
2
4
COM
Motor/Resistive
Brake (BC) Connector
3
1
Contactor Enable
(CED) Connector
Note 14
CONT ENCONT EN+
Kinetix 6000
Common Bus Follower IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
Power Rail
Ground Stud
Note 10
Cable Shield
Clamp
1
2
1
2
3
DC Bus Fusing *
Note 2
N.C.
N.C.
N.C.
4
5
6
Control Power
(CPD) Connector
CTRL 2
CTRL 1
DCDC+
L3
L2
4
Motor Power
(MP) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
L1
W
V
U
MBRK MBRK +
Motor/Resistive
Brake (BC) Connector
COM
PWR
DBRK DBRK +
From Leader
Control Circuit
Connections
1
2
CONT ENCONT EN+
3
2
1
Three-phase
Motor Power
Connections
Note 16
6
5
4
3
2
1
Contactor Enable
(CED) Connector
Note 14
* Indicates User Supplied Component
Publication 2094-UM001A-EN-P — September 2006
Publication 2094-UM001A-EN-P — September 2006
Three-phase
AC Line Filter
Note 3
S
T
Customer
Supplied
120V ac
M1 *
Note 8
E/N
MC
Note 12
Line
Reactors
T1
S1
R1
T
S
R
G
CR1*
L3
Start *
MC2
MC1
Refer to Attention statement (Note 13).
Stop *
CR1*
2
PR3
1
Note 14
Motion Control I/O
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Contactor Enable
(CED) Connector
Note 14
Motor/Resistive
Brake (BC) Connector
CONT ENCONT EN+
I/O (IOD)
Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
Note 10
W
V
U
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
Power Rail
Ground Stud
+24V_PWR
ENABLE
3 +24V_COM
2
1
6
5
PR2
+24V dc
PWR
COM
RDY
N.C.
N.C.
N.C.
3
4
2
Set 8720MC-RPS for
650V dc, nom.
1
2
1
P
N
Single-phase Input
95...264V ac RMS
Notes 1, 2
PR1
L3 AUX
L2 AUX
TB2
L1 AUX
DCDC+
L2
TB3
TB1
L1
TB1
8720MC
Regenerative
Power Supply
8720MC-RPSxxx
Bonded Cabinet
Ground Bus*
Kinetix 6000
Common Bus Follower IAM
2094-BCxx-Mxx
1
2
3
4
5
6
1
2
3
4
Use a pushbutton circuit (instead of an SPST toggle switch) in series with the contactor enable string (between the
8720MC-RPS and Kinetix 6000 drive) to allow a drive fault to remove the dc bus power, and to prevent the drive from
applying dc bus power without your input after clearing a drive fault.
* Indicates User Supplied Component
IMPORTANT
R
Bonded Cabinet
Ground Bus *
Harmonic
Filter
To Motor Fan
Varistor
Motor Fan Fusing *
Input Fusing *
Three-phase Input (+10/-15%)
380V ac rms, 50 Hz
or 460V ac rms, 60 Hz
Notes 1, 2
Three-phase
Motor Power
Connections
Note 16
200
Interconnect Diagrams
8720MC-RPS Leader Drive Wiring Example with Single Follower IAM
Interconnect Diagrams
201
Shunt Module Wiring Examples
Shunt Module Wired for Internal Operation (default configuration)
Kinetix 6000
Shunt Module
2094-BSP2
External Shunt Resistor
(RC) Connector
COL
INT
DC+
External Thermal Switch
(TS) Connector
TS2
TS1
3
2
1
2
1
Shunt Module Wiring Example with External Passive Shunt
External Passive
Shunt Module
Kinetix 6000
Shunt Module
2094-BSP2
3
External Shunt Resistor
(RC) Connector
COL
INT
DC+
External Thermal Switch
(TS) Connector
TS2
2
TS1
1
2
COL
1
DC+
Resistor
Thermal
Switch
Refer to External Shunt Module Specifications on page 184, for a list of
external passive shunt module catalog numbers available for the
Kinetix 6000 drives
IMPORTANT
Only passive shunts with a thermal switch are wired to the TS
connector on the Kinetix 6000 shunt module. If your external
passive shunt does not have a thermal switch, leave the jumper
(default configuration) in place on the TS connector.
Publication 2094-UM001A-EN-P — September 2006
202
Interconnect Diagrams
IAM Wiring Example with Single External Active Shunt
External Active
Shunt Module (1336-MOD-Kxxxx)
Kinetix 6000
Integrated Axis Module
2094-xCxx-Mxx
1
(–) Slave In
3
(–) Master Out
4
DC Bus
Connections
DC-
1
5
DC+
2
6
3
Three-phase
Input (IPD)
Connections
L3
4
L2
5
L1
6
Input Fusing*
Note 23
Single-phase Input
115V ac RMS
50/60 Hz
(+) Slave In
2
TB1
(+) Master Out
(–) DC Bus
(+) DC Bus
1
2
TB3
3
Fault Relay Note 24
4
1336 Master
Shunt chassis
ground screw
Contactor Enable
(CED) Connector
Note 14
1
CONT EN2
CONT EN+
Refer to Attention statement (Note 13).
CR1*
CR1*
M1*
CR1*
* Indicates User Supplied Component
START*
STOP*
24V ac/dc
or
120V ac
50/60 Hz
Notes 8, 14
Refer to External Shunt Module Specifications on page 184 for a list of
external active shunt module catalog numbers available for the
Kinetix 6000 drives.
1336 Active Shunt Input Fuse Specifications
Active Shunt Module
Description
Input Current
Requirements
1336-Kx005 or Kx010
Input current requirement to power logic for fault
contact operation.
0.05 A
1336-KB050
Input current requirement to power fan and logic for
fault contact operation.
0.65 A
1336 Active Shunt Fault Relay Specifications
Publication 2094-UM001A-EN-P — September 2006
Parameter
Description
120V ac
30V ac
On-state current
Current flow when the contact is
closed
0.6 A
2.0 A
On-state resistance
Contact resistance (max)
50 m Ω
50 m Ω
Off-state voltage
Voltage across the contacts
when the relay is open
120V ac
30V ac
Interconnect Diagrams
203
IAM Wiring Example with Multiple External Active Shunts
Kinetix 6000
Integrated Axis Module
2094-xCxx-Mxx
External Active
Shunt Module (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
DC Bus
Connections
DC-
1
DC+
2
(+) Master Out
Note 4
5
6
(–) DC Bus
1
2
3
4
TB1
(+) DC Bus
3
Three-phase
Input (IPD)
Connections
L3
L2
L1
4
1
5
2
6
3
TB3
Fault Relay Note 24
4
1336 Master
Shunt Chassis
Ground Screw
Contactor Enable
(CED) Connector
Note 14
CONT ENCONT EN+
1
External Active
Shunt Module (1336-MOD-Kxxxx)
2
(+) Slave In
Notes 8, 14
24V ac/dc
or
120V ac
50/60 Hz
(–) Slave In
STOP*
(–) Master Out
START*
CR1*
M1*
(+) Master Out
5
CR1*
6
CR1*
Refer to Attention statement (Note 13).
(–) DC Bus
1
2
3
4
TB1
(+) DC Bus
Note 4
1
2
TB3
3
Fault Relay Note 24
4
1336 Slave
Shunt Chassis
Ground Screw
External Active
Shunt Module (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
(+) Master Out
5
6
1
Single-phase Input
115V ac RMS
50/60 Hz
2
Input Fusing*
Note 23
* Indicates User Supplied Component
Note 4
(–) DC Bus
1
2
3
4
TB1
(+) DC Bus
TB3
3
4
Fault Relay Note 24
Shunt Chassis
Ground Screw
1336 Slave
Publication 2094-UM001A-EN-P — September 2006
204
Interconnect Diagrams
Axis Module/Motor Wiring Examples
AM (460V) Wiring Example with MP-Series (MPL-B and MPG-B) Motors
Kinetix 6000
IAM (inverter) or AM
MPL-B3xx, -B4xx, -B45xx,
-B5xx, -B6xx, -B8xx,
-B9xx, and MPG-B
(460V) Servo Motors with
High Resolution Feedback
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Motor Feedback
(MF) Connector
(IAM/AM)
Note 10
Motor Power
(MP) Connector
W
V
U
Motor Feedback
(MF) Connector
4
3
2
1
Green/Yellow
D
1/Blue
2/Black
C
B
3/Brown
A
W
GND
V
Three-phase
U Motor Power
2090-XXNPMP-xxSxx
Motor Power Cable
Note 16
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
2090-UXNBMP-18Sxx Brake Cable
Note 16
6
Black
C
BR-
5
White
A
BR+
4
COM
DBRK DBRK +
2
BR-
1
BR+
BLACK
WHT/BLACK
C
D
E
F
K
L
N
R
RED
WHT/RED
SIN+
SINCOS+
COS-
GREEN
WHT/GREEN
DATA+
DATA-
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
+5VDC
ECOM
+9VDC
TS+
S
BLUE
TS-
1
2
3
4
5
10
14
6
7
11
Thermostat
P
Motor Brake
User Supplied
24V dc (1.2A max.)
3
PWR
Motor Feedback
A
B
COM
Refer to low profile connector
illustration (lower left)
for proper grounding technique.
Resistive Brake
Connections
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 16, 17, 19
MPL-B3xx, -B4xx, -B45xx,
(460V) Servo Motors
with Resolver Feedback
Motor Feedback
(MF) Connector
(IAM/AM)
D
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
C
B
W
A
U
V
GND
Three-phase
Motor Power
A
B
BLACK
WHT/BLACK
S2
S4
1
2
C
D
RED
WHT/RED
S1
S3
3
4
YELLOW
WHT/YELLOW
R1
R2
5
10
R
BLUE
TS+
11
S
WHT/BLUE
TS-
6
Motor Feedback G
H
Clamp
Exposed shield secured
under clamp.
Thermostat
Clamp Screws (2)
Turn clamp over to hold
small cables secure.
Publication 2094-UM001A-EN-P — September 2006
C
BR-
A
BR+
Motor Brake
Refer to low profile connector
illustration (lower left)
for proper grounding technique.
2090-CDNFDMP-Sxx
(flying-lead) Feedback Cable
Notes 16, 17
Interconnect Diagrams
205
AM (230V) Wiring Example with MP-Series (MPL-A and MPG-A) Motors
Kinetix 6000
IAM (inverter) or AM
MPL-A3xx, -A4xx, -A45xx,
-A5xx, and MPG-Axxx
(230V) Servo Motors with
High Resolution Feedback
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Motor Feedback
(MF) Connector
(IAM/AM)
Cable Shield
Clamp
Note 10
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
D
1/Blue
C
B
2/Black
3/Brown
A
W
GND
V
Three-phase
U Motor Power
2090-XXNPMP-xxSxx
Motor Power Cable
Note 16
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
2090-UXNBMP-18Sxx Brake Cable
Note 16
6
Black
C
BR-
5
White
A
BR+
4
COM
User Supplied
24V dc (1.2A max.)
3
PWR
DBRK DBRK +
Motor Feedback
2
BR-
1
BR+
A
B
BLACK
WHT/BLACK
C
D
E
F
K
L
N
R
RED
WHT/RED
ORANGE
WHT/ORANGE
S
BLUE
GREEN
WHT/GREEN
GRAY
WHT/GRAY
3
4
DATA+
DATA+5VDC
ECOM
+9VDC
TS+
5
10
14
6
7
11
TS-
Thermostat
P
Motor Brake
COM
Refer to low profile connector
illustration (lower left)
for proper grounding technique.
Resistive Brake
Connections
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 16, 17, 20
MPL-A3xx, -A4xx, -A45xx,
and -A5xx
(230V) Servo Motors with
Incremental Feedback
D
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
C
B
W
A
U
V
Clamp
Exposed shield secured
under clamp.
GND
A
BRBR+
A
B
C
D
E
F
Motor Feedback K
L
N
R
Thermostat
C
Motor Feedback
(MF) Connector
(IAM/AM)
Three-phase
Motor Power
Clamp Screws (2)
Turn clamp over to hold
small cables secure.
1
2
SIN+
SINCOS+
COS-
Motor Brake
S
T
U
V
P
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
1
2
AM+
AMBM+
BM-
3
4
IM+
IM+5VDC
ECOM
–
TS+
5
10
14
6
7
11
TSS1
S2
S3
COM
12
13
8
Refer to low profile connector
illustration (lower left)
for proper grounding technique.
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 16, 17
Publication 2094-UM001A-EN-P — September 2006
206
Interconnect Diagrams
AM Wiring Example with MP-Series (MPL-A/B, MPF-A/B, and MPS-A/B) Motors
MPL-A/B15xx and -A/B2xx,
MPF-A/Bxxx and MPS-A/Bxxx
Servo Motors with
High Resolution Feedback
Kinetix 6000
IAM (inverter) or AM
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Shield
Note 10
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
Blue
D/
Black
C/W
B/V
Brown
A/U
W
GND
V Three-phase
U Motor Power
2090-XXNPMF-xxSxx
Motor Power Cable
Note 16
Motor Feedback
(MF) Connector
Motor
Feedback
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
6
Black
5
White
4
COM
DBRK DBRK +
2
BR-
1
BR+
BR-
F/+
User Supplied
24V dc (1.2A max.)
3
PWR
G/-
Motor Feedback
(MF) Connector
(IAM/AM)
1
2
BLACK
WHT/BLACK
3
4
RED
WHT/RED
5
6
9
10
11
13
GREEN
WHT/GREEN
14
3
4
ORANGE
WHT/ORANGE
DATA+
DATA+5VDC
ECOM
+9VDC
TS+
5
10
14
6
7
11
BLUE
TS-
GRAY
WHT/GRAY
Thermostat
BR+
COM
12
Refer to low profile connector
illustration (lower left)
for proper grounding technique.
Motor Brake
Note 22
2090-XXNFMF-Sxx
(flying-lead) Feedback Cable
Notes 16, 17, 21
Resistive Brake
Connections
MPL-A/B15xx and -A/B2xx
Servo Motors with
Incremental Feedback
Grounding Technique for
Feedback Cable Shield
D/
Low Profile Connector
(2090-K6CK-D15M shown)
C/W
B/V
A/U
W
GND
V
Three-phase
U Motor Power
Motor
Feedback
Clamp
Exposed shield secured
under clamp.
Thermostat
Clamp Screws (2)
Turn clamp over to hold
small cables secure.
G/-
BR-
F/+
BR+
Motor Brake
Note 22
Motor Feedback
(MF) Connector
(IAM/AM)
1
2
BLACK
WHT/BLACK
3
4
RED
WHT/RED
5
6
9
10
11
13
GREEN
WHT/GREEN
14
15
16
17
12
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
AM+
AMBM+
BMIM+
IM+5VDC
ECOM
–
TS+
TSS1
S2
S3
COM
Refer to low profile connector
illustration (lower left)
for proper grounding technique.
2090-XXNFMF-Sxx
(flying-lead) Feedback Cable
Notes 16, 17
Publication 2094-UM001A-EN-P — September 2006
1
2
SIN+
SINCOS+
COS-
1
2
3
4
5
10
14
6
11
12
13
8
Interconnect Diagrams
207
AM (230V) Wiring Example with TL-Series Motors
Kinetix 6000
IAM (inverter) or AM
TL-Series (230V) Servo Motors
with Incremental Feedback
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Motor Feedback
(MF) Connector
(IAM/AM)
Cable Shield
Clamp
Note 10
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
4
Blue
Black
3
2
Brown
1
W
GND
V
Three-phase
U Motor Power
2090-XXNPT-16Sxx
Motor Power Cable
Note 16
Motor Feedback
(MF) Connector
Motor Feedback
2090-DANBT-18Sxx
Motor Brake Cable
Note 16
Motor/Resistive
Brake (BC) Connector
MBRK MBRK +
COM
PWR
DBRK DBRK +
6
Black
5
White
4
User Supplied
24V dc (1.2A max.)
3
2
BR-
1
BR+
Resistive Brake
Connections
2
BR-
1
BR+
Motor Brake
1
2
BLACK
WHT/BLACK
3
4
RED
WHT/RED
5
10
7
8
GREEN
WHT/GREEN
6
11
15
9
GRAY
WHT/GRAY
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
GREEN
1
2
AM+
AMBM+
BM-
3
4
IM+
IM+5VDC
ECOM
5
10
14
6
S1
S2
S3
12
13
8
SHIELD
2090-XXNFT-Sxx Feedback Cable
with pre-molded connector
Note 16
Publication 2094-UM001A-EN-P — September 2006
208
Interconnect Diagrams
AM (460V) Wiring Example with 1326AB Motors
Kinetix 6000
IAM (inverter) or AM
1326AB (M2L/S2L)
Servo Motors with
High Resolution Feedback
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Motor Feedback
(MF) Connector
(IAM/AM)
Cable Shield
Clamp
Note 10
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
D
1/Blue
W
2/Black
C
B
3/Brown
A
U
V
2090-XXNPMP-xxSxx
Motor Power Cable
Note 16
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
Motor Feedback
2090-UXNBMP-18Sxx Brake Cable
Note 16
MBRK MBRK +
6
Black
C
BR-
5
White
A
BR+
4
COM
User Supplied
24V dc (1.2A max.)
3
PWR
DBRK DBRK +
2
BR-
1
BR+
BLACK
WHT/BLACK
C
D
E
F
K
L
N
R
RED
WHT/RED
ORANGE
WHT/ORANGE
S
BLUE
GREEN
WHT/GREEN
GRAY
WHT/GRAY
1
2
SIN+
SINCOS+
COS-
3
4
DATA+
DATA–
ECOM
+9VDC–
TS+
5
10
14
6
7
11
TS-
Thermostat
P
Motor Brake
COM
Refer to the Kinetix 6000 User Manual,
publication 2094-UM001,
for proper grounding technique.
Resistive Brake
Connections
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Note 16, 17
1326AB Servo Motors with
Resolver Feedback
Kinetix 6000
IAM (inverter) or AM
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
GND
Three-phase
Motor Power
A
B
1326-CPx1-xxx Motor Power Cable
Note 16
Cable Shield
Clamp
4
3
2
1
Braided Shield
8
7
Black
3
T3
Black
2
1
T2
6
Black
6
B1
5
Black
4
B2
Green/Yellow
Note 10
Motor Power
(MP) Connector
W
V
U
Motor Feedback
(MF) Connector
MBRK MBRK +
COM
PWR
DBRK DBRK +
Black
GND
Three-phase
T1 Motor Power
Motor Brake
4
3
2
1
User Supplied
24V dc (1.2A max.)
Motor Feedback
BRBR+
Resistive Brake
Connections
5
Motor/Resistive
Brake (BC) Connector
9
Motor Feedback
(MF) Connector
(IAM/AM)
G
H
GREEN
BLACK
D
E
A
B
K1
K2
Thermostat
(1)
1
2
BLACK
RED
S2
S4
S1
S3
3
4
BLACK
WHITE
R1
R2
5
10
1326-CCU-xxx
(flying-lead) Feedback Cable
Note 16
TS+
TS-
16
17
S
Shielded Cable
(1)
Publication 2094-UM001A-EN-P — September 2006
Wiring the thermal switch on 1326AB (resolver-based) motors requires the use of the Low Profile connector kit
(2090-K6CK-D15MF) and wire extension to the power connector. Pins 16, 17, and S are filtered to prevent noise
transmission back to the drive. Refer to the Kinetix 6000 User Manual, publication 2094-UM001, for wiring
instructions and a diagram.
Interconnect Diagrams
209
AM (230V) Wiring Example with F-Series Motors
Kinetix 6000
IAM (inverter) or AM
F-Series (230V)
Servo Motors with
Incremental Feedback
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cable Shield
Clamp
Note 10
Motor Power
(MP) Connector
W
V
U
4
3
2
1
Green/Yellow
D
1/Blue
2/Black
C
B
3/Brown
A
W
Motor Feedback
(MF) Connector
(IAM/AM)
GND
V
Three-phase
U Motor Power
2090-XXNPH/HF-xxSxx
Motor Power Cable
Note 16
Motor Feedback
(MF) Connector
9101-0330 Brake Cable Connector Kit
Note 16
MBRK MBRK +
COM
PWR
DBRK DBRK +
Motor/Resistive
Brake (BC) Connector
Motor Feedback
6
Black
B
BR-
5
White
A
BR+
4
Motor Brake
User Supplied
24V dc (1.2A max.)
3
2
BR-
1
BR+
Resistive Brake
Connections
Thermostat
3
4
IM+
IMTS+
S3
5
10
11
8
GRAY
+5VDC
14
WHT/GRAY
ECOM
6
13
12
VIOLET
S2
S1
–
WHT/VIOLET
TS-
6
BLACK
WHT/BLACK
C
D
E
F
R
P
K
J
L
M
N
T
H
RED
WHT/RED
S
1
2
AM+
AMBM+
BM-
A
B
GREEN
WHT/GREEN
WHT/BROWN
BROWN
BLUE
WHT/BLUE
Refer to low profile connector
illustration (below)
for proper grounding technique.
2090-XXNFHF-Sxx
(flying-lead) Feedback Cable
Note 16, 17
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
Clamp
Exposed shield secured
under clamp.
Clamp Screws (2)
Turn clamp over to hold
small cables secure.
Publication 2094-UM001A-EN-P — September 2006
210
Interconnect Diagrams
AM (230V) Wiring Example with Y-Series Motors
Kinetix 6000
IAM (inverter) or AM
Y-Series (230V)
Servo Motors with
Incremental Feedback
Note 15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Motor Feedback
(MF) Connector
(IAM/AM)
Cable Shield
Clamp
Note 10
Motor Power
(MP) Connector
W
V
U
Motor Feedback
(MF) Connector
4
3
2
1
Green/Yellow
5
3/Black
2/Black
3
2
1/Black
1
MBRK MBRK +
COM
PWR
DBRK DBRK +
9
10
11
12
BLACK
WHT/BLACK
AM+
AM-
1
2
RED
WHT/RED
BM+
BM-
3
4
13
14
15
Motor
17
Feedback
19
Pigtail –
22
Motor
23
Brake
24
GREEN
WHT/GREEN
IM+
IMS1
S2
5
10
12
13
S3
–
+5VDC
ECOM
DRAIN
8
GND
V
Three-phase
U Motor Power
Pigtail
2090-XXNPY-xxSxx
Motor Power and Brake Cable
Note 16
Motor/Resistive
Brake (BC) Connector
W
Black
9
BR-
Black
7
BR+
6
5
4
2
BR-
1
BR+
Resistive Brake
Connections
BROWN
WHT/BROWN
GRAY
WHT/GRAY
14
6
Refer to low profile connector
illustration (below)
for proper grounding technique.
User Supplied
24V dc (1.2A max.)
3
WHT/BLUE
BLUE
2090-XXNFY-Sxx
(flying-lead) Feedback Cable
Notes 16, 17, 18
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
Clamp
Exposed shield and drain wire
secured under clamp.
Turn clamp over to hold
small cables secure.
Clamp Screws (2)
Controlling a Brake Example
The relay output of the Kinetix 6000 drive (MBRK± BC-5 and -6) is
suitable for directly controlling a motor brake, subject to the relay
voltage limit of 30V dc, and the relay current limit as shown in the
table below.
Brake Relay Current Limit
Kinetix 6000 IAM/AM
2094-AC05-Mxx, -AC09-Mxx,
2094-AMP5, -AM01, -AM02
2094-BC01-Mxx, -BC02-Mxx,
2094-BMP5, -BM01, -BM02
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Brake Current Rating, Max
1.0 A
2094-AC16-Mxx, -AC32-Mxx,
2094-AM03, -AM05
1.3 A
2094-BC04-Mxx, -BC07-Mxx,
2094-BM03, -BM05
3.0 A
Interconnect Diagrams
IMPORTANT
211
For brake requirements outside of these limits, an external relay
must be used.
Coil Currents Rated at < 1.0 A
Compatible Brake Motors
MPL-x15xx
(1)
MPL-x2xx (1)
MPL/MPF/MPS-x310, -x320, -x330 (1)
MPL-x420, -x430, -x4520, -x4530, -x4540
MPF-x430, -x4530, -x4540 (1)
MPG-x004 (1)
MPG-x010
MPG-x050 (1)
(1)
Compatible Brake Motors
Coil Current
0.48 A
1326AB-B4xxx
0.88 A
0.51 A
F-4030, -4050, and -4075
0.69 A
0.50 A
Y-1002 and -1003
0.26 A
Y-2006 and -2012
0.31 A
Y-3023
0.37 A
TL-A110P-H, -A120P-H, and -A130P-H
0.208 A
TL-A220P-H and -A230P-H
0.375 A
TL-A2530P-H and -A2540P-H
0.396 A
TL-A410P-H
0.746 A
(1)
0.64 A
0.33 A
(1)
MPG-x025 (1)
MPG-x110
Coil Current
(1)
0.45 A
0.50 A
1.0 A
Applies to 230V and 460V motors.
Coil Currents Rated at >1.0 A and ≤1.3 A
Compatible Brake Motors
F-6100, -6200, and -6300
H-6100, -6200, and -6300
(1)
Coil Current
Compatible Brake Motors
1.30 A
MPL-x520, -x540, -x560, -x580 (1)
1.13 A
MPF-B540
1326AB-B5xxx, and -B7xxx
Coil Current
1.05...1.28 A
1.20 A
Applies to 230V and 460V motors.
Coil Currents Rated at >1.3 A and ≤3.0 A
Compatible Brake Motors
Coil Current
Compatible Brake Motors
Coil Current
H-8350 and -8500
2.20 A
MPL-B640, -B660, -B680, -B860, -B880,
-B960, -B980
1.91...2.19 A
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212
Interconnect Diagrams
System Block Diagrams
This section provides block diagrams of the Kinetix 6000 modules. For
block diagrams of the line interface module (LIM) and resistive brake
module (RBM), refer to Additional Resources on page 10 for the
documentation available for those products.
Shunt Circuit
(460V only)
Inverter Section
W
V
CTRL 2
DC-
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CAN (2)
GSHUNT (2)
CONV_ID (5)
SYSOK
POWER
RAIL
DC+
CTRL 1
Common Mode
Choke
(460V only)
Chassis
SMPS
FUSE_OK
+/-12V (Control)
+24V (Customer I/O)
+9V, +5V (Motor Feedback)
MBRK
PWR
DBRK
Motor/Resistive Brake Connections
U
Three-phase Motor Output
Motor Shield Clamp
IAM/AM (inverter) Block Diagram
CTRL1
EMC Filter (1)
95C
CONV_OT
DROK/
CONT_EN
CTRL2
CONT_EN2
CONT_EN1
Control Power
ac Input
Rectifier Circuit (2)
DC-
DC+
L2
L3
Vcc
DC Link
Inductor (3)
L1
DCL2
L2
L1
Three-phase
ac Input
DCL1
(4)
(3)
(2)
(1)
Control Power
Loss Detector
120K
Shunt Circuit (2)
DC-
DC+
Vsns
Ground jumper shown in default configuration (grounded facility power).
DC+
GSHUNT
CTRL+
CTRL-
DC-
CHASSIS
SYS_OK
Internal dc link inductor present on 460V converters. Connectors for external dc
link inductor present on 230V converters.
Rectifier and shunt circuits present only on 230V converters.
EMC filter present only on 460V converters.
Chassis
Ground Jumper (4)
Gnd Flt CT
Common Bus
Power Connections
POWER
RAIL
Interconnect Diagrams
213
IAM (converter) Block Diagram
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214
Interconnect Diagrams
Kinetix 6000 drives with the safe-off feature ships with the wiring
header and motion allowed jumper installed. In this configuration, as
illustrated below, the safe-off feature is not used.
Safe-off Feature Block Diagram
Safe-Off Option
Safe-Off (SO)
9-pin Connector
8
9
+24V
+24V_COM
3
4
FDBK1+
FDBK1-
7
ENABLE1+
6
ENABLE-
Gate Control
Power Supply
K1-C
K1-A
K1
5
ENABLE2+
1
2
FDBK2+
FDBK2-
Safety Monitor
uC
K2
Gate Control
Circuit (CCP)
K2-A
K2-C
Motion Allowed Jumper
Wiring Header
Gate Control
Enable Signal
+24V
DRIVE ENABLE
+24V_COM
M
Shunt Module Block Diagram
DC+
POWER
RAIL
Internal
or External
Shunt
Resistor
DC-
SYSOK
Shunt Circuit
CTRL 1
SMPS
CTRL 2
+5V (Control)
+/-15V (IGBT)
24V (Control)
GSHUNT (2)
Chassis
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Appendix
C
Upgrading Firmware
Introduction
215
This appendix provides procedures for upgrading firmware using
either ControlFLASH or DriveExplorer software.
Topic
Page
Introduction
215
Using ControlFLASH Software to Upgrade Drive Firmware
216
Using DriveExplorer Software to Upgrade Drive Firmware
224
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216
Upgrading Firmware
Using ControlFLASH
Software to Upgrade Drive
Firmware
Upgrading axis module firmware using ControlFLASH software
involves selecting the drive to flash, configuring your Logix
communications, and flashing the firmware.
Before You Begin
You will need the following software and information before you
begin.
Description
Catalog Number
Firmware Revision
RSLogix 5000 software
9324-RLD300NE
15.x or later
1756-MxxSE
15.32 or later
1756-L60M03SE
15.4 or later
CompactLogix SERCOS module software
1768-M04SE
15.35 or later
SoftLogix SERCOS PCI card software
1784-PM16SE
15.33 or later
ControlLogix SERCOS module software
RSLinx software
2.50 or later
ControlFLASH software kit (1)
4.00.09 or later
Catalog number of the targeted Kinetix 6000 IAM/AM you want to flash
Network path to the targeted Kinetix 6000 IAM/AM
(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 User
Manual, publication 1756-6.5.6.
IMPORTANT
Control power (24V dc) must be present at CPD-1 and -2 prior to
flashing your drive.
The seven-segment LED on the IAM (inverter) or AM to upgrade
must be displaying a fixed 2, 3, or 4 before beginning this
procedure.
ATTENTION
To avoid personal injury or damage to equipment during the
firmware upgrade due to unpredictable motor activity, do not
apply three-phase ac or common bus dc input power to the
drive.
The ControlFLASH utility software can be accessed by either of these
methods.
Publication 2094-UM001A-EN-P — September 2006
•
Select ControlFLASH from the Tools menu in your RSLogx 5000
software.
•
Select ControlFLASH from the Windows Start button/Program
Files/Flash Tools.
Upgrading Firmware
217
Selecting the Drive to Upgrade
Follow these steps to upgrade (flash) your drive firmware.
1. Open your ControlFLASH software.
The Welcome to ControlFLASH dialog opens.
2. Click Next.
The Catalog Number dialog opens.
3. Select the catalog number of your drive module to flash.
4. Click Next.
5. Minimize the RSLogix 5000 project dialog.
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Upgrading Firmware
Configuring Logix Communications
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 communications.
1. Open the RSLinx Classic software and select Configure Drivers
from the Communications menu.
The Configure Drivers dialog opens.
2. Select Ethernet devices from the Available Driver Types menu.
3. Click the Add New button.
The Add New RSLinx Classic Driver dialog opens.
4. Name the new driver.
5. Click OK.
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219
The Configure driver dialog opens.
6. Enter the IP address of your Logix ethernet module.
The IP address shown is an example. Yours will be different.
7. Click OK.
8. Click Close in the Configure Drivers dialog.
9. Select RSWho from the Communication menu.
The drive selection dialog opens.
10. Locate your servo drive by expanding the ethernet node, Logix
backplane, and SERCOS interface module.
11. Select the servo drive to flash.
12. Click OK.
13. Minimize the RSLinx application dialog and return to your
RSLogix 5000 project dialog.
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Upgrading Firmware
Flashing Firmware
The Firmware Revision dialog opens with the current firmware
revision listed.
1. Select the firmware revision for the upgrade.
2. Click Next.
The Summary dialog opens.
3. Confirm the drive catalog number and firmware revision.
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221
4. Click Finish. This ControlFLASH warning dialog opens.
5. Click Yes (only if you are ready).
This ControlFLASH warning dialog opens.
6. Acknowledge the warning and click OK.
The Progress dialog opens and flashing begins.
The drive module seven-segment LED indicator changes from the
fixed 2, 3, or 4 to F which indicates that flashing is in progress.
After the flash information is sent to the drive, the drive resets and
performs diagnostic checking.
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Upgrading Firmware
7. The Update Status dialog opens and indicates success or failure as
described below.
Flashing
If
1. Update complete appears in a GREEN status dialog.
Succeeded
2. Go to Step 8.
1. Update failure appears in a RED status dialog.
Failed
2. Go to Troubleshooting ControlFLASH.
8. Select OK.
The ControlFLASH software returns to the Welcome screen where
you can flash another drive or select Cancel to exit the program.
Troubleshooting ControlFLASH
If your Update Status dialog in Step 7 indicated failure, check the
following items and begin the process again at Step 1:
Publication 2094-UM001A-EN-P — September 2006
•
Control (24V) power lost at drive.
•
SERCOS ring is down (seven-segment LED no longer displays
fixed 2, 3, or 4).
•
Logix chassis lost power.
•
Bad flashdata checksum.
Upgrading Firmware
223
Verifying the Firmware Upgrade
Follow these steps to verify your firmware upgrade was successful.
This procedure is optional.
1. Return to the RSLinx Classic software and expand the dialog tree
to gain access to your drive module, as you did earlier.
2. Right-click the drive module and select Drive Properties.
The Drive Properties dialog opens.
3. Verify the new firmware revision level.
4. Click Close.
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224
Upgrading Firmware
Using DriveExplorer
Software to Upgrade Drive
Firmware
Upgrading axis module firmware using DriveExplorer involves setting
the Axes to Flash parameter, configuring a HyperTerminal session,
and flashing the firmware.
Before You Begin
You will need the following software and information before you
begin.
Description
Catalog Numbers
Firmware Revision
DriveExplorer Software (1)
9306-4EXP02ENE
2.01 or later
Serial to SCANport Adapter
1203-SSS (Series B)
3.004 or later
RSLogix 5000 Software
9324-RLD300NE
11.0 or later
Firmware upgrade file for your Kinetix 6000 drive (IAM/AM) (2)
Personal computer with HyperTerminal software
(1)
(2)
Refer to DriveExplorer Getting Results Manual, publication 9306-GR001, for instructions.
Contact Rockwell Automation Technical Support at (440) 646-5800 for firmware upgrade file.
IMPORTANT
ATTENTION
Control power (24V dc) must be present at CPD-1 and -2 prior to
flashing your drive.
To avoid personal injury or damage to equipment during the
firmware upgrade due to unpredictable motor activity, do not
apply three-phase ac or common bus dc input power to the
drive. Do not establish communications with the Logix SERCOS
interface module.
Selecting Axis Modules to Upgrade
In this procedure you will use DriveExplorer software to set the Axes
to Flash parameter (x708) and select the axis module to upgrade.
TIP
You will save time by selecting only the axis modules that
require a firmware upgrade.
Follow these steps to set the Axes to Flash parameter.
1. Connect the 1203-SSS serial cable to the appropriate COM port on
your personal computer.
2. Connect the 1203-SSS SCANport cable to the SCANport/DPI
connector on your IAM.
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Upgrading Firmware
225
3. Verify that the 1203-SSS has power by observing the LED indicated
in the figure below.
SCANport/DPI
communication
4. Open the DriveExplorer software and select Connect from the
Explore menu.
The DriveExplorer software proceeds to read your system.
5. Double-click 2094D SERVO Config 0000.
The linear list of parameters dialog appears.
Linear List Legend
N: P. x xxx
Parameter Number
30 = Version Data
Axis Number
0 = IAM (axis 1)
1 = AM (axis 2)
2 = AM (axis 3)
3 = AM (axis 4)
DPI Port Number
Network Node Number
6. Scroll down to parameter x:x.30 (Version Data) and record the
version (VERS: xx.xxx) of each axis module.
7. Double-click Configuration.
The following dialog opens.
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Upgrading Firmware
8. Double-click Axes to Flash.
The Axis to Flash dialog opens.
9. Click (check) each axis to flash.
Example above shows two axes to flash checked.
10. Select OK.
The Axes to Flash parameter is set.
11. Close DriveExplorer.
HyperTerminal Configuration
Follow these steps to begin a new HyperTerminal session.
1. From the Windows Start menu, select Programs\Accessories\
HyperTerminal\HyperTerminal.
The New Connection dialog opens.
2. Type a name the new HyperTerminal file and choose an icon for
the connection.
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Upgrading Firmware
227
3. Select OK.
The following dialog opens.
4. Select the appropriate COM port.
5. Select OK.
The following dialog opens.
6. Select the properties as shown above or as appropriate for your
1203-SSS SCANport adapter.
IMPORTANT
Bits per second of HyperTerminal must match the
1203-SSS SCANport adapter setting for connection to
occur.
7. Select OK.
8. HyperTerminal configuration is complete.
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Upgrading Firmware
Flashing Firmware
This procedure assumes you have identified which axis modules
require flashing, have set the Axes to Flash parameter, and have
configured a HyperTerminal session.
IMPORTANT
You must also know where to find your firmware upgrade file.
1. Press ENTER.
The HyperTerminal main menu opens.
2. Enter 3.
The following dialog opens.
3. Enter 0.
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229
The following dialog opens.
4. Enter Y.
As indicated in the text, the program begins displaying the
character C.
TIP
Program times-out after 60 seconds. If program times-out
before you complete steps 5...8, return to Step 1.
5. From the Transfer menu select Send File.
The Send File dialog opens.
Firmware upgrade file, as provided by Rockwell
Automation Technical Support at (440) 646-5800.
6. Browse for your firmware upgrade file.
7. Select Xmodem protocol.
8. Select Send.
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Upgrading Firmware
The flash upgrade operation begins and the following dialog
opens.
ATTENTION
To avoid unrecoverable fault to drive modules, do not
interrupt control power to IAM, power to the 1203-SSS
SCANport adapter, or power to your PC while the flash
upgrade operation is in progress.
The flash operation completes and the following dialog opens.
9. Close the HyperTerminal session.
10. Verify that parameter 30 for each axis module is now upgraded to
the new firmware revision.
11. Return to DriveExplorer (refer to Selecting Axis Modules to
Upgrade, Step 5) to see the linear list of parameters.
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Appendix
D
DC Common Bus Applications
Introduction
Before You Begin
This appendix provides integration procedures specific to the Kinetix
6000 multi-axis servo-drive systems configured for dc common bus.
The procedure involves calculating capacitance values and setting the
Add Bus Cap parameter using DriveExplorer software.
Topic
Page
Introduction
231
Before You Begin
231
Calculating Total Bus Capacitance
232
Calculating Additional Bus Capacitance
232
Kinetix 6000 Capacitance Values
233
Common Bus Capacitance Example
234
Setting the Additional Bus Capacitance Parameter
235
These procedures assume you have mounted and wired your
Kinetix 6000 dc common bus system.
IMPORTANT
Drive firmware v1.071 or later is required to use the RBM with
the Kinetix 6000 drives.
Before you set the Additional Bus Capacitance (Add Bus Cap)
parameter in DriveExplorer, you need to calculate the following
values.
• Total bus capacitance
• Additional bus capacitance
231
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232
DC Common Bus Applications
Calculating Total Bus
Capacitance
Total bus capacitance is the sum of all capacitance values for your
Kinetix 6000 common bus modules. Specifically, this includes the
capacitance values for each of these modules.
• Leader IAM (converter and inverter)
• Each AM and SM (if present) on the leader IAM power rail
• Each follower IAM (converter and inverter)
• Each AM on the follower IAM power rails
Refer to Kinetix 6000 Capacitance Values on page 233 for IAM/AM/SM
capacitance values.
IMPORTANT
Leader IAM (230V)
2094-AC05-MP5-S
2094-AC05-M01-S
Maximum Bus
Capacitance
µF
7145
Leader IAM (460V)
2094-BC01-MP5-S
2094-BC01-M01-S
Maximum Bus
Capacitance
µF
4585
2094-AC09-M02-S
15,295
2094-BC02-M02-S
8955
2094-AC16-M03-S
34,400
2094-BC04-M03-S
8955
2094-AC32-M05-S
62,825
2094-BC07-M05-S
17,915
IMPORTANT
Calculating Additional Bus
Capacitance
When total bus capacitance exceeds the leader IAM maximum
value, the IAM fault status LED indicator displays error code
E90 (pre-charge time-out fault) and the drive is disabled.
If your total bus capacitance value exceeds the value in the
table above, you must increase the size of the leader IAM or
decrease the total bus capacitance by removing axis modules.
Additional bus capacitance is the sum of all follower IAM and AM
capacitance values for your Kinetix 6000 common bus modules.
Specifically, this includes the capacitance values for each of these
modules.
• Each follower IAM (converter and inverter)
• Each AM on the follower IAM power rails
Enter the additional bus capacitance values in Step 6 of Setting the
Additional Bus Capacitance Parameter.
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DC Common Bus Applications
Kinetix 6000 Capacitance
Values
233
Use the tables below when calculating total bus capacitance and
additional bus capacitance for your Kinetix 6000 common bus
application.
IAM/AM (230V) Modules
IAM Converter (230V)
2094-AC05-MP5-S
2094-AC05-M01-S
Capacitance
µF
270
AM Inverter (230V)
Capacitance
µF
2094-AMP5-S
390
2094-AM01-S
660
2094-AC09-M02-S
540
2094-AM02-S
780
2094-AC16-M03-S
1320
2094-AM03-S
1320
2094-AC32-M05-S
1980
2094-AM05-S
2640
AM Inverter (460V)
Capacitance
µF
IAM/AM (460V) Modules
IAM Converter (460V)
2094-BC01-MP5-S
2094-BC01-M01-S
Capacitance
µF
110
2094-BMP5-S
75
2094-BM01-S
150
2094-BC02-M02-S
220
2094-BM02-S
270
2094-BC04-M03-S
940
2094-BM03-S
840
2094-BC07-M05-S
1410
2094-BM05-S
1175
SM (230/460V) Module
SM (230-460V)
Capacitance
μF
2094-BSP2
470
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234
DC Common Bus Applications
Common Bus Capacitance
Example
In the example below, the sum of the leader IAM power rail modules
capacitance (6530 µF) and the follower IAM power rail modules
capacitance (5280 µF) equals 11,810 µF total bus capacitance.
The sum of the follower IAM power rail modules equal 5280 µF
additional bus capacitance.
Calculating Common Bus Capacitance
AC Line
Filter
Three-phase
Input Power
MAIN VAC
Kinetix 6000 (230V)
Leader IAM
11,810 µF Total Bus Capacitance
Line Interface
Module
(optional
component)
PRF (2094-PRF) N/A
SM (2094-BSP2) 470 µF
AM (2094-AM02) 780 µF
AM (2094-AM03) 1320 µF
AM (2094-AM03) 1320 µF
IAM (2094-AC16-M03) Converter 1320 µF
IAM (2094-AC16-M03) Inverter 1320 µF
DC Common Bus
Kinetix 6000 (230V)
Follower IAM
5280 µF Additional Bus Capacitance
PRF (2094-PRF) N/A
AM (2094-AM03) 1320 µF
AM (2094-AM03) 1320 µF
IAM (2094-AC16-M03) Converter 1320 µF
IAM (2094-AC16-M03) Inverter 1320 µF
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DC Common Bus Applications
Setting the Additional Bus
Capacitance Parameter
235
In this procedure you will set the Add Bus Cap parameter using
DriveExplorer software.
The following hardware and software tools are required to provide
the necessary communication link between your personal computer
and the Kinetix 6000 drive system running DriveExplorer software.
Description
Catalog Numbers
Version
DriveExplorer Software (1) (2)
9306-4EXP02ENE
2.01 or later
Serial to SCANport Adapter (2) (3)
1203-SSS (Series B)
3.004 or later
RSLogix 5000 Software
9324-RLD300NE
15.0 or later
(1)
Refer to DriveExplorer Getting Results Manual, publication 9306-GR001, for instructions.
(2)
Additional information regarding these communication and software tools is available at
http://www.ab.com/support/abdrives.
(3)
Refer to 1203-SSS (Series B) FRN 3.xxx User Manual, publication 20COMM-UM001, for instructions.
ATTENTION
To avoid personal injury or equipment damage, at least one end
of a SERCOS fiber-optic cable must be disconnected from the
drive. This ensures that motion will not occur while changes are
being made to the Add Bus Cap parameter.
Removing SERCOS Communication
Follow these steps to remove (break) SERCOS communications.
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Remove one of the SERCOS fiber-optic cables.
Fiber-optic cable connections (Tx and Rx) are located on the top
of each IAM/AM.
3. Re-apply three-phase and control power.
Publication 2094-UM001A-EN-P — September 2006
236
DC Common Bus Applications
Setting the Additional Bus Capacitance Parameter
Follow these steps to set the Additional Bus Capacitance parameter.
1. Start your DriveExplorer software.
2. From the menu bar choose Explore\Connect\Local or enter Ctrl-L
from the keyboard.
DriveExplorer software will read your system.
3. Observe the Linear List of parameters as grouped by Node, Port,
and Axis hierarchy as shown below.
Linear List Legend
N: P. x xxx
Parameter Number
30 = Version Data
Axis Number
0 = IAM (axis 1)
1 = AM (axis 2)
2 = AM (axis 3)
3 = AM (axis 4)
DPI Port Number
Network Node Number
4. Select Devices\Node\Product\ and navigate to the parameter
x:x:x599 as shown below.
5. Double-click the x:x:x599 Add Bus Cap parameter.
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DC Common Bus Applications
237
The command dialog for parameter x599 - Add Bus Cap opens.
6. Select the Value Edit tab and enter the Add Bus Cap Value (μF).
7. Click OK.
The RBM delay time is changed, but not saved in non-volatile
memory.
Saving the Add Bus Cap Parameter to Non-Volatile Memory
Follow these steps to save the Add Bus Cap parameter to non-volatile
memory.
1. From the menu bar choose Actions\Non-Volatile Memory.
The following message dialog opens.
2. Click Save.
The changes are saved to non-volatile memory and the following
cautionary message dialog opens.
3. Click Yes.
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238
DC Common Bus Applications
The save to non-volatile memory is complete and the following
confirmation message dialog opens.
4. Click OK.
5. Close the DriveExplorer software.
Reconnecting SERCOS Communication
Follow these steps to reconnect SERCOS communication.
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Replace the SERCOS fiber-optic cable removed earlier.
Fiber-optic cable connections (Tx and Rx) are located on the top
of each IAM/AM.
3. Re-apply three-phase and control power.
Publication 2094-UM001A-EN-P — September 2006
Appendix
E
Integrating Resistive Brake Modules
with Kinetix 6000 Drives
Introduction
Before You Begin
This appendix provides Bulletin 2090 Resistive Brake Module (RBM)
integration procedures and interconnect diagrams specific to
Kinetix 6000 multi-axis servo-drive systems. The procedure involves
setting the time delay parameter using either RSLogix 5000 or
DriveExplorer software.
Topic
Page
Introduction
239
Before You Begin
239
Understanding Safety Precautions
240
Resistive Brake Module Wiring Examples
243
The example diagram below shows Kinetix 6000 IAM, AM, and LIM (2094-ALxxS,
-BLxxS, and -XL75S) wired with the Bulletin 2090 RBM in a category 2
configuration.
244
Setting the RBM Delay Time Using DriveExplorer
252
These procedures assume you have mounted and wired your resistive
brake module (RBM) with the Kinetix 6000 drive system. For RBM
installation instructions, refer to the Resistive Brake Module
Installation Instructions, publication 2090-IN009.
IMPORTANT
239
Drive firmware v1.071 or later is required to use the RBM with
the Kinetix 6000 drives.
Publication 2094-UM001A-EN-P — September 2006
240
Integrating Resistive Brake Modules with Kinetix 6000 Drives
Understanding Safety
Precautions
The following precautions apply to resistive brake module (RBM)
installations as shown in the interconnect diagrams. Be sure to read
and thoroughly understand them before proceeding.
ATTENTION
The interconnection diagrams should be used as a general
recommendation on how the safety control circuit may be
implemented. Actual applications may vary due to requirements
based on the machine builders risk assessment. The machine
builder must perform a risk assessment and determine a
category level of safety that must be applied to the machine.
Safety Standards for Reference
Publication 2094-UM001A-EN-P — September 2006
•
EN 1050 Safety of Machinery - Principles for Risk Assessment
•
EN 60204-1 Safety of Machinery - Electrical Equipment of
Machines
•
EN 292-1/2 Safety of Machinery - Basic Concepts, General
Principles for Design
•
EN 954-1 Safety of Machinery - Safety Related Parts of Control
Systems
•
NFPA 79 Electrical Standard for Industrial Machinery
•
ANSI B11.TR3 Risk Assessment and Risk Reduction. A guide to
estimate, evaluate, and reduce risks associated with machine tools.
Integrating Resistive Brake Modules with Kinetix 6000 Drives
241
Background on Safety Design
There are numerous safety standards regarding machine design
including OSHA, NFPA, AMT, CENELEC and ISO. In Europe, CENELEC
and ISO coordinate the development of standards to which products
can satisfy the laws of the Machinery Directive. In the United States,
Standard Development Organizations (SDO) like the NFPA and AMT
sponsor the development of standards to help companies meet OSHA
requirements.
Stop Categories
One of the most basic safety functions is stopping the machine. The
stopping function of a machine must fall into one of three categories
(EN60204-1 and NFPA79). The categories are as follows:
•
Stop Category 0: Stopping by immediate removal of power to the
machine actuators.
•
Stop Category 1: A controlled stop with power to the machine
actuators to achieve the stop and then removal of power when the
stop is achieved.
•
Stop Category 2: A controlled stop with power left available to
the machine actuators.
E-Stops are a special case of stops, and have additional requirements
to those stated above. This appendix is intended to show how a light
curtain or gate interlock might interface with one axis of motion
control to achieve a machine stop and this stop may not be the same
as the E-stop function of a machine.
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Integrating Resistive Brake Modules with Kinetix 6000 Drives
Risk Assessment
The European safety standard (EN 1050) and U.S. technical report
(ANSI B11.TR3) explain the process of risk assessment, which must be
conducted by the machine builder. This is done by analyzing the tasks
that people perform on and around the machine. This includes
functions such as operation, set up, and maintenance. For the purpose
of this appendix, the light curtain or gate interlock is intended to focus
on the operation and perhaps loading/unloading of a machine.
Additional protective measures must be identified by the risk
assessment.
Machinery Directive EN 954-1 Safety Related Parts of Control Systems
defines how to determine the safety requirements by categorizing the
risk. This standard outlines the design of fail-safe control circuits by
categorizing five levels of risk. It is deemed the machine designers
responsibility to objectively identify a risk level for a particular
machine and design all safety related systems to that level. The five
categories are as follows:
Category B: Safety devices and control systems, as a minimum, must
be designed, selected, and assembled to meet the operational
requirements of design limits and influence of the processed materials
and other external influences listed as: effects of vibration, loss of
power supply, and external fields.
Category 1: All conditions of Category B apply, but the safety related
part of the control system must use well tried principles and
components (refer to 7.2.2: prEN951-1). The use of single electronic
components, electronic logic or software is not considered adequate,
even at this level.
Category 2: All conditions of Category B apply, but in addition, the
machine shall be prevented from starting if a fault is detected upon
power up. This suggests the use of an interface relay with redundancy
and self-checking on energization. Single channel operation is
permitted providing that the input devices (E-Stop buttons, gate
switches, etc.) are tested for operation on a regular basis. If regular
testing cannot be guaranteed, then the designer has little choice but to
opt for two channel control.
Category 3: All conditions of Category B apply, but the complete
safety control system shall be designed so that any single fault shall
not lead to the loss of the safety function and, where practical, the
single fault shall be detected. This now calls for not only redundancy
in the interface relay but also in the input devices pointing to dual
channel systems.
Publication 2094-UM001A-EN-P — September 2006
Integrating Resistive Brake Modules with Kinetix 6000 Drives
243
Category 4: All the conditions of Category B apply and, in addition,
any single fault must be detected at or before the next call on the
safety system, or an accumulation of three faults shall not lead to the
loss of the safety function.
Control Reliability
In the United States the AMT has promoted a concept called Control
Reliability as part of the ANSI B11.TR3 standard. This standard has
similar requirements to those in the Machinery Directive EN954-1
Category 3 risk standard.
Control Reliability is defined as the ability of a safety system to go into
a safe state in the event of a failure. In other words, the safety system
must bring the machine to a safe state in the event of a single fault.
Resistive Brake Module
Wiring Examples
This section provides interconnect diagrams to assist you in wiring a
Kinetix 6000 system which includes an RBM. The notes in the table
below apply to the following RBM interconnect example diagrams.
ATTENTION
The National Electrical Code and local electrical codes
take precedence over the values and methods provided.
Implementation of these codes is the responsibility of
the machine builder.
Note
Information
1
Cable shield clamp must be used in order to meet CE requirements. No external connection to ground required.
2
For motor cable specifications, refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001.
3
The BRKTMP0 signal can be wired to a ControlLogix input as overtemp warning in user program.
4
Firmware version 1.071 or later is required to use the DBRK outputs on the Kinetix 6000 IAM or AM.
5
The safety relay time delay should be set beyond the time required to stop and disable the axis when running at full speed.
6
Drive Enable Input Checking must be selected when configuring Axis Properties in RSLogix 5000 software.
Publication 2094-UM001A-EN-P — September 2006
Publication 2094-UM001A-EN-P — September 2006
230V ac Auxiliary
Input Power
(APL) Connector
Three-phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
2
1
4
3
2
1
L2/N
L1
L1
L2
L3
K
I/O (IOL)
Connector
230V ac Output
(P2L) Connector
24V dc Output
(P1L) Connector
1
L1'
L2'
L3'
6
5
4
3
2
COIL_E1
IO_PWR1
COIL_E2
IO_COM1
D
2
8
7
1, 3, 5
1
2, 4, 6
C
B
6
4
A
5
3
1
AUX1_L1
2
AUX1_L2
3
AUX2_L1
AUX2_L2 4
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
4
2
1
3
2
1
2
1
1
CTRL 2
2
CTRL 1
IO_PWR2
Three-phase Output
(OPL) Connector
Single-Phase Output
(CPL) Connector
Kinetix 6000
Line Interface Module
2094-ALxxS, -BLxxS, or
-XL75S-C2
Control Power
(CPD) Connector
IO_PWR1
Note 1
Motor Power
(MP) Connector
Cable Shield
Clamp
Contactor Enable
(CED) Connector
Motor/Resistive
Brake (BC) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
U
V
W
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
1
1
1
2
3
4
5
6
Note 3
IO_PWR1
BRKTMP0
BRKSTAT0
Note 4
B
1
2
3
4
5
6
7
8
1
2
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
2
3
3
2
4
4
AUX3
AUX2
AUX1
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
* Indicates User Supplied Component
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
Resistive Brake Module
2090-XBxx-xx
(RBM_0)
A
B
C
D
U
V
W
M
GND
Refer to the wiring examples in
Appendix B for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
244
Integrating Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM, AM, and LIM
(2094-ALxxS, -BLxxS, and -XL75S) wired with the Bulletin 2090 RBM
in a category 2 configuration.
RBM Wiring Example (Category 2 Configuration per EN954-1)
IO_COM
32
34
36
26
28
30
20
22
24
14
16
18
8
10
12
2
4
6
GND-15
NOT USED
GND-14
GND-15
GND-11
GND-12
GND-13
GND-8
GND-9
GND-10
GND-5
GND-6
GND-7
GND-2
GND-3
GND-4
GND-0
GND-1
33
35
31
25
27
29
19
21
23
11
13
15
17
5
7
9
1
3
BRKSTAT1
BRKSTAT0
BRKTMP1
Note 3
BRKTMP0
* Indicates User Supplied Component
NOT USED
IN-15
NOT USED
IN-13
IN-14
IN-10
IN-11
IN-12
IN-7
IN-8
IN-9
IN-4
IN-5
IN-6
IN-0
IN-1
IN-2
IN-3
ControlLogix Input Device
1756-IB16
D
Latching
Pushbutton *
Note 1
Motor/Resistive
Brake (BC) Connector
Motor Power
(MP) Connector
Cable Shield
Clamp
Kinetix 6000
Axis Module
2094-AMxx or -BMxx
(Axis_1)
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
U
V
W
2
1
2
1
1
2
3
4
5
6
Note 3
Note 4
2
1
IO_PWR1
3
4
5
6
7
8
1
2
BRKTMP1
BRKSTAT1
A
C
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
4
3
4
AUX3
AUX2
AUX1
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
K
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
Bulletin 2090
Resistive Brake Module
2090-XBxx-xx
(RBM_1)
A
B
C
D
U
V
W
M
GND
Refer to the wiring examples in
Appendix B for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
Integrating Resistive Brake Modules with Kinetix 6000 Drives
245
Publication 2094-UM001A-EN-P — September 2006
Publication 2094-UM001A-EN-P — September 2006
Three-phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
K
L1'
L1
COIL_A2
COIL_A1
IO_COM
IO_PWR
MBRK_COM
MBRK_PWR
MBRK_COM
I/O (IOL)
Connector
24V dc Output
(PSL) Connector
L2'
MBRK_PWR
L3'
L2
L1
L2
L3
Three-phase Output
(OPL) Connector
Single-Phase Output
(CPL) Connector
Kinetix 6000
Line Interface Module
2094-AL09 and -BL02
4
3
2
1
B
2
1
2
20-22
4
13
1
24-26
A
6
5
4
3
2
1
1
2
Control Power
(CPD) Connector
Note 1
Motor Power
(MP) Connector
Cable Shield
Clamp
Contactor Enable
(CED) Connector
Motor/Resistive
Brake (BC) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
IO_PWR
CONT ENCONT EN+
L1
L2
L3
DC+
DC-
CTRL 2
CTRL 1
Power Rail
Ground Stud
U
V
W
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
1
1
1
2
3
4
5
6
Note 3
IO_PWR
BRKTMP0
BRKSTAT0
Note 4
1
2
3
4
5
6
7
8
1
2
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
2
3
3
2
4
4
AUX3
AUX2
AUX1
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
* Indicates User Supplied Component
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
Resistive Brake Module
2090-XBxx-xx
(RBM_0)
A
B
C
D
U
V
W
M
GND
Refer to the wiring examples in
Appendix B for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
246
Integrating Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM, AM, and LIM
(2094-AL09 and -BL02) wired with the Bulletin 2090 RBM in a
category 2 configuration.
RBM Wiring Example (Category 2 Configuration per EN954-1)
IO_COM
32
34
36
26
28
30
20
22
24
14
16
18
8
10
12
2
4
6
GND-15
NOT USED
GND-14
GND-15
GND-11
GND-12
GND-13
GND-8
GND-9
GND-10
GND-5
GND-6
GND-7
GND-2
GND-3
GND-4
GND-0
GND-1
33
35
31
25
27
29
19
21
23
11
13
15
17
5
7
9
1
3
BRKSTAT1
BRKSTAT0
BRKTMP1
Note 3
BRKTMP0
* Indicates User Supplied Component
NOT USED
IN-15
NOT USED
IN-13
IN-14
IN-10
IN-11
IN-12
IN-7
IN-8
IN-9
IN-4
IN-5
IN-6
IN-0
IN-1
IN-2
IN-3
ControlLogix Input Device
1756-IB16
B
Latching
Pushbutton *
Note 1
Motor/Resistive
Brake (BC) Connector
Motor Power
(MP) Connector
Cable Shield
Clamp
Kinetix 6000
Axis Module
2094-AMxx or -BMxx
(Axis_1)
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
U
V
W
2
1
2
1
1
2
3
4
5
6
Note 3
Note 4
2
1
IO_PWR
3
4
5
6
7
8
BRKTMP1
BRKSTAT1
A
1
2
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
4
3
4
AUX3
AUX2
AUX1
TS_21
TS_22
CONSTAT_41
CONSTAT_42
SHIELD
COIL_A1
COIL_A2
AUX4
I/O Connections
(TB3) Connector
SHIELD
L1
R3
R2
R1
L3
L2
L1
K
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L2
Cable Shield
Clamp
Drive Connections
(TB1) Connector
Note 1
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
Bulletin 2090
Resistive Brake Module
2090-XBxx-xx
(RBM_1)
A
B
C
D
U
V
W
M
GND
Refer to the wiring examples in
Appendix B for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
Integrating Resistive Brake Modules with Kinetix 6000 Drives
247
Publication 2094-UM001A-EN-P — September 2006
Publication 2094-UM001A-EN-P — September 2006
4
3
2
1
230V ac Auxiliary 1
Input Power 2
(APL) Connector
Three-phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
K
L2/N
L1
L1'
L1
I/O (IOL)
Connector
230V ac Output
(P2L) Connector
24V dc Output
(P1L) Connector
L2'
6
5
4
3
2
1
4
3
2
COIL_E2
COIL_E1
IO_COM1
IO_PWR1
8
B
2, 4, 6
7
A
6
5
4
3
2
1
2
1
L1
L2
L3
DC+
DC-
CTRL 1
CTRL 2
I/O (IOD)
Connector
Note 6
Motor/Resistive
Brake (BC) Connector
Contactor Enable
(CED) Connector
Note 1
U
V
W
+24V_COM
ENABLE
+24V_PWR
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
CONT EN2
CONT EN+
1
IO_PWR1
1, 3, 5
1
AUX1_L1
2
AUX1_L2
3
AUX2_L1
AUX2_L2 4
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
L3'
L2
1
Three-phase Output
(OPL) Connector
L3
CTRL 2
2
CTRL 1
1
Single-Phase Output
(CPL) Connector
Kinetix 6000
Line Interface Module
2094-ALxxS, -BLxxS, or
-XL75S-C2
Power Rail
Ground Stud
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
2
1
1
2
3
4
5
C
D
Note 4
BRKTMP0
2
3
4
5
6
7
8
1
2
Note 3 IO_PWR1 1
E
BRKSTAT0
A
1
1
6
2
3
3
2
4
4
Cable Shield
Clamp
R3
R2
R1
AUX3
AUX2
AUX1
L3
L2
L1
AUX4
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
* Indicates User Supplied Component
TS_21
TS_22
CONSTANT_41
CONSTANT_42
SHIELD
COIL_A1
COIL_A2
SHIELD
I/O Connections
(TB3) Connector
L1
L2
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
Resistive Brake Module
2090-XBxx-xx
(RBM_0)
A
B
C
D
U
V
W
M
GND
Refer to the wiring examples in
Appendix B for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
248
Integrating Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM and LIM
(2094-ALxxS, -BLxxS, and -XL75S) wired with the Bulletin 2090 RBM
in a category 3 configuration.
RBM Wiring Example (Category 3 Configuration per EN954-1)
COM
IN-8
IN-9
IN-10
IN-11
IN-12
IN-13
IN-14
IN-15
GND-2
GND-2
GND-2
GND-2
GND-3
GND-3
GND-3
GND-3
NOT USED
NOT USED
NOT USED
IN-5
IN-6
IN-7
GND-1
GND-1
GND-1
NOT USED
IN-0
IN-1
IN-2
IN-3
IN-4
GND-0
GND-0
GND-0
GND-0
GND-1
31
33
35
25
27
29
19
21
23
13
15
17
1
3 STOPSTAT
5
7
9
BRKTMP0
11
* Indicates User Supplied Component
32
34
36
26
28
30
20
22
24
14
16
18
2
4
6
8
10
12
ControlLogix Input Device
1756-IB16
COM
A2
A1
IO_PWR1
X1
S52
Out2
S21
S22
COM
X2
X4
STOPSTAT
X3
Y39
Y40
Y2
Y1
S34
Reset *
S33
IO_PWR1
Safety Relay *
Allen-Bradley/Guardmaster MSR138DP
Note 5
S12
COM
PWR
E-STOP *
Out1
Light Curtain *
S11
B
14
13
C
24
23
38
37
48
47
E
58
57
COIL0
ENABLE0
BRKSTAT0
IO_PWR1
D
Integrating Resistive Brake Modules with Kinetix 6000 Drives
249
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Publication 2094-UM001A-EN-P — September 2006
Three-phase Input
(IPL) Connector
Bonded Cabinet
Ground Bus*
L1'
L1
K
L2'
1
I/O (IOL)
Connector
IO_PWR
COIL_A2
COIL_A1
IO_COM
IO_PWR
2
1
4
13
A
20-22
24-26
I/O (IOD)
Connector
Note 6
Motor/Resistive
Brake (BC) Connector
DC Bus
and
Three-phase
Input (IPD)
Connector
Note 1
U
V
W
+24V_COM
ENABLE
+24V_PWR
DBRK +
DBRK -
PWR
COM
MBRK +
MBRK -
Motor Power
(MP) Connector
Cable Shield
Clamp
Control Power
(CPD) Connector
Contactor Enable
(CED) Connector
L1
L2
L3
DC+
DC-
CTRL 1
CTRL 2
CONT EN2
CONT EN+
1
6
5
4
3
2
1
1
2
2
24V dc Output MBRK_COM
3
(PSL) Connector MBRK_PWR
4
MBRK_COM
MBRK_PWR
L3'
L2
L1
L2
L3
Three-phase Output
(OPL) Connector
Single-Phase Output
(CPL) Connector
Kinetix 6000
Line Interface Module
2094-AL09 and -BL02
Power Rail
Ground Stud
Kinetix 6000
Integrated Axis Module
2094-ACxx-Mxx or -BCxx-Mxx
(Axis_0)
2090-XXNRB-14F0P7
RBM to Drive Interface Cable
Note 2
3
2
1
1
2
3
4
5
B
C
Note 4
BRKTMP0
2
3
4
5
Note 3 IO_PWR 1
D
BRKSTAT0
6
7
8
1
2
1
1
6
2
3
3
2
4
4
Cable Shield
Clamp
R3
R2
R1
AUX3
AUX2
AUX1
L3
L2
AUX4
K
Note 1
T2
T1
U_MTR
V_MTR
W_MTR
Motor Connections
(TB2) Connector
Cable Shield
Clamp
* Indicates User Supplied Component
TS_21
TS_22
CONSTANT_41
CONSTANT_42
SHIELD
COIL_A1
COIL_A2
SHIELD
I/O Connections
(TB3) Connector
L1
L2
Auxiliary 230V ac
Input (TB4) Connector
(2090-XB120-xx only)
U_DRIVE
V_DRIVE
W_DRIVE
L1
Drive Connections
(TB1) Connector
Note 1
Bulletin 2090
Resistive Brake Module
2090-XBxx-xx
(RBM_0)
A
B
C
D
U
V
W
M
GND
Refer to the wiring examples in
Appendix B for motor power
cable catalog numbers.
Note 2
1
2
3
4
Motor Power
Connections
250
Integrating Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM and LIM
(2094-AL09 and -BL02) wired with the Bulletin 2090 RBM in a
category 3 configuration.
RBM Wiring Example (Category 3 Configuration per EN954-1)
COM
IN-8
IN-9
IN-10
IN-11
IN-12
IN-13
IN-14
IN-15
GND-2
GND-2
GND-2
GND-2
GND-3
GND-3
GND-3
GND-3
NOT USED
NOT USED
NOT USED
IN-5
IN-6
IN-7
GND-1
GND-1
GND-1
NOT USED
IN-0
IN-1
IN-2
IN-3
IN-4
GND-0
GND-0
GND-0
GND-0
GND-1
31
33
35
25
27
29
19
21
23
13
15
17
1
3 STOPSTAT
5
7
9
BRKTMP0
11
* Indicates User Supplied Component
32
34
36
26
28
30
20
22
24
14
16
18
2
4
6
8
10
12
ControlLogix Input Device
1756-IB16
COM
A2
A1
IO_PWR
X1
S52
Out2
S21
S22
COM
X2
X4
STOPSTAT
X3
Y39
Y40
Y2
Y1
S34
Reset *
S33
IO_PWR
Safety Relay *
Allen-Bradley/Guardmaster MSR138DP
Note 5
S12
COM
PWR
E-STOP *
Out1
Light Curtain *
S11
A
14
13
B
24
23
38
37
48
47
D
58
57
COIL0
ENABLE0
BRKSTAT0
IO_PWR
C
Integrating Resistive Brake Modules with Kinetix 6000 Drives
251
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Integrating Resistive Brake Modules with Kinetix 6000 Drives
Setting the RBM Delay Time
Using DriveExplorer
In this procedure you will break SERCOS ring communications, set the
delay time parameter using DriveExplorer software, and re-establish
SERCOS communication.
For This Revision of
RSLogix 5000 Software
Do This
v11 or v12
Proceed with these instructions using DriveExplorer to set
the RBM delay time parameter.
v13 or later
Go to Configure Axis Properties on page 133 and use
RSLogix 5000 software to set the RBM delay time parameter.
The following hardware and software tools are required to provide
the necessary communication link between your personal computer
and the Kinetix 6000 drive system running RSLogix 5000 software.
Description
Catalog Numbers
Version
9306-4EXP02ENE
2.01 or later
Serial to SCANport Adapter (2) (3)
1203-SSS (Series B)
3.004 or later
RSLogix 5000 Software
9324-RLD300NE
11.0 or 12.0
Personal computer with HyperTerminal
N/A
N/A
(1) (2)
DriveExplorer Software
(1)
Refer to DriveExplorer Getting Results Manual, publication 9306-GR001, for instructions.
(2)
Additional information regarding these communication and software tools is available at
http://www.ab.com/support/abdrives.
(3)
Refer to 1203-SSS (Series B) FRN 3.xxx User Manual, publication 20COMM-UM001, for instructions.
ATTENTION
To avoid personal injury or equipment damage, at least one end
of a SERCOS fiber-optic cable must be disconnected from the
drive. This ensures that motion will not occur while changes are
being made to the time delay parameter.
Removing SERCOS Communication
Follow these steps to remove (break) SERCOS communications.
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Remove one of the SERCOS fiber-optic cables.
Fiber-optic cable connections (Tx and Rx) are located on the top
of each IAM/AM.
3. Re-apply three-phase and control power.
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Integrating Resistive Brake Modules with Kinetix 6000 Drives
253
Setting the RBM Delay Time Parameter
Follow these steps to set the RBM delay time parameter.
1. Start your DriveExplorer software.
2. From the menu bar choose Explore\Connect\Local or enter Ctrl-L
from the keyboard.
DriveExplorer software will read your system.
3. Observe the Linear List of parameters as grouped by Node, Port,
and Axis hierarchy as shown below.
Linear List Legend
N: P. x xxx
Parameter Number
30 = Version Data
Axis Number
0 = IAM (axis 1)
1 = AM (axis 2)
2 = AM (axis 3)
3 = AM (axis 4)
DPI Port Number
Network Node Number
4. Select Devices\Node\Product\Axis x Group\Config and navigate
to the Config parameters as shown below.
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Integrating Resistive Brake Modules with Kinetix 6000 Drives
5. Double-click the x:x:x641 RBM Delay parameter.
The command dialog for parameter x641 - RBM Delay opens.
6. Select the Value Edit tab and enter the delay time Value (ms).
The recommended RBM delay time is 71 ms.
7. Click OK.
The RBM delay time is changed, but not saved in non-volatile
memory.
Saving the Delay Time Parameter to Non-Volatile Memory
Follow these steps to save the delay time parameter to non-volatile
memory.
1. From the menu bar choose Actions\Non-Volatile Memory.
The following message dialog opens.
2. Click Save.
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Integrating Resistive Brake Modules with Kinetix 6000 Drives
255
The changes are saved to non-volatile memory and the following
cautionary message dialog opens.
3. Click Yes.
The save to non-volatile memory is complete and the following
confirmation message dialog opens.
4. Click OK.
5. Determine if you have another RBM to configure.
If you
Then
Have another RBM in the Kinetix 6000
system
Go to Setting the RBM Delay Time Parameter (Step 4).
Do not have another RBM in the
Kinetix 6000 system
Close the DriveExplorer software.
Go to Reconnecting SERCOS Communication.
Reconnecting SERCOS Communication
Follow these steps to reconnect SERCOS communication.
1. Remove three-phase and control power from the Kinetix 6000
drive system.
2. Replace the SERCOS fiber-optic cable removed earlier.
Fiber-optic cable connections (Tx and Rx) are located on the top
of each IAM/AM.
3. Re-apply three-phase and control power.
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Integrating Resistive Brake Modules with Kinetix 6000 Drives
Publication 2094-UM001A-EN-P — September 2006
Index
Numerics
1203-SSS serial cable 224, 227
1756-MxxSE 125
1768-M04SE 125
1784-PM16SE 125
26-pin I/O connector 161
A
about this publication 9
ac line filters
noise reduction 39
specifications 183
acronyms 9
additional bus capacitance
calculating 232
example 234
additional resources 10
analog outputs 62
analog test points
DAC0 161
DAC1 161
applying power 135
atune fault 150
aux fdbk noise fault 149
aux feedback AQB 149
aux feedback loss 149
auxiliary encoder error 148
auxiliary feedback
pin-outs 57
specifications 66
axes to flash 224, 226
axis module
catalog number 16
configuring 120
connector designators 51, 52
dimensions 187, 188
status indicators 152
wiring requirements 81
axis properties 133
axis unstable 155
B
backplane comm 150
bandwidth 142
base node address 120
example with double-wide
modules 124
example with two
ControlLogix chassis 123
257
example with two power rails
122
baud rate 121
block diagrams
converter 213
inverter 212
safe-off feature 214
shunt module 214
blown fuse 146
bonding
EMI (ElectroMagnetic
Interference) 27
examples 28
high frequency energy 29
subpanels 29
braided strap 78
brake 210
brake relay 64
building your own cables 70
bus
overcurrent 150
overvoltage 147
regulator 131
status LED 152, 154
undervoltage 147
C
cables
building your own cables 70
categories 37
fiber optic cable length 115
maximum fdbk cable length
181
shield clamp 103
shield, EMC 96, 97, 98
CAN init 150
capacitance values 233
catalog number
axis module 16
integrated axis module 16
shunt module 16
CB1, CB2, CB3 135
CE compliance 16
certifications specifications 182
changing parameters
DriveExplorer 160
HIM 161
circuit breaker
LIM 135
selection 22
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258
Index
specifications 177
clamp 103
comm status LED 152
common bus (refer to DC
common bus)
common bus flt 151
configuration 225
configuring
AM 120
base node address 120
baud rate, IAM 121
delay times 134
feedback only axis 130
IAM 120
optical power level 121
SERCOS module 125
connecting
contactor enable 93
external shunt resistor 113
feedback 104
I/O 104
motor brake 101
motor shield clamp 103
panel-mounted breakout kit
109
premolded feedback cables
108
SERCOS cables 115
connector designators
axis module 52
integrated axis module 52
shunt module 68
connector locations
axis module 51
integrated axis module 50
shunt module 68
contactor enable
relay 63
wiring 93
contactor specifications 179
control power input
specifications 65
control reliability 243
ControlFLASH
flashing firmware 220
software kit 216
controller properties 125
controlling a brake 210
conventions used in this manual
9
conversion tab 133
Publication 2094-UM001A-EN-P — September 2006
converter 213
coordinated system time master
126
CPLD FLT 151
cycle time 128
D
DAC0 161
DAC1 161
data rate 128
data type 129
date and time tab 126
DC common bus
configuring 131
follower IAM 15, 74
fuse requirements 75
interconnect diagram 197, 198,
200
leader IAM 15, 74
pre-charge 15, 74
setting the add bus cap
parameter 235
total bus capacitance 15
typical installation 15
delay times 134
digital I/O not working correctly
146
digital inputs 60
dimensions
AM 187, 188
IAM 185, 186
SM 189
dip switches 128
disable drive 157
download program 134
drive enable fault 149
drive overcurrent 147
drive overtemp 148, 150
drive status LED 137, 152
drive tab 133
drive undervoltage 148
DriveExplorer
flashing firmware 228
software 160, 224, 235, 252
E
earth ground 78
EMC
cable shield 96, 97, 98
motor ground termination 95
Index
EMI (ElectroMagnetic
Interference)
bonding 27
enclosure
requirements 20
selection 23
sizing, Kinetix 6000 180
encoder communication fault
148
environmental specifications 181,
182
erratic operation 156
error codes 146
establishing communications 152
external active shunt resistor
specifications 184
external passive shunt resistor
specifications 184
external shunt resistor 40, 48
wiring 113
F
fault action 157
fault action, programmable 157
fault actions tab 133
feedback only axis 130
feedback power supply 67
feedback tab 133
fiber optic signals 61
fiber-optic cables
drive-to-drive 116
receive and transmit
connectors 115
firmware
upgrade file 229
flashing
axes 224
firmware 220, 228
flashing firmware
ControlFLASH 220
DriveExplorer 228
follow error 148
follower IAM 15, 74
fuse selection 22
fuse specifications 177
G
ground fault 148
ground jumper setting 75
grounded power configuration
259
71
grounding
multiple subpanels 79
H
hardware enable input 139, 141
hardware overtravel 147
headers
motion allowed jumper 52
HF bonding 27
high frequency energy 29
HIM 160
hookup fault 149
hookup tab 138
human interface module (HIM)
160
hyperterminal 226
I
I/O
connections 104
pin-outs, AM 54
pin-outs, IAM 54
specifications 60
I/O connector 161
Ifbk HW fault 149
illegal hall state 147
input connector pin-outs
IAM 58
input power source 136
input power wiring
3-phase delta 72
determining input power 71
ground jumper setting 75
grounded power configuration
71
ungrounded power
configuration 73
installing drive accessories
noise zones
ac line filters 39
external shunt resistor 40
motor brake 42
RBM 42
thermal switch 42
installing your drive 19
bonding examples 28
bonding subpanels 29
cable categories 37
circuit breakers 22
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260
Index
enclosure selection 23
fuse selection 22
HF bonding 27
noise zones 30
system mounting requirements
module properties 129
overview 11
specifications
enclosure sizing 180
system overview 12
20
transformer 21
integrated axis module
catalog number 16
configuring 120
connector designators 52
connector locations 50
dimensions 185, 186
interconnect diagram 193, 194,
196, 197, 198, 200
status indicators 152
wiring BC connector 101
wiring CED connector 93
wiring CPD connector 90
wiring IPD connector 91
wiring MP connector 95
wiring requirements 80, 81
wiring SO connector 94
interconnect diagrams
2094 with 1326AB motor 208
2094 with F-Series motor 209
2094 with MPG-A motor 205
2094 with MPG-B motor 204
2094 with MPL/MPF/MPS
motor 206
2094 with MPL-A motor 205
2094 with MPL-B motor 204
2094 with TL-Series motor 207
2094 with Y-Series motor 210
notes 192, 243
power, DC common bus 197,
198, 200
power, IAM with LIM 193, 194
power, IAM without LIM 196
RBM 243
shunt module 201, 202, 203
interpreting status indicators 146
inverter 212
IPM fault 147
K
Kinetix 6000
additional resources 10
axis properties 133
capacitance values 233
Publication 2094-UM001A-EN-P — September 2006
L
leader IAM 15, 74
LED
bus status 152, 154
comm status 152
drive status 137, 152
logic power 136
SERCOS interface module 137
seven-segment 137
shunt fault 154
status 137
temperature fault 154
line interface module
circuit breakers 135
interconnect diagram 193, 194,
196
three-phase power 136
wiring 24V connector 89
wiring APL connector 84
wiring CPL connector 87
wiring IPL connector 85
wiring OPL connector 86
wiring P2L connector 88
logic power LED 136
low profile connector kits
wiring 110
M
maintenance 146
maximum fdbk cable length 181
specifications 181
memory init 150
module mismatch 150
module mounting order 44
module properties
IAM 129
SERCOS module 127
monitor system variables 161
motion allowed jumper 52, 94
motion group properties 132
motor accel/decel problems 155
motor and feedback tab 133
motor brake 42
motor encoder error 148
Index
motor feedback loss 147
motor jumps when first enabled
overview 11
146
motor overheating 156
motor overtemp 146
motor velocity 155
motors
brake wiring 101
feedback pin-outs 55, 105
feedback specifications 66
ground termination 95
interconnect diagram
1326AB 208
F-Series 209
MPG-A 205
MPG-B 204
MPL/MPF/MPS 206
MPL-A 205
MPL-B 204
TL-Series 207
Y-Series 210
power and brake pin-outs 59
power wiring
1326AB 98
MP 96, 97
Y-Series 100
shield clamp wiring 103
testing 138
tuning 138
mounting your drive
external shunt resistor 48
module mounting order 44
mounting modules 45
mtr fdbk noise fault 149
N
no communication 152
no rotation 156
node address 129
noise
abnormal 156
feedback 156
reduction 39
zones 30
NV mem init 150
O
objects init 150
optical power level 121, 128
overspeed fault 148
261
P
panel
requirements 20
panel-mounted breakout kit 109
parameters, changing 160
pin-outs
auxiliary feedback connector
57
I/O connector
IAM/AM 54
input connector
IAM 58
motor and brake connector 59
motor feedback connector 55,
105
safe-off connector
IAM/AM 52
shunt module connector 68
planning your installation 19
power dissipation specifications
180
power indicator not on 146
power phase loss 149
power rail
connecting braided strap 78
removing 166
removing modules 164
replacing 167
power supply, feedback 67
power up 135
pre-charge 15, 74
pre-charge fault 148
pre-charge flt 151
premolded feedback cables 108
publications, related 10
R
RBM 42
related publications 10
relay output 210
removing modules 164
replacing modules 165
resistive brake module
interconnect diagrams 243
setting the RBM delay time 252
wiring 114
risk assessment 242
routing power and signal wiring
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262
Index
70
RSLinx software 216
RSLogix 5000 software 125, 160,
216, 224, 235, 252
S
safe-off
block diagram 214
motion allowed jumper 52, 94
pin-outs, AM 52
pin-outs, IAM 52
wiring 94
safe-off HW fault 149
safety
control reliability 243
risk assessment 242
standards 240
stop categories 241
SCANport comm 150
SCANport/DPI adapter 224, 235,
252
SCANport/DPI connector 224
self sense fault 149
SERCOS
connecting cables 115
connections 61
SERCOS init 150
SERCOS module 125
properties 127
SERCOS ring fault 149
SERCOS same addr 149
setting the add bus cap parameter
235
seven-segment status LED 137
shield clamp 103
shunt fault LED 154
shunt module 214
catalog number 16
connector designators 68
connector locations 68
dimensions 189
interconnect diagram 201, 202,
203
pin-outs 68
system specifications 174
troubleshooting 153
wiring requirements 81
shunt time fault 151
shunt time out 150
shutdown 157
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software
RSLogix 5000 125, 160
software overtravel 148
specifications
ac line filters 183
certifications 182
circuit breakers 177
contactor ratings 179
environmental 181, 182
external active shunt resistor
184
external passive shunt resistor
184
feedback
motor and auxiliary 66
power supply 67
fuses 177
I/O
analog outputs 62
brake relay 64
contactor enable relay 63
control power input 65
digital inputs 60
maximum fdbk cable length
181
power
AM 230V 172
AM 460V 173
IAM 230V 170
IAM 460V 171
SM 173
power dissipation 180
SERCOS connections 61
shunt module, system 174
transformer 179
weight 182
status indicators 146
status LEDs 137, 152
status only 157
stop categories 241
stop motion 157
supplemental troubleshooting
information 160
surge suppression 102
switches
base node address 120
baud rate 121
optical power level 121
system block diagrams
converter 213
inverter 212
Index
safe-off feature 214
shunt module 214
system ground 78
system mounting requirements
20
system overview 12
DC common bus 15
with LIM 13
without LIM 14
T
task init 150
temperature fault LED 154
testing axes
hookup tab 138
thermal switch 42
total bus capacitance 15
calculating 232
example 234
training 9
transformer sizing 21
transformer specifications 179
troubleshooting
bus status LED 152, 154
comm status 152
disable drive 157
drive status LED 152
error codes 146
fault action 157
general
atune fault 150
aux fdbk noise fault 149
aux feedback AQB 149
aux feedback loss 149
auxiliary encoder error
148
backplane comm 150
blown fuse 146
bus overcurrent 150
bus overvoltage 147
bus undervoltage 147
CAN init 150
common bus flt 151
CPLD FLT 151
digital I/O not working
correctly 146
drive enable fault 149
drive overcurrent 147
drive overtemp 148, 150
drive undervoltage 148
263
encoder communication
fault 148
follow error 148
ground fault 148
hardware overtravel 147
hookup fault 149
Ifbk HW fault 149
illegal hall state 147
IPM fault 147
memory init 150
module mismatch 150
motor encoder error 148
motor feedback loss 147
motor jumps when first
enabled 146
motor overtemp 146
mtr fdbk noise fault 149
NV mem init 150
objects init 150
overspeed fault 148
power indicator not on
146
power phase loss 149
pre-charge fault 148
pre-charge timeout flt 151
safe-off HW fault 149
SCANport comm 150
self sense fault 149
SERCOS init 150
SERCOS ring fault 149
SERCOS same addr 149
shunt module fault 151
shunt time out 150
software overtravel 148
task init 150
unknown axis 149
general system problems 155
abnormal noise 156
axis unstable 155
erratic operation 156
feedback noise 156
motor accel/decel
problems 155
motor overheating 156
motor velocity 155
no rotation 156
Logix/drive fault behavior 157
programmable fault action 157
shunt fault LED 154
shunt module 153
shutdown 157
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264
Index
status only 157
stop motion 157
supplemental troubleshooting
information 160
changing parameters 160
using analog test points
161
temperature fault LED 154
tuning axes
bandwidth 142
tune tab 141
typical installation
DC common bus 15
with LIM 13
without LIM 14
U
ungrounded power configuration
73
units tab 133
unknown axis 149
W
weight specifications 182
who should use this manual 9
wiring
building your own cables 70
contactor enable 93
earth ground 78
external shunt resistor 113
ground jumper setting 75
grounded power configuration
71
I/O connections 104
Publication 2094-UM001A-EN-P — September 2006
IAM
BC connector 101
CED connector 93
CPD connector 90
IPD connector 91
MP connector 95
SO connector 94
IAM with LIM
24V connector 89
APL connector 84
CPL connector 87
IPL connector 85
OPL connector 86
P2L connector 88
input power
determining type 71
low profile connectors 110
motor brake 101
motor cable shield clamp 103
motor power 96, 97, 98, 100
requirements 69
IAM 80
IAM, AM 81
SM 81
resistive brake module 114
routing power and signal
wiring 70
safe-off feature 94
SERCOS fiber optic cables 115
ungrounded power
configuration 73
X
Xmodem 229
Rockwell Automation
Support
Rockwell Automation provides technical information on the Web to assist
you in using its products. At http://support.rockwellautomation.com, you can
find technical manuals, a knowledge base of FAQs, technical and application
notes, sample code and links to software service packs, and a MySupport
feature that you can customize to make the best use of these tools.
For an additional level of technical phone support for installation,
configuration, and troubleshooting, we offer TechConnect Support programs.
For more information, contact your local distributor or Rockwell Automation
representative, or visit http://support.rockwellautomation.com.
Installation Assistance
If you experience a problem with a hardware module within the first 24
hours of installation, please review the information that's contained in this
manual. You can also contact a special Customer Support number for initial
help in getting your module up and running.
United States
1.440.646.3223
Monday – Friday, 8am – 5pm EST
Outside United
States
Please contact your local Rockwell Automation representative for any
technical support issues.
New Product Satisfaction Return
Rockwell tests all of its products to ensure that they are fully operational
when shipped from the manufacturing facility. However, if your product is
not functioning, it may need to be returned.
United States
Contact your distributor. You must provide a Customer Support case
number (see phone number above to obtain one) to your distributor in
order to complete the return process.
Outside United
States
Please contact your local Rockwell Automation representative for
return procedure.
Publication 2094-UM001A-EN-P — September 2006
Supersedes Publication 2094-IN001G-EN-P and 2094-IN002E-EN-P
Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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