Rockwell Automation Kinetix 6000 Multi-Axis Servo Drive Integration Manual
The Kinetix 6000 Multi-Axis is a powerful and versatile servo drive system that can be used in a wide variety of applications. The Kinetix 6000 features a modular design that allows you to customize the system to meet your specific needs. The system can be used to control a variety of motor types, including AC and DC motors, and can be integrated with a variety of control systems, including Rockwell Automation's ControlLogix and SoftLogix platforms. The Kinetix 6000 Multi-Axis is a great choice for applications that require high performance and flexibility.
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Kinetix 6000 Multi-Axis
Servo Drive
(Catalog Numbers
2094-AC05-MP5, -AC05-M01, -AC09-M02
-AC16-M03, -AC32-M05
2094-BC01-MP5, -BC01-M01, -BC02-M02
-BC04-M03, -BC07-M05
2094-BC01-MP5-S, -BC01-M01-S,
-BC02-M02-S, -BC04-M03-S, -BC07-M05-S
2094-AMP5, -AM01, -AM02, -AM03, -AM05
2094-BMP5, -BM01, -BM02, -BM03, -BM05
2094-PRS1, -PRS2, -PRS3, -PRS4, -PRS5,
-PRS6, -PRS7, -PRS8
2094-PR1, -PR2, -PR4, -PR6, -PR8
2094-PRF
2094-AL09, -AL75S
2094-BL02, -BL75S
2094-XL75S-C1
2094-XL75S-C2
2094-BSP2)
Integration 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://www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety considerations.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:
• identify a hazard
• avoid a hazard
• recognize the consequence
SHOCK HAZARD
Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.
BURN HAZARD
Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be dangerous temperatures.
Allen-Bradley, A-B, ControlLogix, and Kinetix are registered trademarks of Rockwell Automation.
DriveExplorer, RSLogix, RSLogix 5000, SoftLogix, and SCANport are trademarks of Rockwell Automation.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
i
Table of Contents
Commission Your Kinetix 6000
Preface
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Product Receiving and Storage Responsibility . . . . . . . . . . . P-2
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . P-4
Chapter 1
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Startup Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Understand IAM/AM Connectors . . . . . . . . . . . . . . . . . . . . 1-2
Integrated Axis Module/Axis Module Connectors . . . . . . 1-2
Locate IAM Connectors and Indicators . . . . . . . . . . . . . . . . 1-3
Locate AM Connectors and Indicators . . . . . . . . . . . . . . . . . 1-4
Understand SM Connectors . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Locate Shunt Module Connectors . . . . . . . . . . . . . . . . . 1-5
Understand LIM Connectors and Indicators . . . . . . . . . . . . . 1-6
Line Interface Module Connectors . . . . . . . . . . . . . . . . . 1-6
Locate SERCOS Interface Fiber-Optic Connectors . . . . . . . . 1-9
Configure Your Kinetix 6000 . . . . . . . . . . . . . . . . . . . . . . . 1-9
Configure Your Integrated Axis Module. . . . . . . . . . . . 1-10
Configure Your Axis Module(s) . . . . . . . . . . . . . . . . . . 1-15
Configure Your Logix SERCOS interface Module . . . . . . . . 1-16
Configure Your Logix Controller . . . . . . . . . . . . . . . . . 1-16
Configure Your Logix Module . . . . . . . . . . . . . . . . . . . 1-17
Configure Your Kinetix 6000 Modules . . . . . . . . . . . . . 1-19
Configure the Motion Group . . . . . . . . . . . . . . . . . . . . 1-23
Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . 1-24
Download Your Program . . . . . . . . . . . . . . . . . . . . . . 1-25
Apply Power to Your Kinetix 6000 . . . . . . . . . . . . . . . . . . 1-26
Apply Power to Your Kinetix 6000 (with LIM) . . . . . . . 1-26
Apply Power to Your Kinetix 6000 (without LIM). . . . . 1-30
Test and Tune Your Axes. . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Test Your Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Tune Your Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Chapter 2
Troubleshoot Your Kinetix 6000
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Troubleshoot IAM/AM Status LEDs . . . . . . . . . . . . . . . . . . . 2-8
Drive Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Comm Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Publication 2094-IN002E-EN-P — September 2005
ii Table of Contents
Interconnect Diagrams
Bus Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Troubleshoot SM Status LEDs . . . . . . . . . . . . . . . . . . . . . . 2-10
General Shunt Module Troubleshooting . . . . . . . . . . . . 2-10
Bus Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Temperature Fault LED . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Shunt Fault LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Troubleshoot LIM Status LEDs . . . . . . . . . . . . . . . . . . . . . 2-12
Troubleshoot RBM Status LEDs . . . . . . . . . . . . . . . . . . . . . 2-12
24V dc Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
230V ac Auxiliary Power Status LED . . . . . . . . . . . . . . 2-13
Troubleshoot General System Problems . . . . . . . . . . . . . . 2-14
Understand Logix/Drive Fault Behavior. . . . . . . . . . . . . . . 2-16
Supplemental Troubleshooting Information . . . . . . . . . . . . 2-19
Tools for Changing Parameters . . . . . . . . . . . . . . . . . . 2-19
Using Analog Test Points to Monitor System Variables . 2-20
Replace Kinetix 6000 System Components. . . . . . . . . . . . . 2-22
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Remove Modules from the Power Rail. . . . . . . . . . . . . . . . 2-23
Replace Power Rail Modules. . . . . . . . . . . . . . . . . . . . . . . 2-24
Remove the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Replace the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Remove the Line Interface Module . . . . . . . . . . . . . . . . . . 2-27
Replace the Line Interface Module . . . . . . . . . . . . . . . . . . 2-28
Appendix A
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Kinetix 6000 Interconnect Diagram Notes . . . . . . . . . . . . . . A-1
Power Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . A-3
DC Common Bus Interconnect Diagrams . . . . . . . . . . . . . . A-8
Shunt Module Interconnect Diagrams . . . . . . . . . . . . . . . . A-13
1336 Active Shunt Input Fuse Specifications . . . . . . . . . A-14
1336 Active Shunt Fault Relay Specifications . . . . . . . . A-14
AM/Motor Interconnect Diagrams . . . . . . . . . . . . . . . . . . . A-16
Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . A-24
System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . A-26
IAM/AM Inverter Block Diagram . . . . . . . . . . . . . . . . . A-26
IAM Converter Block Diagram . . . . . . . . . . . . . . . . . . . A-27
Safe-Off Feature Block Diagram. . . . . . . . . . . . . . . . . . A-28
SM Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28
LIM Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . A-29
RBM Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . A-34
Publication 2094-IN002E-EN-P — September 2005
Upgrade Your Kinetix 6000
Firmware
Integrate Resistive Brake
Modules with Kinetix 6000 Drives
DC Common Bus Applications
Table of Contents iii
Appendix B
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Upgrade Drive Firmware Using DriveExplorer . . . . . . . . . . B-1
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Select Axis Modules to Upgrade . . . . . . . . . . . . . . . . . . B-1
HyperTerminal Configuration . . . . . . . . . . . . . . . . . . . . B-4
Flash Your Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Appendix C
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Understand Safety Precautions . . . . . . . . . . . . . . . . . . . . . . C-2
Safety Standards for Reference . . . . . . . . . . . . . . . . . . . C-2
Background on Safety Design . . . . . . . . . . . . . . . . . . . . C-3
Stop Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Control Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Resistive Brake Module Interconnect Diagram Notes . . . . . . C-5
Resistive Brake Module Interconnect Diagrams . . . . . . . . . . C-6
Set the RBM Delay Time Using DriveExplorer . . . . . . . . . . C-14
Remove SERCOS Communication . . . . . . . . . . . . . . . . C-14
Set the RBM Delay Time Parameter . . . . . . . . . . . . . . . C-15
Save the Delay Time Parameter to Non-Volatile
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Reconnect SERCOS Communication . . . . . . . . . . . . . . C-17
Appendix D
Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Calculate Total Bus Capacitance . . . . . . . . . . . . . . . . . . D-2
Calculate Additional Bus Capacitance . . . . . . . . . . . . . . D-3
Kinetix 6000 Capacitance Values . . . . . . . . . . . . . . . . . . D-3
Common Bus Capacitance Example . . . . . . . . . . . . . . . D-4
Set the Additional Bus Capacitance Parameter. . . . . . . . . . . D-5
Remove SERCOS Communication . . . . . . . . . . . . . . . . . D-5
Set the Additional Bus Capacitance Parameter . . . . . . . . D-6
Save the Add Bus Cap Parameter to Non-Volatile
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Reconnect SERCOS Communication . . . . . . . . . . . . . . . D-8
Publication 2094-IN002E-EN-P — September 2005
iv Table of Contents
Publication 2094-IN002E-EN-P — September 2005
1
Preface
Introduction
Who Should Use this
Manual
Read this preface to familiarize yourself with the rest of the manual.
This preface contains the following topics:
• Who Should Use this Manual
• Purpose of this Manual
• Contents of this Manual
• Product Receiving and Storage Responsibility
• Related Documentation
• Conventions Used in this Manual
This manual is intended for engineers or programmers directly involved in the operation, field maintenance, and integration of the
Kinetix 6000 multi-axis servo drive with the SERCOS interface module.
If you do not have a basic understanding of the Kinetix 6000, contact your local Allen-Bradley representative for information on available training courses before using this product.
Purpose of this Manual
This manual provides the startup, configuration, and troubleshooting procedures for the Kinetix 6000. The purpose of this manual is to assist you in the integration of your Kinetix 6000 servo drive with the
ControlLogix 1756-MxxSE SERCOS interface module or SoftLogix
1784-PM16SE SERCOS PCI card.
Publication 2094-IN002E-EN-P — September 2005
P-2
Contents of this Manual
Refer to the following listing for the descriptive contents of this installation manual.
Chapter
Chapter 1
Chapter 2
Appendix A
Appendix B
Appendix C
Appendix D
Title
Preface
Commission Your Kinetix 6000
Troubleshoot Your Kinetix 6000
Interconnect Diagrams
Upgrade Your Kinetix 6000
Firmware
Integrate Resistive Brake
Modules with Kinetix 6000
Drives
DC Common Bus Applications
Contents
Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended.
Provides steps to follow when configuring your
Kinetix 6000, the Logix SERCOS interface module, and when applying power to the Kinetix
6000 for the first time.
Provides diagnostic aids that help isolate problems with your drive and Kinetix 6000 removal/replacement procedures.
Provides interconnect diagrams between the
Kinetix 6000 and the Line Interface Module,
Shunt Module, Resistive Brake Module and servo motors.
Provides steps to follow when you need to upgrade (flash) your IAM and AM firmware.
Provides safety precautions, interconnect diagrams, and procedures specific to configuring the RBM with the Kinetix 6000.
Explains how to calculate capacitance values and set the Add Bus Cap parameter for DC common bus applications.
Product Receiving and
Storage Responsibility
You, the customer, are responsible for thoroughly inspecting the equipment before accepting the shipment from the freight company.
Check the item(s) you receive against your purchase order. If any items are obviously damaged, it is your responsibility to refuse delivery until the freight agent has noted the damage on the freight bill. Should you discover any concealed damage during unpacking, you are responsible for notifying the freight agent. Leave the shipping container intact and request that the freight agent make a visual inspection of the equipment.
Store the product in its shipping container prior to installation. If you are not going to use the equipment for a period of time, store using the following guidelines.
• Use a clean, dry location
• Maintain an ambient temperature range of -40 to 70° C
(-40 to 158° F)
• Maintain a relative humidity range of 5% to 95%, non-condensing
• Store it where it cannot be exposed to a corrosive atmosphere
• Store it in a non-construction area
Publication 2094-IN002E-EN-P — September 2005
P-3
Related Documentation
The following documents contain additional information concerning related Allen-Bradley products. To obtain a copy, contact your local
Allen-Bradley office, distributor, or download them from www.rockwellautomation.com/literature.
For
The instructions needed for the installation and wiring of the Kinetix
6000
Installation instructions for the LIM and removal/replacement procedures for selected internal LIM components
Information on wiring and troubleshooting your Kinetix 6000 safety drive
Read This Document
Kinetix 6000 Installation Manual
Kinetix 6000 Line Interface Module Installation
Instructions
Kinetix Safe-Off Feature Safety Reference Manual
Catalog Number
2094-IN001
2094-IN005
GMC-RM002
A description and specifications for the 2094 family including motors and motor accessories
Kinetix Motion Control Selection Guide
Drive and motor sizing with application analysis software
SoftLogix SERCOS interface PCI card installation instructions
Motion Analyzer CD
(v4.1 or above)
PST-SG003
Kinetix 6000 User Documentation and CAD Files CD 2094-CL001 Kinetix 6000 user documentation and CAD files
More detailed information on the use of ControlLogix motion features and application examples
ControlLogix SERCOS interface module installation instructions
ControlLogix Motion Module Programming Manual 1756-RM086
SERCOS interface Module Installation Instructions 1756-IN572
16 Axis PCI SERCOS interface Card Installation
Instructions
1784-IN041
The instructions needed to program a motion application
Logix5000 Controllers Motion Instructions
Reference Manual
GMC-SG001
1756-RM007
Information on configuring and troubleshooting your ControlLogix
SERCOS and analog motion modules
Information on configuring and troubleshooting your SoftLogix PCI card
Information on the installation and wiring of Bulletin 2090 Resistive
Brake Modules
Information on proper handling, installing, testing, and troubleshooting fiber-optic cables
Information, examples, and techniques designed to minimize system failures caused by electrical noise
Logix5000 Motion Modules User Manual
SoftLogix Motion Card Setup and Configuration
Manual
Resistive Brake Module Installation Instructions
Fiber-Optic Cable Installation and Handling
Instructions
System Design for Control of Electrical Noise
For declarations of conformity (DoC) currently available from Rockwell
Automation
Rockwell Automation Product Certification website
1756-UM006
1784-UM003
2090-IN009
2090-IN010
GMC-RM001
An article on wire sizes and types for grounding electrical equipment
A glossary of industrial automation terms and abbreviations
National Electrical Code
Allen-Bradley Industrial Automation Glossary www.ab.com/ certification/ce/docs
Published by the National
Fire Protection Association of Boston, MA.
AG-7.1
Publication 2094-IN002E-EN-P — September 2005
P-4
Conventions Used in this
Manual
The following conventions are used throughout this manual.
• Bulleted lists such as this one provide information, not procedural steps
• Numbered lists provide sequential steps or hierarchical information
• Words that you type or select appear in bold
• When we refer you to another location, the section or chapter name appears in italics
• Acronyms for the Kinetix 6000 components, shown in the table below, are used throughout this manual.
Kinetix 6000 Component Catalog Numbers
Power Rail 2094-PRx
Power Rail (slim)
Power Rail Slot Filler
2094-PRSx
2094-PRF
Integrated Axis Module
Axis Module
Line Interface Module
Shunt Module
Resistive Brake Module
2094-xCxx-Mxx
2094-xMxx
2094-xLxx and -xLxxS-xx
2094-BSP2
2090-XBxx-xx
IAM
AM
LIM
SM
RBM
Acronym
PR
PRS
PRF
Publication 2094-IN002E-EN-P — September 2005
1
Chapter Objectives
General Startup
Precautions
Chapter
1
Commission Your Kinetix 6000
This chapter provides you with information to apply power and configure your Kinetix 6000. This chapter includes:
• General Startup Precautions
• Understand IAM/AM/SM and LIM Connectors
• Locate Connectors and Indicators
• Locate SERCOS Interface Fiber-Optic Connectors
• Configure Your Kinetix 6000
• Configure Your Logix SERCOS interface Module
• Apply Power to Your Kinetix 6000
• Test and Tune Your Axes
Note: Some of the procedures in this chapter include information regarding integration with other products.
The following precautions pertain to all of the procedures in this chapter. Be sure to read and thoroughly understand them before proceeding.
ATTENTION
This product contains stored energy devices. To avoid hazard of electrical shock, verify that all voltages on the system bus network have been discharged before attempting to service, repair or remove this unit. Only qualified personnel familiar with solid state control equipment and safety procedures in publication NFPA 70E or applicable local codes should attempt this procedure.
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.
Publication 2094-IN002E-EN-P — September 2005
1-2
Commission Your Kinetix 6000
Understand IAM/AM
Connectors
The following table provides a brief description of the Kinetix 6000
IAM/AM connectors.
Integrated Axis Module/Axis Module Connectors
Designator Description
IPD
CED
MP
BC
SO
IOD
MF
AF
CPD
Tx and Rx
DPI
User I/O (drive)
Motor Feedback
Auxiliary Feedback
Control Input Power (drive)
DC Bus and VAC Input Power (drive)
230V
DC Bus and VAC Input Power (drive)
460V
Contactor Enable
Motor Power
Resistive/Motor Brake
Safe-Off
SERCOS Transmit and Receive
DPI
Connector
26-pin high-density D-shell
15-pin high-density D-shell (male)
15-pin high-density D-shell (female)
2-position connector housing
6-position connector housing
6-position connector housing
2-position connector housing
4-position connector housing
6-position connector housing
9-position plug/header
SERCOS fiber optic (2)
DPI
IAM
IAM
IAM/AM
IAM/AM
IAM/AM
IAM/AM
IAM
Present on
IAM or AM
IAM/AM
IAM/AM
IAM/AM
IAM
IAM
Publication 2094-IN002E-EN-P — September 2005
Commission Your Kinetix 6000 1-3
Locate IAM Connectors and
Indicators
Use the figure below to locate the Integrated Axis Module connectors and indicators. Although the physical size of the 2094-BCxx-Mxx
(460V) IAM is larger than the 2094-ACxx-Mxx (230V) IAM, the location of the connectors and indicators is identical.
Figure 1.1
Kinetix 6000 Integrated Axis Modules (2094-ACxx-Mxx and -BCxx-Mxx)
Integrated Axis Module, top view
(2094-BM01-MP5-S is shown)
Control Power
(CPD) Connector
Motor Cable
Shield Clamp
DC Bus / AC Input Power
(IPD) Connector
Contactor Enable
(CED) Connector
Safe-Off
(SO) Connector
(present only on the 2094-BCxx-Mxx-S)
CTRL 2
CTRL 1
DC-
DC+
L3
L2
L1
CONT EN-
CONT EN+
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
Motor Power
(MP) Connector
Motor/Resistive Brake
(BC) Connector
RX
DPI
TX
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-M01 is shown)
SERCOS
Node Address Switch
Seven Segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Mounting Screw
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
Note: Power, feedback, and I/O connectors are shown, however for wiring information, refer to the Kinetix 6000 Multi-Axis Servo
Drive Installation Manual (publication 2094-IN001).
Publication 2094-IN002E-EN-P — September 2005
1-4
Commission Your Kinetix 6000
Locate AM Connectors and
Indicators
Use the figure below to locate the Axis Module connectors and indicators. Although the physical size of the 2094-BMxx (460V) AM is larger than the 2094-AMxx (230V) AM, the location of the connectors and indicators is identical.
Figure 1.2
Kinetix 6000 Axis Modules (2094-AMxx and -BMxx)
Axis Module, top view
(2094-BMP5-S is shown)
Motor Cable
Shield Clamp
Safe-Off
(SO) Connector
(present only on the 2094-BMxx-S)
RX
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
Motor Power
(MP) Connector
Motor/Resistive Brake
(BC) Connector
TX
BAUD
RATE
SERCOS Baud Rate and Optical Power Switches
SERCOS Transmit (Tx) Connector
SERCOS Receive (Rx) Connector
Axis Module, front view
(2094-AM01 is shown)
Seven Segment
Fault Status LED
Drive Status LED
COMM Status LED
Bus Status LED
I/O (IOD) Connector
Mounting Screw
Auxiliary Feedback (AF) Connector
Motor Feedback (MF) Connector
Note: Power, feedback, and I/O connectors are shown, however for wiring information, refer to the Kinetix 6000 Multi-Axis Servo
Drive Installation Manual (publication 2094-IN001).
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Commission Your Kinetix 6000
Understand SM Connectors
Use the table below and Figure 1.3 to locate the Shunt Module connectors and indicators.
1-5
Motor Cable
Shield Clamp
COL
INT
DC+
TS2
TS1
Locate
Shunt Module Connectors
Designator Description
RC External Shunt Resistor Connector
TS External Thermal Switch Connector
Connector
3-position connector housing
2-position connector housing
Figure 1.3
Kinetix 6000 Shunt Modules (2094-BSP2)
Shunt Module, top view
External Shunt Resistor
(RC) Connector
External Thermal Switch
(TS) Connector
Shunt Module, front view
Shunt Fault LED
Over-Temp Fault LED
Bus Status LED
Mounting Screw
Note: Power connectors are shown, however for wiring information, refer to the Kinetix 6000 Multi-Axis Servo Drive Installation
Manual (publication 2094-IN001).
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Understand LIM Connectors and Indicators
Use the tables below and figures 1.4 and 1.5 to locate the Line
Interface Module connectors.
Line Interface Module Connectors
The following table describes the Line Interface Module connectors used with catalog numbers 2094-AL75S, -BL75S, and -XL75S-Cx.
Designator Description
IOL Status I/O (LIM)
IPL
OPL
VAC LINE Input Power (LIM)
VAC LOAD Output Power
P1L
P2L
CPL
APL
1
Brake and I/O Power Output (24V dc)
Auxiliary Power Output (230V ac)
Control Power Output (LIM)
Auxiliary Power Input (LIM)
Connector
21-pin (plugable) terminal block
4-position plug/header
4-position plug/header
6-position plug/header
4-position plug/header
2-position plug/header
2-position plug/header
1
Auxiliary Power Input (APL) connector is only present on the 2094-XL75S-Cx model.
The following table describes the Line Interface Module connectors used with catalog numbers 2094-AL09 and -BL02.
Designator Description
IOL Status I/O (LIM)
IPL
OPL
VAC LINE Input Power (LIM)
VAC LOAD Output Power
PSL
CPL
Brake and I/O Power Output (24V dc)
Control Power Output (LIM)
Connector
26-pin high-density D-shell
4-position terminals
4-position terminals
4-position plug/header
2-position plug/header
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VAC Line
(IPL) Connector
Commission Your Kinetix 6000 1-7
Use the figure below to locate the Line Interface Module connectors and indicators.
Figure 1.4
Kinetix 6000 Line Interface Modules (2094-AL09 and -BL02)
Line Interface Module, top view
(2094-AL09 is shown)
L1
L2/N
Control Power Load
(CPL) Connector
PE
L3
L2
L1
MBRK PWR
MBRK COM
MBRK PWR
MBRK COM
PE
1
L3
1
L2
1
L1
1
VAC Load
(OPL) Connector
24 VDC Brake Power (PSL) Connector
Line Interface Module, front view
(2094-AL09 is shown)
Brake Power Status LED
I/O Power Status LED
I/O (IOL) Connector
MAIN VAC AUX VAC BRAKE - I/O VAC
CB1
Main
VAC
CB2 CB3
Control/AUX
VAC
Brake - I/O
VAC
Line Interface Module 2094-AL09
200/230V AC
20A Output
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Use the figure below to locate the Line Interface Module connectors and indicators.
Figure 1.5
Kinetix 6000 Line Interface Modules (2094-AL75S, -BL75S, and -XL75S-Cx)
Auxiliary Power Input
(APL) Connector
1
L1
L2N
VAC Line
(IPL) Connector
L3
L2
L1
VAC Load
(OPL) Connector
L3'
L2'
L1'
CTRL2
CTRL1
AUX2
AUX2
AUX1
AUX1
I/O_COM
I/O_PWR
I/O_COM
I/O_PWR
I/O_COM
I/O_PWR
Control Power Output (CPL) Connector
230V ac Auxiliary Power Output (P2L) Connector
24V dc Brake Power Output (P1L) Connector
Line Interface Module, top view
(2094-XL75S-Cx is shown)
Main VAC
I/O Power
Status LED
CB1
ON
MAIN VAC
OFF
I/O (IOL) Connector
IOL Connector
(as viewed from side)
CB3 CB2
Brake-I/O
VAC
Fuse
Block
Control/AUX
VAC
Line Interface Module, front view
(2094-XL75S-Cx is shown)
1
Auxiliary Power Input (APL) connector is only present on the 2094-XL75S-Cx model.
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Locate SERCOS Interface
Fiber-Optic Connectors
Use the figure below to locate the SERCOS interface fiber-optic connectors. The fiber-optic ring is connected using the SERCOS
Receive and Transmit connectors.
Note: Plastic cable is available in lengths up to 32 m (105.0 ft). Glass cable is available in lengths up to 200 m (656.7 ft).
Figure 1.6
ControlLogix and SoftLogix SERCOS Connector Locations
SERCOS interface
TM
CP OK
ControlLogix
1756-M xxSE SERCOS interface Module
Front View
Tx (rear)
Rx (front)
Bottom View
SERCOS Receive Connector, Rx (front)
SERCOS Transmit Connector, Tx (rear)
RSLogix 5000
D
E
F
0
9A 8
1
2
3
67
OK
SoftLogix
1784-PM16SE SERCOS interface PCI Card
(as viewed from the back of your PC)
TX
CP
SERCOS Transmit Connector, Tx
RX
SERCOS Receive Connector, Rx
Configure Your Kinetix 6000
These procedures assume you have completed mounting, wiring, and connecting your SERCOS interface module and Kinetix 6000 drive as described in the Kinetix 6000 Multi-Axis Servo Drive Installation
Manual (publication 2094-IN001).
The procedures in this section apply to Kinetix 6000 drive components and describe how to:
• Configure your Kinetix 6000 IAM and AM(s)
• Configure your SERCOS interface module using RSLogix 5000 software
• Download your program to your Logix controller
• Apply power to your Kinetix 6000 drive components
• Test and tune your motor using RSLogix 5000 software
These procedures assume you have connected the fiber optic cables between your IAM (2094-xCxx-Mxx, inverter section), axis modules
(2094-xMxx), and the ControlLogix chassis with 1756-MxxSE interface module or personal computer with 1784-PM16SE PCI card.
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Commission Your Kinetix 6000
Configure Your Integrated Axis Module
To configure your IAM:
1. Verify that there is no power applied to the IAM and that the
SERCOS fiber-optic cables are plugged into the Tx and Rx connectors. To verify your fiber-optic cable connections, refer to the Kinetix 6000 Multi-Axis Servo Drive Installation Manual
(publication 2094-IN001).
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). Refer to the table below for switch operation. Refer to for switch location.
To Press
Increment the (MSD/LSD) node address The plus (+) switch.
Decrement the (MSD/LSD) node address The minus (-) switch.
Figure 1.7
Setting the Base Address Switches
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.
IMPORTANT
After setting the base node address, always cycle control power to initialize the IAM.
IMPORTANT
When two or more IAMs are connected to the same SERCOS interface module, each node address must be unique.
Refer to figures 1.9, 1.10, and 1.11 for examples of how node addresses are assigned.
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Refer to Figure 1.8 for an example of the fiber-optic ring connections between the Kinetix 6000 drive(s) and the SoftLogix PCI card.
Although Figure 1.8 only illustrates the SERCOS fiber-optic ring with the SoftLogix PCI card, node addressing for SoftLogix is done the same way as shown in the three ControlLogix examples.
Figure 1.8
Fiber-Optic Ring Connection
Transmit
Receive
E
F
OK
CP
TX
RX
SoftLogix
1784-PM16SE SERCOS interface PCI Card
Receive
SERCOS fiber-optic ring
Transmit Receive
Transmit
Kinetix 6000
Figure 1.9
Node Addressing Example 1
1756-MxxSE SERCOS interface Module
SERCOS interface TM
CP OK
ControlLogix Chassis
Transmit
Tx (rear)
Rx (front)
Receive
SERCOS Fiber-Optic ring
Receive
Kinetix 6000
System 1
(6-axis power rail)
Receive Transmit
Kinetix 6000
Transmit
Kinetix 6000
System 2
(2-axis power rail)
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
17 = AM (axis 2) node address
16 = IAM (axis 1) base node address
In the example above, 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 slots 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.
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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.
SERCOS interface TM
CP OK
Figure 1.10
Node Addressing Example 2
1756-MxxSE SERCOS interface Module 1
ControlLogix Chassis
Transmit
Tx (rear)
Rx (front)
Receive
SERCOS Fiber-Optic rings
1756-MxxSE SERCOS interface Module 2
SERCOS interface TM
CP OK
ControlLogix Chassis
Tx (rear)
Rx (front)
Transmit
Receive
Transmit
Receive
Transmit
Kinetix 6000
(8-axis power rail)
Receive
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.
Note: 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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Commission Your Kinetix 6000 1-13
Kinetix 6000
(8-axis power rail)
Figure 1.11
Node Addressing Example 3
1756-MxxSE SERCOS interface Module
SERCOS interface TM
CP OK
ControlLogix Chassis
Transmit
Tx (rear)
Rx (front)
Receive
SERCOS Fiber-Optic ring
Receive
Transmit
08 = Slot Filler node address
07 = AM (axis 4) node address
06 = Not Used (AM right most slot)
05 = AM (axis 3) node address
04 = Not Used (AM right most slot)
03 = AM (axis 2) node address
02 = Not Used (IAM right most slot)
01 = IAM (axis 1) base node address
In the example above, 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 left-most slot of a double-wide module determines the node address. So, in the example above, node addresses 02, 04, and 06
(the right-most slots of the double-wide modules) are not used.
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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Commission Your Kinetix 6000
3. Set the SERCOS baud rate using DIP switches 2 and 3, as shown in
Figure 1.12. Refer to the table below for baud rate switch settings.
For this baud rate
4M baud
8M baud
Set switch 2
OFF
ON
Set switch 3
ON
OFF
4. Set the SERCOS optical power level to High using DIP switch 1, as shown in Figure 1.12. Refer to the table below for optical power level switch setting.
For this optical power level
Low
High
Set switch 1
OFF
ON
Integrated Axis Module, top view
(2094-ACxx-Mxx)
Figure 1.12
SERCOS Baud Rate and Optical Power DIP Switches
DIP switches set for
4M baud applications
(high power setting)
3 2 1
ON
OFF
ON
OFF
DIP switches set for
8M baud applications
(high power setting)
3 2 1
Switch in OFF position
SERCOS Baud Rate and Optical Power Switches
Note: Switch numbers as seen on the IAM are upside down in this orientation.
turned around for clarity.
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Configure Your Axis Module(s)
This procedure assumes you have configured your IAM. Use the following procedure to configure your axis module(s). In this procedure you will set the baud rate and optical power level switches for your IAM and each AM.
IMPORTANT
The node address for each axis module is determined by the base node address switch setting on the IAM. Refer to Figure 1.9.
To configure your Axis Module(s):
1. Verify that there is no power applied to the IAM and that the
SERCOS fiber-optic cables are plugged into the Tx and Rx connectors. To verify your fiber-optic cable connections, refer to the Kinetix 6000 Multi-Axis Servo Drive Installation Manual
(publication 2094-IN001).
2. Set the SERCOS baud rate using DIP switches 2 and 3, as shown in
Figure 1.12 (page 1-14). Refer to the table below for the baud rate switch settings.
For this baud rate
4M baud
8M baud
Set switch 2
OFF
ON
Set switch 3
ON
OFF
3. Set the optical power level to High using DIP switch 1, as shown in Figure 1.12. Refer to the table below for optical power level switch setting.
For this optical power level
Low
High
Set switch 1
OFF
ON
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Configure Your Logix
SERCOS interface Module
This procedure assumes that you have wired your Kinetix 6000 system and have configured the Kinetix 6000 baud rate and optical power switches.
IMPORTANT
In order for the Kinetix 6000 to communicate with the SERCOS interface module (indicated by the three
LEDs on the module going solid green), your
RSLogix 5000 software must be version 11.0 or above.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication.
For
Detailed information on configuring and troubleshooting your ControlLogix motion module
Detailed information on configuring and troubleshooting your SoftLogix PCI card
Refer to this Document
Logix5000 Motion Modules User
Manual
SoftLogix Motion Card Setup and
Configuration Manual
Publication Number
1756-UM006
1784-UM003
If you have already configured your Logix module using one of the setup and configuration manuals listed above, go directly to Apply
Power to Your Kinetix 6000 (page 1-26). If not, go to Configure Your
Logix Controller beginning below.
Configure Your Logix Controller
To configure your Logix controller:
1. Apply power to your Logix chassis/PC containing the SERCOS interface module and open your RSLogix 5000 software.
2. Select New in the File menu. The New Controller window opens.
• Select controller type
• Select RSLogix 5000 revision
• Name the file
• Select the Logix chassis size
• Select the Logix processor slot
3. Select OK.
4. Select Controller Properties in the edit menu. The Controller
Properties window opens.
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5. Select the Date and Time tab.
Commission Your Kinetix 6000 1-17
6. 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.
7. Select OK.
Configure Your Logix Module
To configure your Logix module:
1. Right-click on I/O Configuration in the explorer window and select New Module. The Select Module window opens.
2. Expand the Motion category and select 1756-MxxSE,
-L60M03SE, or 1784-PM16SE as appropriate for your actual hardware configuration.
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3. Select OK. The New Module window opens. Your new module appears under the I/O Configuration folder in the explorer window.
• Name the module
• Select the slot where your module resides (left most slot = 0)
• Select an Electronic Keying option (select Disable Keying if unsure)
• Check the box Open Module Properties.
4. Select OK. The Module Properties window opens.
5. Select the SERCOS Interface tab and reference the table below.
Publication 2094-IN002E-EN-P — September 2005
Logix SERCOS Module Number of Axes Data Rate
1756-M03SE or
1756-L60M03SE
1756-M08SE up to 3 up to 8 4 or 8 Mbits/s
1756-M16SE or
1784-PM16SE up to 16
Commission Your Kinetix 6000 1-19
6. Select Data Rate, Cycle Time and Optical Power settings.
• Ensure the Data Rate setting matches DIP switches 2 and 3
(baud rate) as set on the IAM and AM(s), or use the Auto
Detect setting.
• Set the Cycle Time according to the table below.
Data Rate
4 Mbits/s
8 Mbits/s
Number of Axes
up to 2 up to 4 up to 8
Cycle Time
0.5 ms
1 ms
2 ms
No support for axes 9 to 16 up to 4 0.5 ms up to 8 up to 16
1 ms
2 ms
Note: The number of axes/module is limited to the number of axes as shown in step 5.
• Ensure the Optical Power setting (high or low) matches DIP switch 1 as set on the IAM and AM(s).
• Transition to Phase default setting is 4 (phase 4). The
Transition to Phase setting will stop the ring in the phase specified.
7. Select OK.
8. Repeat steps 1-7 for each Logix module.
Configure Your Kinetix 6000 Modules
To configure your Kinetix 6000 modules:
1. Right-click on the new Logix module you just created and select
New Module. The Select Module window opens.
2. Select your 2094-xCxx-Mxx (IAM) or 2094-xMxx (AM) as appropriate for your actual hardware configuration.
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3. Select OK. The Module Properties window opens.
• Name the module
• Set the Node address
Note: Set node address in the software to match the node setting on the drive. Refer to Configure Your Integrated
Axis Module, step 2, on page 1-10.
• Select an Electronic Keying option
• Check the box Open Module Properties
4. Select OK.
5. Select the Associated Axes tab.
6. Select the New Axis button. The New Tag window opens.
• Name the axis
• Select AXIS_SERVO_DRIVE as the Data Type
7. Select OK. The axis appears under the Ungrouped Axes folder in the explorer window.
8. Assign your axis to the node address (as shown in the window below).
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With drive firmware version 1.80 (or above) and RSLogix 5000 software version 13 (or above), 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 page is set to Feedback Only (as shown below).
9. Select OK.
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)
Bulletin 1336 active shunt module
1394-SRxxxx
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 the Kinetix 6000 Multi-Axis Servo Drive
Installation Instructions (publication 2094-IN001) for fuse specifications.
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
Appendix D for the procedures.
12. Select OK.
13. Repeat steps 1-9 for each 2094-xMxx Axis Module (AM).
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Configure the Motion Group
To configure the motion group:
1. Right-click Motion Groups in the explorer window and select New
Motion Group. The New Tag window opens.
2. Name the new motion group.
3. Select OK. New group appears under the Motion Groups folder.
4. Right-click on the new motion group and select Properties. The
Motion Group Properties window 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. Select OK.
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Configure Axis Properties
To configure axis properties:
1. Right-click on an axis in the explorer window and select
Properties. The Axis Properties window opens.
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2. Select the Drive/Motor tab.
• Set the Kinetix 6000 Amplifier (2094-xCxx-Mxx)
• Set the Motor Catalog Number
• Set Loop Configuration to Position Servo
• Drive Enable Input Checking, when checked (default), means a hard drive enable input signal is required. Uncheck to remove that requirement.
Note: For amplifier and motor catalog numbers refer to the amplifier and motor name plate.
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.
Commission Your Kinetix 6000 1-25
6. Select the Fault Actions tab and click on the Set Custom Stop
Action... tab. The Custom Stop Action Attributes window opens.
The Custom Stop Action Attributes window allows you to 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).
• Set the Brake Engage Delay Time
• Set the Brake Release Delay Time
• Set the Resistive Brake Contact Delay time (0 - 1000 ms range)
Note: The recommended delay time for 2090-XB33-xx and
-XB120-xx resistive brake modules is 71 ms.
Note: If you are using RSLogix 5000 v12 or lower, refer to Set the
RBM Delay Time Using DriveExplorer on page C-14.
• Select Close
7. Select OK.
8. Repeat steps 1-7 for each axis module.
9. Verify your Logix program and save the file.
Download Your Program
After completing the Logix configuration you must download your program to the Logix processor.
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Apply Power to Your
Kinetix 6000
Use the table below to determine where to begin applying power to your Kinetix 6000.
If your Kinetix 6000 system
Includes a (2094-xLxx or -xLxxS-xx) LIM
Does not include a (2094-xLxx or -xLxxS-xx) LIM
Then
Go to Apply Power to Your Kinetix 6000 (with
LIM)
Go to Apply Power to Your Kinetix 6000 (without
LIM)
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.
Apply Power to Your Kinetix 6000 (with LIM)
This procedure assumes that you have wired and configured your
Kinetix 6000 (including the LIM) and your SERCOS interface module.
IMPORTANT
Follow this procedure if your Kinetix 6000 system includes a Line Interface Module (LIM).
To apply power to your Kinetix 6000 system:
1. Ensure CB1, CB2, and CB3 on the LIM are in the OFF position
(refer to figures 1.4 and 1.5 for the location of the CB1, CB2, and
CB3).
2. Disconnect the load to the motor(s).
ATTENTION
To avoid personal injury or damage to equipment, disconnect the load to the motor(s).
Ensure each motor is free of all linkages when initially applying power to the system.
3. Apply three-phase input power to the LIM VAC Line connector.
4. Set CB3 on the LIM to the ON position.
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5. Observe the Brake Power Status LED on the LIM (2094-xLxx only).
Refer to Figure 1.4 for the location of the Brake Power Status LED.
If the Brake Power Status
LED is
Solid green
Status
Brake power is ready
Not solid green Brake power fault
Do This
Go to step 6.
Go to Troubleshoot LIM Status LEDs on page 2-12.
6. Observe the I/O Power Status LED on the LIM. Refer to Figure 1.4
(2094-xLxx) or Figure 1.5 (2094-xLxxS-xx) for the location of the
I/O Power Status LED.
If the I/O Power Status
LED is
Solid green
Not solid green
Status Do This
I/O power is ready
I/O power fault
Go to step 7.
Go to Troubleshoot LIM Status LEDs on page 2-12.
7. Set CB2 on the LIM to the ON position.
8. Set CB1 on the LIM to the ON position.
9. Verify the Hardware Enable Input signal (IOD pin 2) for each axis is at 0 volts.
If the Hardware Enable
Input signal is
0 volts
Then
24 volts
Go to step 10.
1. Remove connection between IOD-1 and IOD-2.
2. Go to step 10.
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10. Observe the IAM/AM front panel logic power LED as shown in the figure below.
Figure 1.13
Logic Power and Status LED Display
Seven Segment Fault Status LED
Logic Power LED
If the Logic Power LED is
ON
Then
Go to step 11.
Not ON
1. Check your control power connections.
2. Repeat step 10.
11. Observe the IAM/AM front panel seven segment status LED display as shown in Figure 1.13.
Note: The seven segment LED will first flash the SERCOS node address, then cycle through phases until final configuration
(phase 4) is reached.
If
The seven segment status LED on your
2094-xCxx-Mxx IAM or
2094-xMxx AM
Is
Actively cycling
(phase 0)
Status
The drive is looking for a closed SERCOS ring. Wait for phase 1 or take corrective action until you reach phase 1.
Do This
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.
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 program motor and drive configuration against installed hardware.
Check motor catalog number against selection.
1
Displaying a fixed 4
(phase 4)
The drive is configured and active.
Flashing an E followed by two numbers
Drive is faulted.
Go to step 12.
Go to Error Codes on page 2-3.
1
You can get diagnostic information from the module by highlighting the module name in RSLogix 5000. A Pseudo
Key Failure often indicates that the motor selection does not match the motor installed.
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If the Drive Status LED is
Off
Steady red
12. Observe the Drive Status LED.
Status
Normal condition
Drive is faulted
Do This
Go to step 13.
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
If the Comm Status LED is
Flashing green
Steady green
Off
13. Observe the Comm Status LED.
Status Do This
Establishing communication with network
Wait for steady green.
Communication is ready
No ring present
Go to step 14.
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
If the Bus Status LED is
Steady green
Flashing green
Off
1
14. Observe the Bus Status LED.
Status
Bus is up, axis is disabled
(normal status)
Do This
Axis is enabled when status should be disabled
1. Verify Hardware Enable Input
(IOD-2) is open.
2. Verify MSO instruction is not commanded in RSLogix 5000.
3. Return to Apply Power to Your
Kinetix 6000 (with LIM) on page 1-26.
Go to step 15.
DC bus is not present
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
1
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.
15. Observe the three SERCOS LEDs on the SERCOS module.
If the three SERCOS LEDs are
Flashing green and red
Steady green
Not flashing green and red/ not steady green
Status
Establishing communication
Communication ready
SERCOS module is faulted
Do This
Wait for steady green on all three
LEDs.
Go to Test and Tune Your Axes.
Go to the appropriate Logix motion module setup and configuration manual for specific instructions and troubleshooting.
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Apply Power to Your Kinetix 6000 (without LIM)
This procedure assumes that you have wired and configured your
Kinetix 6000 and SERCOS interface module.
IMPORTANT
Follow this procedure if your Kinetix 6000 system does not include a Line Interface Module (LIM).
To apply power to your Kinetix 6000 system:
1. Disconnect the load to the motor(s).
ATTENTION
To avoid personal injury or damage to equipment, disconnect the load to the motor(s).
Ensure each motor is free of all linkages when initially applying power to the system.
2. Apply (95-264V ac) control power to the IAM (CPD connector) and observe the logic power LED as shown in the figure below.
Figure 1.14
Logic Power and Status LED Display
Seven Segment Fault Status LED
Logic Power LED
If the Logic Power LED is
ON
Then
Go to main step 3.
Not ON
1. Check your control power connections.
2. Repeat main step 2.
Note: The seven segment LED will first flash the SERCOS node address, then cycle through phases until final configuration
(phase 4) is reached.
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If the Drive Status LED is
Off
Steady red
3. Apply 195-265V ac (230V) or 324-528V ac (460V) input power to the IAM (IPD connector) and observe the front panel seven segment Status LED display as shown in Figure 1.14.
If
The seven segment status LED on your
2094-xCxx-Mxx IAM or
2094-xMxx AM
Is
Actively cycling
(phase 0)
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)
Status
The drive is looking for a closed SERCOS ring. Wait for phase 1 or take corrective action until you reach phase 1.
Do This
Check fiber-optic connections.
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
Flashing an E followed by two numbers
Drive is faulted
Go to step 4.
Go to Error Codes on page 2-3.
1
You can get diagnostic information from the module by highlighting the module name in RSLogix 5000. A Pseudo
Key Failure often indicates that the motor selection does not match the motor installed.
4. Observe the Drive Status LED.
Status
Normal condition
Drive is faulted
Do This
Go to step 5.
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
If the Comm Status LED is
Flashing green
Steady green
Off
5. Observe the Comm Status LED.
Status Do This
Establishing communication with network
Wait for steady green.
Communication is ready
No ring present
Go to step 6.
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
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6. Observe the Bus Status LED.
If the Bus Status LED is
Steady green
Flashing green
Off
1
Status
Bus is up, axis is disabled
(normal status)
Do This
DC bus is present. Axis is enabled when status should be disabled.
1. Verify Hardware Enable Input
(IOD-2) is open.
2. Verify MSO instruction is not commanded in RSLogix 5000.
3. Return to Apply Power to Your
Kinetix 6000 (without LIM) on page 1-30.
Go to step 7.
DC bus is not present
Go to Troubleshoot IAM/AM Status
LEDs on page 2-8.
1
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 LEDs on the SERCOS module.
If the three SERCOS LEDs are
Flashing green and red
Steady green
Not flashing green and red/ not steady green
Status
Establishing communication
Communication ready
SERCOS module is faulted
Do This
Wait for steady green on all three
LEDs.
Go to Test and Tune Your Axes.
Go to the appropriate Logix motion module setup and configuration manual for specific instructions and troubleshooting.
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Test and Tune Your Axes
This procedure assumes that you have configured your Kinetix 6000, 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 status LEDs are as described in the table below.
Status LED
Drive
Comm
Bus
Seven Segment
Must be
Off
Steady green
Flashing green
Displaying a fixed 4 (phase 4)
Status
Normal condition
Communication is ready
Bus is up, axis is disabled (normal status)
The drive is configured and active.
For greater detail on the RSLogix 5000 software as it applies to
ControlLogix and SoftLogix modules, refer to the table below for the appropriate publication.
For
Detailed information on configuring and troubleshooting your ControlLogix motion module
Detailed information on configuring and troubleshooting your SoftLogix PCI card
Refer to this Document
Logix5000 Motion Modules User
Manual
SoftLogix Motion Card Setup and
Configuration Manual
Publication Number
1756-UM006
1784-UM003
If you have already tested and tuned your Logix module using one of the setup and configuration manuals listed above, you are finished commissioning your Kinetix 6000 system. If not, go to Test Your Axes beginning below.
Test Your Axes
To test your axes:
1. Verify the load was removed from each axis.
2. Right-click on an axis in your Motion Group folder in the explorer window and select Axis Properties. The Axis Properties window appears.
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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
Test Marker
Test Feedback
Test Command &
Feedback
Performs this Test
Verifies marker detection capability as you rotate the motor shaft.
Verifies feedback connections are wired correctly as you rotate the motor shaft.
Verifies motor power and feedback connections are wired correctly as you command the motor to rotate.
Also, allows you to 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.
Commission Your Kinetix 6000 1-35
6. Select the Test (Marker/Feedback/Command & Feedback) button to verify connections. The Online Command window opens.
Follow the on-screen test instructions. When the test completes, the Command Status changes from Executing to Command
Complete.
7. Select OK.
8. The Online Command - Apply Test window opens (Feedback and
Command & Feedback tests only). When the test completes, the
Command Status changes from Executing to Command Complete.
9. Select OK.
If Then
Your test completes successfully, this window appears:
1. Select OK.
2. Remove Hardware Enable Input signal (IOD-2).
3. Go to Tune Your Axes.
Your test failed, this widow appears:
1. Select OK.
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 step 6 and run the test again.
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Tune Your Axes
To tune your 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.
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3. Enter values for Travel Limit and Speed. In this example, Travel
Limit = 5 and Speed = 10.
Note: 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.
Commission Your Kinetix 6000 1-37
7. Select the Start Tuning button to auto-tune your axis. The Online
Command - Tune Servo window opens. When the test completes, the Command Status changes from Executing to Command
Complete.
8. Select OK. The Tune Bandwidth window opens.
Note: 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. Select OK.
10. The Online Command - Apply Tune window opens. When the test completes, the Command Status changes from Executing to
Command Complete.
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11. Select OK.
If
Your test completes successfully, this window appears:
Then
1. Select OK.
2. Remove the Hardware Enable
Input signal (IOD-2) applied earlier.
3. Go to step 12.
Your test failed, this widow appears:
1. Select 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 Your Axes for each axis.
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Chapter Objectives
Chapter
2
Troubleshoot Your Kinetix 6000
This chapter provides a description of maintenance and troubleshooting activities for the Kinetix 6000. This chapter includes:
• Safety Precautions
• General Troubleshooting
• Troubleshoot IAM/AM Status LEDs
• Troubleshoot SM Status LEDs
• Troubleshoot LIM Status LEDs
• Troubleshoot RBM Status LEDs
• Troubleshoot General System Problems
• Understand Logix/Drive Fault Behavior
• Supplemental Troubleshooting Information
• Replace Kinetix 6000 System Components
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Safety Precautions
Observe the following safety precautions when troubleshooting your
Kinetix 6000 drive.
ATTENTION
DC bus capacitors may retain hazardous voltages after input power has been removed, but will normally discharge in several seconds. Before working on the drive, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval listed on 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. If you do not correct a drive or system malfunction, it could result in personal injury and/or damage to equipment as a result of uncontrolled machine system operation.
If you use an oscilloscope (or chart recorder) for troubleshooting, you must properly ground it. The oscilloscope chassis can be at a potentially fatal voltage if you do not properly ground it. Always connect the oscilloscope chassis to an earth ground.
General Troubleshooting
Refer to the Error Codes section to identify problems, potential causes, and appropriate actions to resolve the problems. If problems persist after attempting to troubleshoot the system, please contact your
Allen-Bradley representative for further assistance. To determine if your Kinetix 6000 drive has an error, refer to the table below.
If the Logic Power LED is ON and the
Status LED display on your
2094-xCxx-Mxx-x IAM
All drives
Is
Actively cycling segments in a full circle
Displaying a fixed 4
Flashing an E followed by two numbers
Then
Your Kinetix 6000 drive is ready, but SERCOS communications is not available.
Your Kinetix 6000 drive is ready.
Your Kinetix 6000 drive has an error. Proceed to the section Error Codes.
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Troubleshoot Your Kinetix 6000 2-3
Error
Code
Fault Message
RSLogix (HIM)
E00
BusUndervoltage
Fault
(Blown fuse)
E04
MotorOvertemp
Fault
(Motor Overtemp)
E05
DriveOvercurrent
Fault
(Power Fault)
Error Codes
The following list of problematic symptoms (no error code shown) and problems with assigned error codes is designed to help you resolve problems.
When a fault is detected, the 7-segment LED will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the problem is cleared.
Problem or Symptom is
Power (PWR) indicator not
ON
Motor jumps when first enabled
Potential Cause is
No AC power or auxiliary logic power.
Internal power supply malfunction.
Motor wiring error.
Possible Resolution is
Verify AC control power is applied to the
Kinetix 6000.
Call your Allen-Bradley representative to return module for repair.
• Check motor wiring.
• Run Hookup test in RSLogix 5000.
Verify the proper motor is selected.
Verify connections and I/O power source.
Digital I/O not working correctly
Incorrect motor chosen.
I/O power supply disconnected.
A blown fuse was detected on the inverter PCB
Blown fuse.
Call your Allen-Bradley representative to return module for repair.
Motor thermal switch tripped
Self-protection of the
Intelligent Power Module
(IPM) is indicating a major power related fault condition.
• High motor ambient temperature and/or
• Excessive current
Motor wiring error.
Incorrect motor selection.
Motor cables shorted.
Motor winding shorted internally.
Kinetix 6000 temperature too high.
Operation above continuous power rating and/or product environmental ratings.
Kinetix 6000 has a short circuit, overcurrent, or failed component.
• Operate within (not above) the continuous torque rating for the ambient temperature
40 °C (104 °F) maximum.
• Lower ambient temperature, increase motor cooling.
Check motor wiring at MF connector on the
IAM/AM.
Verify the proper motor has been selected.
Verify continuity of motor power cable and connector.
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.
• Ensure cooling is not restricted by insufficient space around the unit.
• Verify ambient temperature is not too high.
• 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.
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Error
Code
E06
E07
Fault Message
RSLogix (HIM)
HardOvertravel
Fault
(+/- Hard Overtravel)
MotFeedbackFault
(Motor Feedback Loss)
E09
E10
E11
E16
E18
E19
E20
E21
BusUndervoltage
Fault
(Bus Undervoltage)
DriveOvervoltage
Fault
(Bus Overvoltage)
MotFeedbackFault
(Illegal Hall State)
Softovertravel
Fault
(+/- Software
Overtravel)
OverSpeedFault
(Overspeed Fault)
PositionErrorFault
(Follow Error)
MotFeedbackFault
(Mtr Fdbk AQB)
AuxFeedbackFault
(Aux Feedback Comm)
Problem or Symptom is Potential Cause is Possible Resolution is
Axis moved beyond the physical travel limits in the positive/negative direction.
Dedicated overtravel input is inactive.
The feedback wiring is open, shorted, or missing.
With three-phase power present, the DC bus voltage is below limits.
• DC bus voltage for 460V system is below 275V
• DC bus voltage for 230V system is below 137V
• Check wiring.
• Verify motion profile.
• Verify axis configuration in software.
• Check motor encoder wiring.
• Run Hookup test in RSLogix 5000.
• Verify voltage level of the incoming AC power.
• Check AC power source for glitches or line drop.
• Install an uninterruptible power supply
(UPS) on your AC input.
DC bus voltage fell below the undervoltage limit while an axis on the follower power rail was enabled.
Disable follower axis before removing power.
The DC bus voltage is above limits.
State of Hall feedback inputs is incorrect.
Excessive regeneration of power.
When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the Kinetix 6000’s 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
• Change the deceleration or motion profile.
• Use a larger system (motor and Kinetix
6000).
• Install shunt module.
Verify input is within specifications.
Bad connections.
Axis position exceeded maximum software setting.
• Verify the Hall wiring at the MF connector on the IAM/AM.
• Verify 5V power supply to the encoder.
• Verify motion profile.
• Verify overtravel settings are appropriate.
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.
Position error limit was exceeded.
Motor Encoder State Error
The motor encoder encountered an illegal transition.
• Check cables for noise.
• Check tuning.
• Increase the feed forward gain.
• Increase following error limit or time.
• Check position loop tuning.
• Verify sizing of system.
• Verify mechanical integrity of system within specification limits.
• Use shielded cables with twisted pair wires.
• Route the feedback away from potential noise sources.
• Check the system grounds.
• Replace the motor/encoder.
Communication was not established with an intelligent encoder.
Verify auxiliary encoder wiring.
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Troubleshoot Your Kinetix 6000 2-5
Error
Code
E30
E34
E35
E36
E37
E38
E39
E43
Fault Message
RSLogix (HIM)
Problem or Symptom is Potential Cause is Possible Resolution is
MotFeedbackFault
(Motor Feedback Comm)
GroundShortFault
(Ground Fault)
DriveUndervoltage
Fault
(Pre-charge Fault)
DriveOvertemp
Fault
(System
Overtemperature)
PowerPhaseLoss
Fault
(Phase Loss Flt)
SERCOSFault
(SERCOS Ring Flt)
DriveHardFault
(Self Sense Flt)
DriveEnableInput
Fault
(Drive Enable Flt)
Communication was not established with an intelligent encoder.
Excessive ground current in the converter was detected.
Wiring error.
Motor internal ground short.
Internal malfunction.
Grounded control power terminal
(applies to 230V systems only)
• Verify motor selection.
• Verify the motor supports automatic identification.
• Verify motor encoder wiring.
• Check motor power wiring.
• Check input power wiring (refer to
Kinetix 6000 Installation Manual, publication 2094-IN001).
Replace motor.
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 A-B representative.
• Remove ground from control power input.
• Wire control power to use main power as shown in Figure A.3.
• Add isolation transformer for control power.
Check input AC voltage on all phases.
Converter pre-charge cycle failed.
Low AC input voltage.
Internal malfunction.
Call your A-B representative.
Converter thermal switch tripped.
Excessive heat exists in the power circuitry.
• Reduce acceleration rates.
• Reduce duty cycle (ON/OFF) of commanded motion.
• Increase time permitted for motion.
• Use larger Kinetix 6000 converter.
• Check for clogged vents or defective fan.
• Ensure cooling is not restricted by insufficient space around the unit.
• One or more phases of the input AC power is missing.
• Axis was enabled when main (3-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.
Cable disconnected.
• Check input AC voltage on all phases.
• Disable axis before removing power.
Check that fiber-optic cable is present and connected properly.
Self-sensing Commutation
Startup Error
Motion required for self-sensing startup commutation was obstructed.
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.
• Verify that there are no impediments to motion at startup, such as hard limits.
• Increase self-sensing current if high friction or load conditions exist.
• Check motor or encoder wiring using wiring diagnostics.
• Disable the Drive Enable Input fault.
• Verify that Drive Enable hardware input is active whenever the drive is enabled through software.
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Troubleshoot Your Kinetix 6000
Error
Code
E49
E50
E54
E60
Fault Message
RSLogix (HIM)
DriveHardFault
(Safe-Off HW Flt)
SERCOSFault
(SERCOS Same ADDR)
DriveHardFault
(Ifbk HW Fault)
DriveHardFault
(Unknown Axis)
E61
E62
E63
E64
E65
E66
E67
E68
E69
E70
E71
Problem or Symptom is Potential Cause is Possible Resolution is
For symptom, cause, and resolution of this error code, refer to the Kinetix Safe-Off Feature Safety Reference Manual
(publication GMC-RM002). Applies to IAM (2094-xCxx-Mxx-S) and AM (2094-xMxx-S) with Safe-Off feature.
Duplicate node address detected on SERCOS ring.
Current feedback hardware fault detected.
Verify that each SERCOS drive is assigned a unique node address.
Replace the module
AuxFeedbackFault
(Aux Fdbk AQB)
AuxFeedbackFault
(Aux Fdbk Loss)
AuxFeedbackNoise
(Aux Fdbk Noise)
MotorFeedbackNoise
(Mtr Fdbk Noise)
Illegal ID bits detected
Auxiliary Encoder State
Error
Noise on auxiliary feedback cable.
Noise on motor feedback cable.
The auxiliary encoder encountered an illegal transition.
The feedback wiring is open, shorted, or missing.
Recommended grounding, per installation instructions, has not been followed.
Replace the module
• Use shielded cables with twisted pair wires.
• Route the feedback away from potential noise sources.
• Check the system grounds.
• Replace the motor/encoder.
Check the motor feedback cable connectors/wiring to the IAM/AM and motor.
• Verify grounding.
• Route feedback cable away from noise sources.
• Refer to System Design for Control of
Electrical Noise Reference Manual
(publication GMC-RM001).
No Fault Message
(condition indicated by on-screen message)
(Hookup Fault)
Hookup procedure failed
No Fault Message
(condition indicated by on-screen message)
(Atune Flt)
Motor or feedback device malfunction.
• Check motor power/feedback wiring.
• Refer to on-screen message for resolution.
Autotune procedure failed
Operating system failed
Motor or feedback device malfunction.
Software initialization fault detected due to hardware failure.
• Check motor power/feedback wiring.
• Refer to on-screen message for resolution.
• Perform Hookup in RSLogix 5000.
• Consult RSLogix 5000 help screen.
• Cycle power.
• If fault persists, replace module.
DriveHardFault
(Task init)
DriveHardFault
(SCANport Comm)
DriveHardFault
(Objects Init)
DriveHardFault
(NV Mem Init)
DriveHardFault
(Memory Init)
DPI communication failed The DPI device or cable is faulty.
Non-volatile memory is corrupt due to control board hardware failure.
Non-volatile memory is corrupt due to control board software error.
RAM or Flash memory validation failure
Check DPI connections.
Load default parameters, save to non-volatile memory, and recycle power or reset the drive.
Load default parameters, save to non-volatile memory, and recycle power or reset the drive.
• Cycle power.
• If fault persists, replace module.
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-7
Error
Code
Fault Message
RSLogix (HIM)
Problem or Symptom is Potential Cause is Possible Resolution is
E72
E73
E74
E75
E76
DriveOvertemp
Fault
(Drive Overtemp)
Communicate
(Backplane Comm)
DriveOvercurrent
Fault
(Bus OverCurrent)
DriveOvervoltage
Fault
(Shunt Time Out)
DriveHardFault
(Can Init)
Inverter thermal switch tripped
Power rail CAN communications failed.
Power rail connection shorted or open.
DC link current exceeds rating.
The IAM, AM, or SM has exceeded its shunt resistor continuous rating.
DPI hardware initialization fault detected.
The fan on the IAM or an AM failed.
The cabinet ambient temperature is above rating.
The machine duty cycle requires an RMS current exceeding the continuous rating of the controller.
The airflow access to the Kinetix 6000 is limited or blocked.
Motor or transmission malfunction.
IAM not properly sized.
Control board hardware failure.
Replace the failed module.
Check the cabinet temperature.
Change the command profile to reduce speed or increase time.
Check airflow and re-route cables away from the Kinetix 6000.
Check module for proper mount.
Check power rail and module for foreign objects.
• Check for proper motor sizing.
• Check/replace transmission device.
• Check/replace motor.
• Check for proper IAM sizing.
• Install larger kW rated IAM.
• Use a properly sized shunt or modify duty cycle of the application.
• System uses internal shunt and requires external shunt for additional capacity.
• Reset System.
• If fault persists, replace system module.
E77
E78
E79
DriveHardFault
(Module Mismatch)
DriveHardFault
(SERCOS Init)
DriveOvervoltage
Fault
(Shunt Module Flt)
Either 230V AM is installed on power rail with 460V IAM, or 460V AM is installed on power rail with 230V IAM.
Module missing from power rail.
Replace mismatched module.
Control hardware fault detected.
SM Temperature Fault LED status is Steady Red
SM Shunt Fault LED status is Steady Red
Refer to Temperature Fault LED on page 2-11.
Refer to Shunt Fault LED on page 2-11.
• Cycle power.
• If fault persists, replace module.
• Install missing module on power rail.
• Fill empty slot with slot filler module.
E80
E81
E90
DriveHardFault
(CPLD FLT)
DriveHardFault
(Common Bus FLT)
DriveHardFault
(Pre-charge Timeout FLT)
All others
RESERVED
Control hardware fault detected.
Follower IAM detected AC input power being applied.
Pre-charge resistor power exceeds the resistor rating.
Replace module.
Remove AC input power connections from
Follower IAM.
Allow resistor to cool.
Call your local Allen-Bradley representative.
Publication 2094-IN002E-EN-P — September 2005
2-8
Troubleshoot Your Kinetix 6000
Troubleshoot IAM/AM
Status LEDs
If the Drive Status
LED is
Off
Steady Red
Status is
Normal, no faults
Drive faulted
Drive Status LED
Use the table below for troubleshooting the Drive Status LED on your
Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).
Potential Cause is
N/A
Seven-segment LED displays error code
Possible Resolution is
N/A
Refer to the section Error Codes and continue troubleshooting.
Comm Status LED
Use the table below for troubleshooting the Comm Status LED on your
Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).
If the Comm Status
LED is
Steady Green
Flashing Green
Off
Status is
Communication ready
Establishing communication
No communication
1
Potential Cause is Possible Resolution is
No faults or failures.
System is still in the process of establishing
SERCOS communication.
Node address setting on the drive module does not match SERCOS controller configuration.
Loose fiber-optic connection.
Broken fiber-optic cable.
Receive fiber-optic cable connected to
SERCOS transmit connector and vice versa.
N/A
Wait for steady green LED status.
Verify proper node switch setting.
Verify proper fiber-optic cable connections.
Replace fiber-optic cable.
Check proper SERCOS fiber-optic cable connections.
1
Refer to Fiber Optic Cable Installation and Handling Instructions (publication 2090-IN010) for more information.
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-9
Bus Status LED
Use the table below for troubleshooting the Bus Status LED on your
Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).
If the Bus Status LED is Status is
Steady Green
Flashing Green
Off
Bus power is present, axis enabled.
No faults or failures.
Bus power is present, axis disabled.
No faults or failures.
Bus power not present.
Bus power is present in Follower IAM.
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.
• Fault exists, refer to seven segment Error Code and General Troubleshooting beginning on page 2-2.
• Follower IAM is not configured as Common Bus Follower in RSLogix 5000.
• After DC bus voltage is applied, a 2.5 second delay before the LED begins flashing green is normal operation to provide common bus leader time to complete pre-charge.
Publication 2094-IN002E-EN-P — September 2005
2-10
Troubleshoot SM Status
LEDs
Troubleshoot Your Kinetix 6000
Each of the shunt module LEDs provide specific troubleshooting information, as described in Bus Status LED, Temperature Fault LED, and Shunt Fault LED.
IMPORTANT
Use of the Kinetix 6000 (rail mounted) shunt module
(catalog number 2094-BSP2), requires IAM/AM firmware revision 1.068 or above.
General Shunt Module Troubleshooting
Shunt Module Faults are Under these Conditions
Latched
Cleared
Until fault condition is corrected and cleared.
• Using RSLogix MASR, MAFR, MGSR commands or the HIM (red stop button).
• Only after the DC bus is discharged (SM Bus Status LED is flashing).
• Drive must be configured with 2094-BSP2 or Bulletin 1394 external shunt module.
IAM/AM Internal Shunts are
Under these Conditions
Disabled (for DC Bus regulation)
• 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.
• When configured in common bus follower mode.
Enabled to discharge the
DC Bus
Disabled from discharging the DC bus
Drive (IAM or IAM Leader) three-phase power is removed.
When configured in common bus follower mode.
IMPORTANT
Under some fault conditions, two reset commands may be required to clear drive and SM faults.
Status is
All three SM status LEDs flash simultaneously
The following table applies when all three SM LEDs are flashing.
Potential Cause is
Shunt module hardware failure
Possible Resolution is
• Cycle power
• If problem persists, replace shunt module
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-11
Bus Status LED
Use the table below for troubleshooting the Bus Status LED on your
Kinetix 6000 SM (2094-BSP2).
If the Bus Status
LED is
Flashing
Steady Green
Off
Status is Potential Cause is
Normal condition when control power is applied and bus voltage is less than
60V dc.
Normal condition when control power is applied and bus voltage is greater than 60V dc.
Control power is not present Internal power supply failure
Possible Resolution is
N/A
N/A
Replace shunt module.
Temperature Fault LED
Use the table below for troubleshooting the Temperature Fault LED on your Kinetix 6000 SM (2094-BSP2).
If the Temp Fault
LED is
Off
Steady Red
Status is
Normal condition
SM internal temperature exceeds operating temperature specification
External over temperature condition
Potential Cause is
Shunt module fan failed
Shunt module temperature exceeds rating
External temperature switch is open
TS jumper is not present
Possible Resolution is
N/A
Replace shunt module.
• Allow shunt module to cool.
• Reset faults.
• Verify IAM bus regulator configuration.
• Allow shunt module to cool.
• Reset faults.
• Verify IAM bus regulator configuration.
Install jumper.
Shunt Fault LED
Use the table below for troubleshooting the Shunt Fault LED on your
Kinetix 6000 SM (2094-BSP2).
If the Shunt Fault
LED is
Off
Steady Red
Status is
Normal condition
Shorted internal or external shunt resistor
Potential Cause is Possible Resolution is
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
Publication 2094-IN002E-EN-P — September 2005
2-12
Troubleshoot Your Kinetix 6000
Troubleshoot LIM Status
LEDs
If the Status LED is Status is
Steady Green
Off
Normal, 24V power enabled
• 24V power disabled
(2094-AL75S, -BL75S, and
XL75S-Cx)
• Brake power disabled
(2094-AL09, and -BL02)
• I/O power disabled
(2094-AL09, and -BL02)
The following troubleshooting table applies to the following Line
Interface Module status LEDs:
• 24V Power status LED (2094-AL75S, -BL75S, and -XL75S-Cx)
• Brake Power status LED (2094-AL09 and -BL02)
• I/O Power status LED (2094-AL09 and -BL02)
Potential Cause is Possible Resolution is
N/A
CB3 is open
24V polarity is reversed at the load
N/A
• Set breaker to on position.
• If breaker continues to trip, call your Allen-Bradley representative to return module for repair.
• Correct polarity.
• If polarity is correct and LED is not steady green, call your
Allen-Bradley representative to return module for repair.
Troubleshoot RBM Status
LEDs
The Resistive Brake Module (RBM) contactor status LED is visible from the front of the RBM. Use the table below for troubleshooting the
RBM status LEDs.
24V dc Status LED
The 24V dc Status LED is on when 24V is applied between COIL_A1 and COIL_A2 (e.g. a Brake Enable signal is received from the drive).
If the Status LED is RBM Contactor Status is
Contactor engaged
(direct connection between drive and motor)
Steady Green
Contactor disengaged
(no connection between drive and motor)
Blinking Green
(audible clicking)
Off
(intended)
Off
(unintended)
Contactor rapidly engaging/ disengaging
Contactor disengaged
(connection open between drive and motor)
Potential Cause is
No faults or failures
Contactor failure
Recommended grounding not followed
Control circuit improperly wired
Possible Resolution is
N/A
• Monitor CONSTAT_41/42 status to verify lack of drive/motor power (output is NC).
• Contact A-B representative.
• Verify ground wiring.
• Route wires away from noise sources.
• Refer to System Design for Control of Electrical Noise
Reference Manual (publication GMC-RM001).
Verify control wiring and programming.
No faults or failures N/A
+24V not applied between
COIL_A1 and COIL_A2
• +24V supply is off.
• Verify wiring.
• Drive not enabled.
• Contact A-B representative.
T1 (Fault) thermostat open Duty cycle exceeded, allow RBM to cool.
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-13
230V ac Auxiliary Power Status LED
Note: The 230V ac Auxiliary Power Status LED only applies to
2090-XB120-xx RBMs.
The 230V ac Status LED is on when 230V ac is applied to L1 and L2
(TB4) and the contactor is engaged by applying 24V dc across
COIL_A1 and COIL_A2 (e.g. a Brake Enable signal is received from the drive).
If 230V Status LED is
Contactor Status is Potential Cause is
Contactor Engaged
(direct connection between drive and motor)
No faults or failures
Steady Green
Blinking Green
(audible clicking)
Off
(intended)
Off
(unintended)
Contactor Disengaged
(no connection between drive and motor)
Contactor rapidly engaging/disengaging
Contactor Engaged
Contactor Disengaged
Contactor Engaged
Contactor Disengaged
Contactor failure
Grounding
230V ac is varying
Control circuit improperly wired
Contactor failure
(contacts welded together)
No faults or failures
Contactor failure
(contacts welded together)
LED failure
+24V signal not functioning properly
Contactor failure (coil damaged)
No 230V ac signal
Possible Resolution is
N/A
• Monitor CONSTAT_41/42 status to verify lack of drive/motor power
(output is NC).
• Contact A-B representative.
• Verify ground wiring.
• Route wires away from noise sources.
• Refer to System Design for Control of
Electrical Noise Reference Manual
(publication GMC-RM001).
• Check VAC loading.
• Check VAC source.
• Verify wiring.
Verify control wiring and programming.
• Monitor CONSTAT_41/42 status to verify lack of drive/motor power
(output is NC).
• Contact A-B representative.
N/A
• Monitor CONSTAT_41/42 status to verify lack of drive/motor power
(output is NC).
• Contact A-B representative.
• Contact A-B representative.
Refer to 24V dc Status LED troubleshooting table on page 2-12.
Contact A-B representative.
• Verify wiring.
• Verify 230V ac source.
Publication 2094-IN002E-EN-P — September 2005
2-14
Troubleshoot Your Kinetix 6000
Troubleshoot General
System Problems
Use the tables below for troubleshooting general system faults. For a list of Bulletin 1756 product manuals, refer to Related Documentation in the Preface.
Condition
Axis or System is unstable
You cannot obtain the motor acceleration/deceleration that you want
Motor does not respond to a
Velocity Command
Potential Cause is
The position feedback device is incorrect or open.
Unintentionally in torque mode.
Possible Resolution is
Check wiring.
Check to see what primary operation mode was programmed.
Run Tune in RSLogix 5000.
Motor tuning limits are set too high.
Position loop gain or position controller accel/decel rate is improperly set.
Improper grounding or shielding techniques are causing noise to be transmitted into the position feedback or velocity command lines, causing erratic axis movement.
Run Tune in RSLogix 5000.
Check wiring and ground.
Motor Select limit is incorrectly set (servo motor is not matched to axis module).
Mechanical resonance
Torque Limit limits are set too low.
Incorrect motor selected in configuration.
The system inertia is excessive.
The system friction torque is excessive.
Available current is insufficient to supply the correct accel/decel rate.
Acceleration limit is incorrect.
Velocity Limit limits are incorrect.
The axis cannot be enabled for 1.5 seconds after disabling.
Enable signal has not been applied or the enable wiring is incorrect.
The motor wiring is open.
The motor thermal switch has tripped.
• Check setups.
• Run Tune in RSLogix 5000.
Notch filter or output filter may be required
(refer to Axis Properties window, Output tab in RSLogix 5000).
Verify that current limits are set properly.
Select the correct motor and run Tune in
RSLogix 5000 again.
• Check motor size vs. application need.
• Review servo system sizing.
Check motor size vs. application need.
• Check motor size vs. application need.
• Review servo system sizing.
Verify limit settings and correct them, as necessary.
Verify limit settings and correct them, as necessary.
Disable the axis, wait for 1.5 seconds, and enable the axis.
• Check the controller.
• Check the wiring.
Check the wiring.
• Check for a fault.
• Check the wiring.
Repair or replace the motor.
The motor has malfunctioned.
The coupling between motor and machine has broken (i.e., the motor moves, but the load/machine doesn’t).
Primary operation mode is set incorrectly.
Velocity or current limits are set incorrectly.
Check and correct the mechanics.
Check and properly set the limit.
Check and properly set the limit(s).
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-15
Condition
Presence of noise on
Command or motor feedback signal wires
No Rotation
Motor Overheating
Abnormal Noise
Erratic Operation - Motor locks into position, runs without control or with reduced torque
Potential Cause is
Recommended grounding per installation instructions have not been followed.
Line frequency may be present.
Possible Resolution is
• Verify grounding.
• Route wire away from noise sources.
• 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.
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.
The motor connections are loose or open.
Foreign matter is lodged in the motor.
The motor load is excessive.
The bearings are worn.
The motor brake is engaged (if supplied).
The motor is not connect to the load.
The duty cycle is excessive.
Check motor wiring and connections.
Remove foreign matter.
Verify the servo system sizing.
Return the motor for repair.
• Check brake wiring and function.
• Return the motor for repair.
Check coupling.
Change the command profile to reduce accel/ decel or increase time.
The rotor is partially demagnetized causing excessive motor current.
Motor tuning limits are set too high.
Return the motor for repair.
Loose parts are present in the motor.
Through bolts or coupling is loose.
The bearings are worn.
Mechanical resonance
Run Tune in RSLogix 5000 again.
• Remove the loose parts.
• Return motor for repair.
• Replace motor.
Tighten bolts.
Return motor for repair.
Notch filter may be required (refer to Axis
Properties window, Output tab in RSLogix
5000).
Motor power phases U and V, U and W, or V and W reversed.
Sine, Cosine or Rotor leads are reversed in the feedback cable connector.
Check and correct motor power wiring.
Check and correct motor feedback wiring.
Sine, Cosine, Rotor lead sets of resolver feedback are reversed.
Check and correct motor feedback wiring.
Publication 2094-IN002E-EN-P — September 2005
2-16
Troubleshoot Your Kinetix 6000
Understand Logix/Drive
Fault Behavior
This section provides the drive fault actions and indicates whether the fault action is programmable.
The following drive fault action definitions apply:
Drive Fault Action
Shutdown
Disable Drive
Stop Motion
Status Only
Definition
The drive disables and the contactor enable relay opens. Uncontrolled stop, motor coasts to a stop.
The drive is disabled. Uncontrolled Stop, motor coasts to a stop.
Logix configuration for velocity loop Kp/Ki is followed. When zero speed is reached or stopping time is exceeded, the drive is disabled.
Note: Stopping time and stopping torque are configurable parameters in
RSLogix 5000.
Drive continues to operate. Status is provided by 7-Segment Fault Status
LED, Drive Status LED, and DPI (if used).
Fault Message RSLogix
(HIM)
BusUndervoltageFault
(Blown fuse)
Error
Code
E00
Description
MotorOvertempFault
(Motor Overtemp)
DriveOvercurrentFault
(Power Fault)
HardOvertravelFault
(+/- Hard Overtravel)
MotFeedbackFault
(Motor Feedback Loss)
BusUndervoltageFault
(Bus Under Voltage)
DriveOvervoltageFault
(Bus Overvoltage)
MotFeedbackFault
(Illegal Hall State)
SoftovertravelFault
(+/- Software Overtravel)
OverSpeedFault
(Overspeed Fault)
PositionErrorFault
(Follow Error)
E04
E05
E06
E07
E09
E10
E11
E16
E18
E19
Drive Fault
Action
A blown fuse was detected in the inverter pcb.
SHUTDOWN
The motor thermal switch was tripped.
Note: Firmware I
2 t 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
An instantaneous over-current was detected in the inverter power section.
SHUTDOWN
Axis moved beyond the physical travel limits in the positive/negative direction. This fault can be configured for status only.
STOP
The feedback wiring is open, shorted or missing.
DISABLE
With 3 phase present, the DC bus voltage is below limits. The trip point is 275V and 137V DC for 460V/230V drives respectively.
DC bus voltage is below limits when any axis on common bus follower power rail was enabled.
The DC bus voltage is above limits. The trip point is 820V and 410V
DC for 460V/230V drives respectively.
SHUTDOWN
SHUTDOWN
State of Hall feedback inputs in incorrect.
DISABLE
Axis position exceeded maximum software setting in the positive/ negative direction. This fault can be configured for status only.
Axis position error limit has been exceeded. This fault can be configured for status only.
STOP
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
STOP
RSLogix
Programmable
Fault Action?
N
Y
N
Y
N
N
N
N
Y
N
Y
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-17
Fault Message RSLogix
(HIM)
MotFeedbackFault
(Mtr Fdbk AQB)
AuxFeedbackFault
(Aux Feedback Comm)
MotFeedbackFault
(Motor Feedback Comm)
GroundShortFault
(Ground Fault)
DriveUndervoltageFault
(Precharge Fault)
DriveOvertempFault
(System Overtemperature)
Error
Code
E20
E21
E30
E34
E35
E36
PowerPhaseLossFault
(Phase Loss Flt)
E37
Description
Motor encoder has encountered an illegal state transition.
Communication was not established with an intelligent (i.e.
Stegmann) encoder on the Auxiliary feedback port.
Communication was not established with an intelligent (i.e.
Stegmann) encoder on the Motor feedback port.
Excessive ground current in the converter was detected.
The converter pre-charge cycle has failed.
Drive Fault
Action
DISABLE
STOP
STOP
SHUTDOWN
SHUTDOWN
N
N
N
N
Converter internal temperature limit exceeded.
SHUTDOWN N
• One or more phases of the input AC power is missing.
• Axis was enabled when main (3-phase) power was removed.
• Common bus follower axis was enabled when DC bus power was removed.
SHUTDOWN/ STOP N
The SERCOS ring is not active after being active and operational.
STOP N
SERCOSFault
(SERCOS Ring Flt)
DriveHardFault
(Self Sense Flt)
DriveEnableInputFault
(Drive Enable Flt)
DriveHardFault
(Safe-Off HW Flt)
SERCOSFault
(SERCOS Same ADDR)
DriveHardFault
(Ifbk HW Fault)
DriveHardFault
(Unknown Axis)
AuxFeedbackFault
(Aux Fdbk AQB)
AuxFeedbackFault
(Aux Fdbk Loss)
AuxFeedbackNoise
(Aux Fdbk Noise)
MotorFeedbackNoise
(Mtr Fdbk Noise)
No Fault Message
(condition indicated by on-screen message)
(Hookup Fault)
E38
E39
E43
E49
E50
E54
E60
E61
E62
E63
E64
E65
Self-sensing commutation fault detected
Generated when Enable input switches off when drive is enabled.
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.
Duplicate node address detected on SERCOS ring.
Current feedback hardware fault detected.
Invalid module type identified by firmware during power on
Auxiliary encoder has encountered an illegal state transition.
The feedback wiring is open, shorted or missing.
Presence of noise on auxiliary feedback cable.
Presence of noise on motor feedback cable.
Hookup procedure failed
DISABLE
STOP
SHUTDOWN
STOP
SHUTDOWN
SHUTDOWN
DISABLE
DISABLE
DISABLE
DISABLE
RSLogix
Programmable
Fault Action?
N
N
Y
N
N
N
N
N
N
Y
N
Publication 2094-IN002E-EN-P — September 2005
2-18
Troubleshoot Your Kinetix 6000
Communicate
(Backplane Comm)
DriveOvercurrentFault
(Bus OverCurrent)
DriveOvervoltageFault
(Shunt Time Out)
DriveHardFault
(Can Init)
DriveHardFault
(Module Mismatch)
DriveHardFault
SERCOS Init
DriveOvervoltageFault
(Shunt Module Flt)
HardwareFault
(CPLD FLT)
HardwareFault
(Common Bus FLT)
HardwareFault
(Pre-charge Timeout FLT)
RESERVED
Fault Message RSLogix
(HIM)
No Fault Message
(condition indicated by on-screen message)
(Atune Flt)
DriveHardFault
(Task init)
DriveHardFault
(SCANport Comm)
DriveHardFault
(Objects Init)
DriveHardFault
(NV Mem Init)
DriveHardFault
(Memory Init)
Error
Code
E66
E67
E68
E69
E70
E71
DriveOvertempFault
(Drive Overtemp)
E72
E73
Description
Autotune procedure failed
Operating System Failed
DPI Communication Failed
Non-Volatile Memory attribute out of range
Non-Volatile Memory Corrupted
Drive Fault
Action
DISABLE
SHUTDOWN
STOP
SHUTDOWN
SHUTDOWN
RAM or Flash memory validation failure.
Inverter temperature limit exceeded.
Note: Firmware I
2 t protection does not generate a fault, rather it dynamically folds back current when 110% of drive rating is reached.
Power Rail Backplane CAN communications failed
SHUTDOWN
SHUTDOWN
STOP
E74
E75
E76
E77
E78
E79
E80
E81
E90
All
Others
The converter has exceeded its converter rating.
The IAM, AM, or SM has exceeded its shunt resistor continuous rating.
Note: SHUTDOWN for IAM, DISABLE for AM. IAM also provides fault handling for Shunt Module.
Either DPI or Backplane CAN initialization failure
Generated by IAM if the power rating of one of the AM’s on the power rail does not match with IAM input power rating
Control hardware fault detected
Power Rail mounted Shunt Module Fault. Displayed on IAM
7-segment fault status LED.
Control hardware fault detected
Common Bus Follower IAM detected AC input power being applied.
Pre-charge resistor power exceeds the resistor rating.
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
SHUTDOWN
N
N
N
N
N
RSLogix
Programmable
Fault Action?
N
Y
N
N
N
N
N
N
N
N
N
N
Publication 2094-IN002E-EN-P — September 2005
Supplemental
Troubleshooting
Information
Troubleshoot Your Kinetix 6000
This section provides information for accessing and changing parameters not accessible through RSLogix 5000 software.
2-19
Tools for Changing Parameters
Most parameters are accessible through RSLogix 5000 software.
Alternatives to RSLogix 5000 software for changing parameters include the DPI compatible Human Interface Module (HIM) and
DriveExplorer software. Refer to the table below for catalog numbers.
Method
DriveExplorer
HIM
Description
DriveExplorer Software
1
Catalog Number
9306-4EXP02ENE
Serial to SCANport Adapter 1203-SSS (Series B)
Full Numeric LCD HIM 20-HIM-A3
2
Firmware Revision
2.01 or later
3.004 or later
N/A
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Compatible catalog numbers include all 20-HIM-Ax.
Changing Parameters Using DriveExplorer
To navigate using DriveExplorer, refer to the figure 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 SERCOS ring is active. You must break SERCOS ring to change parameters.
To save changes, perform a non-volatile save (NVS) prior to cycling power.
Figure 2.1
DriveExplorer Example
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Troubleshoot Your Kinetix 6000
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.
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
↵
.
• Analog Output 1 is displayed. Press
↵
.
• For Analog Output 2 use arrows to select. Press
↵
.
4. Press Sel.
5. Enter parameter number. Press
↵
.
Publication 2094-IN002E-EN-P — September 2005
Using Analog Test Points to Monitor System Variables
There are two analog output test points accessible from the IOD
26-pin connector on each IAM and AM (refer to figures and 1.2 for connector locations).
IOD Pin Description
23 Analog Output 0
24
25
26
Analog Output Common
Analog Output 1
Analog Output Common
Signal
DAC0
DAC_COM
DAC1
DAC_COM
Figure 2.2
Pin Orientation for 26-pin I/O (IOD) Connector
26-pin IAM/AM
I/O Connector
Pin 26
Pin 18
Pin 9
Pin 19
Pin 10
Pin 1
Refer to the Kinetix 6000 Multi-Axis Servo Drive Installation Manual
(publication 2094-IN001) for analog output specifications.
Troubleshoot Your Kinetix 6000 2-21
1
2
Analog
Output
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
Use the two analog output test points to monitor system variables, as shown in the table below.
Controlling Parameter
Parameter Number
1
Default Value
1
x681
x683
xx40
xx84
1
x = slot number
Scale Parameter
Parameter Number
1
Default Value
x682
x684
0.0060
0.1000
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.
To monitor dynamic system variables on analog outputs, use the values shown in the table below.
Attribute
Velocity Feedback
1
Velocity Commanded
1
Torque Feedback
2
Torque Commanded
2
Following Error
3
Parameter Number
xx40
xx36
xx84
xx80
x189
4
1
Velocity Command and Feedback scaling value is 0.25V = 1000 rpm (using default scaling).
2
Torque Command and Feedback scaling value is 0.25V = 100% rated motor current or amplifier rating (whichever is less) using default scaling.
3
Output scaling is dependant on feedback device and drive resolution.
4
x = slot number
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Troubleshoot Your Kinetix 6000
Replace Kinetix 6000
System Components
Use these procedures to:
• Determine what you need to replace modules
• Remove a module from the Power Rail
• Install a replacement Power Rail module
• Remove the Power Rail
• Install a replacement Power Rail
• Remove the Line Interface Module
• Install a replacement Line Interface Module
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.
Before You Begin
Before you replace modules, be sure to have the following:
• A flat blade screw driver
• A small flat blade screw driver, 3.5 mm (0.14 in.)
• Voltmeter
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Troubleshoot Your Kinetix 6000 2-23
Remove Modules from the
Power Rail
To remove module(s) 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
Commission Your Kinetix 6000 (pages 1-3 to 1-5).
Note: 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 figure below.
Figure 2.3
Depressing the Spring Clamp
Vertical Cable Clamp
Orientation Example
Motor
Cable
Use flat blade screwdriver with
3.5 mm (0.14 in.) tip to depress spring and remove cable.
Horizontal Cable Clamp
Orientation Example
Cable Clamp
Cable Clamp
Screwdriver tip in slot
Vent holes on top of IAM/AM
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Troubleshoot Your Kinetix 6000
5. Loosen the mounting screw (bottom center of each module).
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 pin(s) (module will pivot on top bracket). Lift the bracket out of the power rail slot and remove module from the power rail.
Figure 2.4
Removing Module from Power Rail
Guide Pin(s)
Power Rail
(side view)
Integrated Axis Module
(side view)
Replace Power Rail
Modules
Publication 2094-IN002E-EN-P — September 2005
To replace the power rail module(s):
1.
If you are
Replacing a power rail module on the existing power rail
Replacing a power rail module on a new power rail
Then
Go to step 3.
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 pin(s) on the power rail with the guide pin hole(s) in the back of the module (refer to Figure 2.4).
Note: 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.
Troubleshoot Your Kinetix 6000 2-25
5. Use 2.26 N-m (20 lb-in.) torque to tighten the mounting screw.
6. Re-connect the module connectors.
7. Re-apply power to the system.
8. Verify that the system is operating properly.
Note: Because IAM and AM parameters reside in the RSLogix 5000 software, you do not need to perform any tuning or setup procedures.
Remove the Power Rail
This procedure assumes you have disconnected all power from the power rail modules and removed all modules from the power rail.
To remove the power rail:
1. Disconnect the braided grounding strap from the grounding stud on the right side of the power rail, as shown in the figures below.
Figure 2.5
Removing Ground Strap (2094-PRx)
Braided Ground Strap
100 mm (3.9 in.)
Bonded Cabinet Ground
Figure 2.6
Removing Ground Strap (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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Troubleshoot Your Kinetix 6000
Replace the Power Rail
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
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 the Kinetix 6000 Multi-Axis Servo Drive
Installation Manual (publication 2094-IN001) for complete installation instructions.
ATTENTION
To avoid damage to Power Rail during installation, do not remove the protective boots until the module for each slot is ready for mounting.
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 figures 2.5 and 2.6).
Publication 2094-IN002E-EN-P — September 2005
Troubleshoot Your Kinetix 6000 2-27
Remove the Line Interface
Module
To remove the Line Interface Module (LIM):
1. Verify that all input power has been removed from the LIM.
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
To avoid hazard of electrical shock, verify that all voltage on the capacitors has been discharged before attempting to service, repair, or remove this unit. This product contains stored energy devices. You should only attempt the procedures in this document if you are qualified to do so and familiar with solid-state control equipment and the safety procedures in publication NFPA 70E.
3. Label and remove all connectors and wires from the LIM. To identify each connector, refer to page 1-6.
4. Loosen the mounting bolts (removing the bolts is not necessary).
5. Lift the LIM up and off of the mounting bolts.
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Troubleshoot Your Kinetix 6000
Replace the Line Interface
Module
This procedure assumes you do not need to change the location of the LIM on the panel and you intend to reuse the mounting bolts of the LIM you just removed.
IMPORTANT
If you need to change the location of the LIM, refer to the Kinetix 6000 Multi-Axis Servo Drive
Installation Manual (publication 2094-IN001) for complete installation instructions.
1. Align the replacement LIM over the existing mounting bolts.
IMPORTANT
To improve the bond between the LIM and subpanel, construct your subpanel out of zinc plated (paint-free) steel.
2. Tighten the mounting bolts.
3. Re-connect the LIM wires and connectors. To locate wires and connectors, refer to page 1-6.
4. Re-apply power to the LIM.
5. Verify that the LIM is operating properly.
Publication 2094-IN002E-EN-P — September 2005
1
Appendix
A
Interconnect Diagrams
Chapter Objectives
This appendix contains the following interconnect diagrams:
• Power Interconnect Diagrams
• DC Common Bus Interconnect Diagrams
• Shunt Module Interconnect Diagrams
• AM/Motor Interconnect Diagrams
• Controlling a Brake Example
• System Block Diagrams
Kinetix 6000 Interconnect
Diagram Notes
This section provides interconnect diagram notes to assist you in wiring the Kinetix 6000 system. The notes apply to the interconnect diagrams on the pages that follow.
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.
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A-2
Interconnect Diagrams
14
15
16
17
18
7
8
4
5
2
3
Note Information
1 For power wiring specifications, refer to Kinetix 6000 Installation Manual (publication 2094-IN001).
For input fuse and circuit breaker sizes, refer to Kinetix 6000 Installation Manual (publication 2094-IN001).
For AC line filter specifications, refer to Kinetix 6000 Installation Manual (publication 2094-IN001).
6
Terminal block is required to make connections.
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.
LIM models 2094-AL75S and -BL75S 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.
9
10
Contactor coil (M1) needs integrated surge suppressors for AC coil operation.
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.
Cable shield clamp must be used in order to meet CE requirements. No external connection to ground required.
Jumper is factory set, indicating grounded system at user site. Ungrounded sites must jumper the bleeder resistor to prevent high electrostatic buildup. Refer to Kinetix 6000 Installation Manual (publication 2094-IN001) for more information.
11
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).
12
13
19
20
ATTENTION
Wiring the Contactor Enable relay is required. To avoid injury or damage to the drive, wire the Contactor Enable relay into your safety control string. The recommended minimum wire size for wiring the safety circuit to the contactor enable connector is 1.5 mm
2
(16 AWG).
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).
For motor cable specifications, refer to the Kinetix Motion Control Selection Guide (publication GMC-SG001).
Wire colors are for flying lead cable (2090-XXNFxx-Sxx) and may vary from the premolded connector cable (2090-UXNFBxx-Sxx).
Y-Series feedback cables have a drain wire that must be folded back under the Low Profile connector clamp.
Only the MPG-Bxxx encoder uses the +5V dc supply. MPL-Bxxx encoders use the +9V dc supply.
Brake wires on MPF/MPS-A/B5xx motors are labeled plus (+) and minus (-). All other MP-Series Food Grade and Stainless Steel motor brake wires are labeled F and G.
Refer to Kinetix 6000 Installation Manual (publication 2094-IN001) 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.
Refer to Kinetix 6000 Installation Manual (publication 2094-IN001) 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-IN002E-EN-P — September 2005
Interconnect Diagrams A-3
Power Interconnect
Diagrams
Bonded Cabinet
Ground Bus*
The interconnect wiring for an IAM is shown beginning below.
In the configuration below the IAM has input power, brake power, and the start/stop string wired from a LIM (2094-AL09 or -BL02). The
2094-xLxx LIM contains an AC line filter, so an external filter is not required.
Figure A.1
IAM Power Interconnect Diagram (IAM with LIM)
Kinetix 6000
LINE INTERFACE MODULE
2094-AL09 or -BL02
Single-Phase (CPL) Output
195-264V ac RMS
Notes 1
L2
L1
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 3-Phase (OPL) Output
195-264V ac RMS or 324-528V ac RMS
Note 1
L3'
L2'
L1'
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
Power Rail
Ground Stud
Cable Shield
Clamp
Note 9
1
2
CTRL 2
CTRL 1
1
4
5
2
3
6
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus and
3-Phase
Input (IPD)
Connector
Motor Power
(MP) Connector
W
V
U
2
1
4
3
Three-Phase
Motor Power
Connections
Note 14
24V dc Output
(PSL) Connector
MBRK_PWR
MBRK_COM
MBRK_PWR
MBRK_COM
3
4
1
2
I/O (IOL)
Connector
Note 11, 12
IO_PWR
24-26
COIL_A1
IO_COM
COIL_A2
13
20-22
4
STOP *
1
2
CONT EN-
CONT EN+
Motor/Resistive
Brake (BC) Connector
Contactor Enable
(CED) Connector
Note 12
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
3
2
1
6
5
4
BR-
BR+
Motor Brake
Connections
BR-
BR+
Resistive Brake
Connections
* INDICATES USER SUPPLIED COMPONENT
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A-4
Interconnect Diagrams
In the configuration below two IAMs have input power, brake power, and the start/stop string wired from the same LIM (2094-AL75S,
-BL75S, or -XL75S-Cx). The 2094-xL75S-xx LIM does not contain an AC line filter, so an external filter is added between the LIM and IAM.
Bonded Cabinet
Ground Bus*
VAC LINE
3-Phase (IPL) Input
195-264V ac RMS or 324-528V ac RMS
Note 1
3
4
1
2
L3
L2
L1
Figure A.2
IAM Power Interconnect Diagram (IAM with LIM)
Kinetix 6000
LINE INTERFACE MODULE
2094-AL75S, -BL75S, or -XL75S-Cx
Control Power
Single-Phase (CPL) Output
195-264V ac RMS
Note 1
CTRL 2
CTRL 1
1
2
Note 4
VAC LOAD
3-Phase (OPL) Output
195-264V ac RMS or 324-528V ac RMS
Note 1
L3'
L2'
L1'
1
2
3
4
Note 4
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(IAM_1)
Power Rail
Ground Stud
Cable Shield
Clamp
Note 9
1
2
CTRL 2
CTRL 1
To CPD connector,
IAM_2
Note 6
Three-Phase
AC Line Filter
Note 3
3
4
1
2
5
6
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus and
3-Phase
Input (IPD)
Connector
Motor Power
(MP) Connector
W
V
U
2
1
4
3
To IPD connector,
IAM_2
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
24V dc (P1L) Output
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
IO_PWR2
IO_COM2
3
4
1
2
5
6
To BC connector, IAM_2
IO_PWR1
1, 3, 5
I/O (IOL)
Connector
Note 11, 12
COIL_E1
IO_COM1
COIL_E2
7
2, 4, 6
8
STOP *
1
2
CONT EN-
CONT EN+
Motor/Resistive
Brake (BC) Connector
Contactor Enable
(CED) Connector
Note 12
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
3
2
1
5
4
6
Motor Brake
Connections
BR-
BR+
BR-
BR+
Resistive Brake
Connections
Three-Phase
Motor Power
Connections
Note 14
* INDICATES USER SUPPLIED COMPONENT
To CED connector, IAM_2
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-5
Bonded Cabinet
Ground Bus*
From CPL connector, LIM
From OPL connector, LIM
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
(IAM_2)
1
2
Power Rail
Ground Stud
CTRL 2
CTRL 1
Cable Shield
Clamp
Note 9
Control Power
(CPD) Connector
Motor Power
(MP) Connector
W
V
U
2
1
4
3
Three-Phase
AC Line Filter
Note 3
3
4
1
2
5
6
DC-
DC+
L3
L2
L1
DC Bus and
3-Phase
Input (IPD)
Connector
Three-Phase
Motor Power
Connections
Note 14
From IOL connector, LIM and CED connector, IAM_1
Motor/Resistive
Brake (BC) Connector
1
2
CONT EN-
CONT EN+
Contactor Enable
(CED) Connector
Note 12
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
3
2
1
6
5
4
BR-
BR+
Motor Brake
Connections
BR-
BR+
From P1L connector, LIM
Resistive Brake
Connections
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A-6
Interconnect Diagrams
The configuration on this page does not include a LIM. You must supply input power components. The diagram below is preferred because one three-phase line filter is utilized by both control power and main input power connections. The three-phase line filter is wired upstream of fusing and the M1 contactor.
ATTENTION
Wiring the Contactor Enable relay is required. To avoid injury or damage to the drive, wire the
Contactor Enable relay into your safety control string.
Figure A.3
IAM Power Interconnect Diagram (IAM without LIM - Preferred)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
Three-Phase Input
195-264V ac RMS or 324-528V ac RMS
Notes 1, 2
Bonded Cabinet Ground Bus *
Chassis
Single-Phase Input
95-264V ac RMS
Notes 1, 2
Three-Phase
AC Line Filter
Note 3
1
2
CTRL 2
CTRL 1
Input Fusing *
Isolation
Transformer *
Notes 5, 6
Input Fusing * M1 *
Notes 7, 8
3
4
1
2
5
6
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus and
3-Phase
Input (IPD)
Connector
Motor/Resistive
Brake (BC) Connector
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
Notes 7, 12
Power Rail
Ground Stud
1
2
CONT EN-
CONT EN+
STOP * START *
Contactor Enable
(CED) Connector
Note 12
CR1 *
W
V
U
2
1
4
3
4
3
6
5
2
1
24V ac/dc or
120V ac
50/60 Hz M1 * CR1 *
CR1 *
Refer to Attention statement (Note 11)
Ground Jumper
Note 10
BR-
BR+
BR-
BR+
Three-Phase
Motor Power
Connections
Note 14
Motor Brake
Connections
User Supplied
24V dc (1.2A maximum)
Resistive Brake
Connections
* INDICATES USER SUPPLIED COMPONENT
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-7
The configuration on this page does not include a LIM. You must supply input power components. The diagram below is not preferred because two line filters are required. The single-phase and three-phase line filters are wired downstream of fusing and the M1 contactor.
ATTENTION
Wiring the Contactor Enable relay is required. To avoid injury or damage to the drive, wire the
Contactor Enable relay into your safety control string.
Figure A.4
IAM Power Interconnect Diagram (IAM without LIM - Alternate)
Kinetix 6000
INTEGRATED AXIS MODULE
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet Ground Bus *
Chassis
Single-Phase Input
95-264V ac RMS
Three-Phase Input
195-264V ac RMS or 324-528V ac RMS
Notes 1, 2
Notes 1, 2
Three-Phase
AC Line Filter
Note 3
Power Rail
Ground Stud
Input Fusing *
Single-Phase
AC Line Filter
Note 3
Isolation
Transformer *
Note 5
1
2
CTRL 2
CTRL 1
Note 4
Control Power
(CPD) Connector
3
4
1
2
5
6
DC-
DC+
L3
L2
L1
DC Bus and
3-Phase
Input (IPD)
Connector
Input Fusing * M1 *
Notes 7, 8
Motor/Resistive
Brake (BC) Connector
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Notes 7, 12
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
STOP *
START *
1
2
CONT EN-
CONT EN+
Contactor Enable
(CED) Connector
Note 12
24V ac/dc or
120V ac
50/60 Hz
CR1 *
M1 * CR1 *
CR1 *
Refer to Attention statement (Note 11)
Ground Jumper
Note 10
W
V
U
2
1
4
3
6
5
4
3
2
1
BR-
BR+
BR-
BR+
Three-Phase
Motor Power
Connections
Note 14
Motor Brake
Connections
User Supplied
24V dc (1.2A maximum)
Resistive Brake
Connections
* INDICATES USER SUPPLIED COMPONENT
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A-8
Interconnect Diagrams
DC Common Bus
Interconnect Diagrams
The interconnect wiring for common bus configurations is shown beginning below. The example on this page shows a Kinetix 6000
Leader IAM and Follower IAM connected via the DC common bus.
Figure A.5
Leader IAM with Single Follower IAM Power Interconnect Diagram
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-9
In the figure below, the 8720MC-RPS regenerative power supply and
Kinetix 6000 (460V) Follower IAM are shown.
Figure A.6
Non-Kinetix 6000 Leader Drive with Single Follower IAM Power Diagram
Publication 2094-IN002E-EN-P — September 2005
A-10
Interconnect Diagrams
In the figure below, a Kinetix 6000 Leader IAM is connected to two
Follower IAMs via the DC common bus.
Figure A.7
Leader IAM with Multiple Follower IAM Diagram
To Follower
DC Bus Connections
To Follower
Control Power
Connections
Bonded Cabinet
Ground Bus *
Single-Phase Input
95-264V ac RMS
Notes 1, 2
Note 4
Three-Phase Input from LIM or input power contactor (M1)
195-264V ac RMS or 324-528V ac RMS
Notes 1, 2, 7, 8
Kinetix 6000
COMMON BUS LEADER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Power Rail
Ground Stud Note 9
Cable Shield
Clamp
1
2
CTRL 2
CTRL 1
1
4
5
2
3
6
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus and
3-Phase
Input (IPD)
Connector
Motor Power
(MP) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
2
1
4
3
3
2
1
6
5
4
1
2
CONT EN-
CONT EN+
Contactor Enable
(CED) Connector
Note 12
Three-Phase
Motor Power
Connections
Note 14
Wire the Leader and Follower IAM contactor enable terminals in series with the safety control string or LIM I/O.
To Follower
Control Circuit
Connections
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-11
From Leader
Control Power
Connections
From Leader
DC Bus Connections
From Leader
Control Circuit
Connections
Note 4
Note 4
DC Bus Fusing *
Note 2
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
N.C.
N.C.
N.C.
Power Rail
Ground Stud
Note 9
Cable Shield
Clamp
1
2
CTRL 2
CTRL 1
1
4
5
2
3
6
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus and
3-Phase
Input (IPD)
Connector
Motor Power
(MP) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
1
2
CONT EN-
CONT EN+
Contactor Enable
(CED) Connector
Note 12
2
1
4
3
3
2
1
6
5
4
Three-Phase
Motor Power
Connections
Note 14
DC Bus Fusing *
Note 2
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-ACxx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus *
N.C.
N.C.
N.C.
Power Rail
Ground Stud Note 9
Cable Shield
Clamp
1
2
CTRL 2
CTRL 1
4
5
6
1
2
3
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus and
3-Phase
Input (IPD)
Connector
Motor Power
(MP) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
1
2
CONT EN-
CONT EN+
Contactor Enable
(CED) Connector
Note 12
2
1
4
3
4
3
6
5
2
1
* INDICATES USER SUPPLIED COMPONENT
Three-Phase
Motor Power
Connections
Note 14
Publication 2094-IN002E-EN-P — September 2005
A-12
Interconnect Diagrams
Bonded Cabinet
Ground Bus*
Three-Phase Input from LIM or input power contactor (M1)
Notes 1, 2, 7, 8
In the figure below, a non-Kinetix 6000 leader drive and Kinetix 6000
Follower IAM are shown.
L3
L2
L1
Non-Kinetix 6000
COMMON BUS LEADER
Ground Stud
DC Bus
Connections
DC-
DC+
Figure A.8
Non-Kinetix 6000 Leader Drive with Single Follower IAM Power Diagram
Pre-charge
Circuitry*
Kinetix 6000
COMMON BUS FOLLOWER IAM
2094-AC xx-Mxx or -BCxx-Mxx
Bonded Cabinet
Ground Bus*
Single-Phase Input
95-264V ac RMS
Notes 1, 2
DC Bus Fusing*
N.C.
N.C.
N.C.
Power Rail
Ground Stud
Note 9
Cable Shield
Clamp
1
2
CTRL 2
CTRL 1
1
4
5
2
3
6
DC-
DC+
L3
L2
L1
Control Power
(CPD) Connector
DC Bus
Connections
Ground
3-Phase
Input (IPD)
Connector
Motor Power
(MP) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
1
2
CONT EN-
CONT EN+
Contactor Enable
(CED) Connector
Note 12
2
1
4
3
4
3
6
5
2
1
Three-Phase
Motor Power
Connections
Note 14
DRIVE OK-
DRIVE OK+
Contactor Enable
* INDICATES USER -SUPPLIED COMPONENT
Wire the Leader and Follower IAM contactor enable terminals in series with the safety control string or LIM I/O.
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-13
Shunt Module Interconnect
Diagrams
In the figure below, the Kinetix 6000 Shunt Module is shown wired for internal shunt operation. This is the factory default jumper setting.
Figure A.9
Internal Shunt Module Interconnect Diagram
Kinetix 6000
SHUNT MODULE
2094-BSP2
External Shunt Resistor
(RC) Connector
COL
INT
DC+
3
2
1
External Thermal Switch
(TS) Connector
TS2
TS1
2
1
In the figure below, the Kinetix 6000 shunt module is shown wired with an external passive shunt resistor.
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 factory installed jumper in place on the TS connector.
Figure A.10
External Passive Shunt Module Interconnect Diagram
Kinetix 6000
SHUNT MODULE
2094-BSP2
External Shunt Resistor
(RC) Connector
COL
INT
DC+
3
2
1
COL
DC+
EXTERNAL PASSIVE
SHUNT RESISTOR
Resistor
External Thermal Switch
(TS) Connector
TS2
TS1
2
1
Thermal
Switch
Publication 2094-IN002E-EN-P — September 2005
A-14
Interconnect Diagrams
Kinetix 6000
INTEGRATED AXIS MODULE
2094-xCxx-Mxx
In the figure below, the Kinetix 6000 IAM (without the LIM) is shown wired with a Bulletin 1336 external active shunt.
Figure A.11
External Active Shunt Module Interconnect Diagram
DC Bus
Connections
Three-Phase
Input (IPD)
Connections
L3
L2
L1
DC-
DC+
3
4
1
2
5
6
Single-Phase Input
115V ac RMS
50/60 Hz
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
Input Fusing*
Note 19
1
2
4
5
6
1
2
3
(+) Slave In
(–) Slave In
(–) Master Out
(+) Master Out
(–) DC Bus
(+) DC Bus
TB3
3
4
TB1
Fault Relay
Note 20
1336 Master
Shunt chassis ground screw
Contactor Enable
(CED) Connector
Note 12
CONT EN-
CONT EN+
1
2
* INDICATES USER SUPPLIED COMPONENT
Refer to Attention statement (Note 11)
CR1*
CR1*
M1*
CR1*
START* STOP*
Notes 7, 12
24V ac/dc or
120V ac
50/60 Hz
1336 Active Shunt Input Fuse Specifications
Active Shunt Module
1336-
Kx005 or Kx010
KB050
Description
Input Current
Requirements
Input current requirement to power logic for fault contact operation.
Input current requirement to power fan and logic for fault contact operation.
0.05A
0.65A
Parameter
On State Current
On State Resistance
Off State Voltage
1336 Active Shunt Fault Relay Specifications
Description
Current flow when the contact is closed
Contact resistance (maximum)
Voltage across the contacts when the relay is open
120V ac
0.6A
50 mOhms
120V ac
30V ac
2.0A
50 mOhms
30V ac
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-15
Kinetix 6000
INTEGRATED AXIS MODULE
2094-xCxx-Mxx
DC Bus
Connections
Three-Phase
Input (IPD)
Connections
L3
L2
L1
DC-
DC+
3
4
1
2
5
6
24V ac/dc or
120V ac
50/60 Hz
Contactor Enable
(CED) Connector
Note 12
CONT EN-
CONT EN+
1
2
Notes 7, 12
STOP* START*
CR1*
M1*
CR1*
CR1*
Refer to Attention statement (Note 11)
In the figure below, the Kinetix 6000 IAM is shown (without a LIM) wired with a Bulletin 1336 external active shunt (master) and two slave units.
Figure A.12
External Active Shunt Module Interconnect Diagram
Note 4
1
2
3
4
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
(+) Master Out
3
4
1
2
5
6
(–) DC Bus
(+) DC Bus
TB1
TB3
Fault Relay Note 20
Shunt chassis ground screw
1336 Master
Note 4
3
4
1
2
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
(+) Master Out
1
2
3
4
5
6
(–) DC Bus
(+) DC Bus
TB1
TB3
Fault Relay Note 20
Shunt chassis ground screw
1336 Slave
Single-Phase Input
115V ac RMS
50/60 Hz
Input Fusing*
Note 19
* INDICATES USER SUPPLIED COMPONENT
Note 4
3
4
1
2
EXTERNAL ACTIVE SHUNT
RESISTOR (1336-MOD-Kxxxx)
(+) Slave In
(–) Slave In
(–) Master Out
(+) Master Out
1
2
3
4
5
6
(–) DC Bus
(+) DC Bus
TB1
TB3
Fault Relay Note 20
Shunt chassis ground screw
1336 Slave
Publication 2094-IN002E-EN-P — September 2005
A-16
Interconnect Diagrams
AM/Motor Interconnect
Diagrams
This section contains the motor power, brake, and feedback signal interconnect diagrams between an Axis Module and MP-Series,
1326AB, or F-, H-, N-, and Y-Series servo motors.
In the figure below, the Kinetix 6000 axis module (460V) is shown connected to MP-Series Low Inertia and Integrated Gear (460V) motors.
Figure A.13
Axis Module to MP-Series (460V) Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Note 13
10
11
12
13
7
8
9
14
15
5
6
3
4
0
1
2
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
2
1
4
3
Green/Yellow
1/Blue
2/Black
3/Brown
2090-XXNPMP-xxSxx
Motor Power Cable
Note 14
3
2
1
6
5
4
2090-UXNBMP-18Sxx Brake Cable
Note 14
Black
White
BR-
BR+
User Supplied
24V dc (1.2A max.)
Resistive Brake
Connections
C
A
D
C
B
A
MPL-B and MPG-B (460V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
W
V
U
BR-
BR+
GND
Three-Phase
Motor Power
Motor Feedback
Motor Brake
Thermostat
A
B
N
R
E
F
K
L
C
D
S
P
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
+9VDC
TS+
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
14
6
7
11
Refer to Low Profile Connector illustration (lower left) for proper grounding technique.
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15, 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.
MPL-B (460V) SERVO MOTORS
WITH RESOLVER FEEDBACK
C
A
D
C
B
A
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
A
B
C
D
G
H
R
Thermostat
S
BR-
BR+
Motor Brake
BLACK
WHT/BLACK
RED
WHT/RED
YELLOW
WHT/YELLOW
BLUE
WHT/BLUE
S2
S4
S1
S3
R1
R2
TS+
TS-
Refer to Low Profile Connector illustration (lower left) for proper grounding technique.
Motor Feedback
(MF) Connector
(IAM/AM)
1
2
3
4
5
10
11
6
2090-CDNFDMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-17
In the figure below, the Kinetix 6000 axis module (230V) is shown connected to MP-Series Low Inertia (MPL) and Integrated Gear (MPG)
230V servo motors.
Figure A.14
Axis Module to MP-Series (230V) Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Note 13
Cable Shield
Clamp
Note 9
9
10
11
12
7
8
5
6
13
14
15
0
3
4
1
2
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
2
1
4
3
Green/Yellow
1/Blue
2/Black
3/Brown
2090-XXNPMP-xxSxx
Motor Power Cable
Note 14
4
3
6
5
2
1
2090-UXNBMP-18Sxx Brake Cable
Note 14
Black
White
BR-
BR+
User Supplied
24V dc (1.2A max.)
Resistive Brake
Connections
C
A
D
C
B
A
MPL-A and MPG-A (230V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
W
V
U
GND
Three-Phase
Motor Power
BR-
BR+
Motor Feedback
Motor Brake
N
R
A
B
K
L
E
F
C
D
Thermostat
P
S
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.
C
A
D
C
B
A
MPL-A (230V) SERVO MOTORS
WITH INCREMENTAL FEEDBACK
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
N
R
K
L
E
F
C
D
A
B
Thermostat
BR-
BR+
Motor Brake
U
V
P
S
T
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
–
TS+
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
14
6
7
11
Refer to Low Profile Connector illustration (lower left) for proper grounding technique.
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
AM+
AM-
BM+
BM-
IM+
IM-
+5VDC
ECOM
–
TS+
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
14
6
7
11
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
–
S1
S2
S3
Refer to Low Profile Connector illustration (lower left) for proper grounding technique.
12
13
8
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Publication 2094-IN002E-EN-P — September 2005
A-18
Interconnect Diagrams
Kinetix 6000
IAM (inverter) or AM
Note 13
Cable Shield
Clamp
Note 9
10
11
12
13
8
9
6
7
14
15
4
5
2
3
0
1
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
2
1
4
3
6
5
4
3
2
1
In the figure below, the Kinetix 6000 axis module is shown connected to MP-Series Food Grade (MPF) and MP-Series Stainless Steel (MPS) servo motors.
Figure A.15
Axis Module to MP-Series Food Grade and Stainless Steel Motors
MPF-A or MPS-A (230V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Shield
Green/Yellow
Blue
Black
Brown
2090-XXNPMF-xxSxx
Motor Power Cable
Note 14
Black
White
BR-
BR+
User Supplied
24V dc (1.2A max.)
Resistive Brake
Connections
G/-
F/+
D/
C/W
B/V
A/U
W
GND
V
U
Three-Phase
Motor Power
Motor
Feedback
Thermostat
BR-
BR+
Motor Brake
Note 18
1
2
3
4
9
10
5
6
11
13
14
12
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
BLUE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
+5VDC
ECOM
–
TS+
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
14
6
11
TS-
COM
Refer to Low Profile Connector illustration (lower left) for proper grounding technique.
2090-XXNFMF-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
MPF-B or MPS-B (460V)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
D/
C/W
B/V
A/U
Clamp
Exposed shield secured under clamp.
Clamp screws (2)
Turn clamp over to hold small cables secure.
G/-
F/+
W
V
U
GND
Three-Phase
Motor Power
Motor
Feedback
Thermostat
BR-
BR+
Motor Brake
Note 18
5
6
9
10
11
13
1
2
3
4
14
12
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
BLUE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
–
ECOM
+9VDC
TS+
Motor Feedback
(MF) Connector
(IAM/AM)
1
2
3
4
5
10
6
7
11
TS-
COM
Refer to Low Profile Connector illustration (lower left) for proper grounding technique.
2090-XXNFMF-Sxx
(flying-lead) Feedback Cable
Notes 14, 15
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-19
Kinetix 6000
IAM (inverter) or AM
Note 13
12
13
14
15
8
9
10
11
6
7
4
5
2
3
0
1
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
2
1
4
3
3
2
1
6
5
4
In the figure below, the Kinetix 6000 axis module (230V) is shown connected to TL-Series (230V) servo motors.
Figure A.16
Axis Module to TL-Series (230V) Motor Interconnect Diagram
TL-Series (230V) MOTORS
WITH INCREMENTAL FEEDBACK
Green/Yellow
Blue
Black
Brown
2090-XXNPT-16Sxx
Motor Power Cable
Note 14
2090-DANBT-18Sxx
Motor Brake Cable
Note 14
Black
White
BR-
BR+
User Supplied
24V dc (1.2A max.)
Resistive Brake
Connections
4
3
2
1
2
1
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
3
4
1
2
7
8
5
10
BR-
BR+
Motor Brake
6
11
15
9
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
BLUE
WHT/BLUE
YELLOW
WHT/YELLOW
AM+
AM-
BM+
BM-
IM+
IM-
+5VDC
ECOM
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
14
6
S1
S2
S3
12
13
8
2090-XXNFT-Sxx Feedback Cable with pre-molded connector
Note 14
Publication 2094-IN002E-EN-P — September 2005
A-20
Interconnect Diagrams
In the figure below, the Kinetix 6000 axis module (460V) is shown connected to 1326AB-Bxxxx (460V) servo motors.
Figure A.17
Axis Module to 1326AB Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Note 13
1326AB (M2L/S2L)
SERVO MOTORS WITH
HIGH RESOLUTION FEEDBACK
9
10
11
12
7
8
5
6
13
14
15
0
3
4
1
2
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
2
1
4
3
Green/Yellow
1/Blue
2/Black
3/Brown
2090-XXNPMP-xxSxx
Motor Power Cable
Note 14
4
3
6
5
2
1
2090-UXNBMP-18Sxx Brake Cable
Note 14
Black
White
BR-
BR+
User Supplied
24V dc (1.2A max.)
Resistive Brake
Connections
C
A
D
C
B
A
W
V
U
BR-
BR+
GND
Three-Phase
Motor Power
Motor Feedback
Motor Brake
Thermostat
N
R
K
L
E
F
A
B
C
D
S
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
GRAY
WHT/GRAY
ORANGE
WHT/ORANGE
SIN+
SIN-
COS+
COS-
DATA+
DATA-
–
ECOM
+9VDC–
TS+
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
14
6
7
11
P
Refer to the
Kinetix 6000 Installation Manual
(publication 2094-IN001) for proper
2090-XXNFMP-Sxx
(flying-lead) Feedback Cable
Note 14, 15
Kinetix 6000
IAM (inverter) or AM
Note 13
1326AB SERVO MOTORS
WITH RESOLVER FEEDBACK
1326-CPx1-xxx Motor Power Cable
Note 14
12
13
14
15
8
9
10
11
6
7
4
5
2
3
0
1
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
W
V
U
Motor/Resistive
Brake (BC) Connector
2
1
4
3
4
3
6
5
2
1
Green/Yellow
Braided Shield
Black
Black
Black
3
2
1
8
7
T3
GND
T2
T1
Three-Phase
Motor Power
Black
Black
User Supplied
24V dc (1.2A max.)
BR-
BR+
Resistive Brake
Connections
4
6 B1
B2
Motor Brake
Motor Feedback
G
H
D
E
A
B
GREEN
BLACK
BLACK
RED
BLACK
WHITE
S2
S4
S1
S3
R1
R2
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
5
1
2
10
5
9
K1
K2
Thermostat
1
1326-CCU-xxx
(flying-lead) Feedback Cable
Note 14
TS+
TS-
16
17
S
Shielded Cable
1
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 Installation Manual (publication 2094-IN001) for wiring instructions and a diagram.
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-21
In the figure below, the Kinetix 6000 axis module (230V) is shown connected to H- and F-Series (230V) servo motors.
Figure A.18
Axis Module to H/F-Series Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Note 13
11
12
13
14
7
8
9
10
15
5
6
3
4
0
1
2
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
Motor/Resistive
Brake (BC) Connector
W
V
U
2
1
4
3
Green/Yellow
1/Blue
2/Black
3/Brown
2090-XXNPH/HF-xxSxx
Motor Power Cable
Note 14
2
1
4
3
6
5
9101-0330 Brake Cable Connector Kit
Note 14
Black
White
User Supplied
24V dc (1.2A max.)
B
A
BR-
BR+
Resistive Brake
Connections
D
C
B
A
H/F-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
W
V
U
GND
Three-Phase
Motor Power
BR-
BR+
Motor Feedback
Motor Brake
Thermostat
A
B
R
P
E
F
C
D
N
T
H
L
M
K
J
S
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BROWN
BROWN
GRAY
WHT/GRAY
BLUE
WHT/BLUE
VIOLET
ECOM
S2
S1
–
WHT/VIOLET
TS-
Refer to Low Profile Connector illustration (below) for proper grounding technique.
AM+
AM-
BM+
BM-
IM+
IM-
TS+
S3
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
11
8
+5VDC 14
6
13
12
6
2090-XXNFHF-Sxx
(flying-lead) Feedback Cable
Note 14, 15
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-IN002E-EN-P — September 2005
A-22
Interconnect Diagrams
In the figure below, the Kinetix 6000 axis module (230V) is shown connected to N-Series (230V) servo motors.
Figure A.19
Axis Module to N-Series Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Note 13
11
12
13
14
7
8
9
10
15
5
6
3
4
0
1
2
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
Motor/Resistive
Brake (BC) Connector
W
V
U
2
1
4
3
Green/Yellow
1/Blue
2/Black
3/Brown
2090-XXNPN-xxSxx
Motor Power Cable
Note 14
2
1
4
3
6
5
9101-1698 Brake Cable Connector Kit
Note 14
Black
White
User Supplied
24V dc (1.2A max.)
C
B
A
BR-
BR+
Resistive Brake
Connections
C
B
A
E
D
N-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
N/C
W
V
U
GND
Three-Phase
Motor Power
Motor Feedback
BR-
BR+
N/C
Motor Brake
Thermostat
A
B
R
V
E
F
C
D
L
M
K
J
U
T
H
S
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BROWN
BROWN
GRAY
WHT/GRAY
BLUE
WHT/BLUE
VIOLET
ECOM
S2
S1
–
WHT/VIOLET
TS-
Refer to Low Profile Connector illustration (below) for proper grounding technique.
AM+
AM-
BM+
BM-
IM+
IM-
TS+
S3
Motor Feedback
(MF) Connector
(IAM/AM)
3
4
1
2
5
10
11
8
+5VDC 14
6
13
12
6
2090-XXNFN-Sxx
(flying-lead) Feedback Cable
Note 14, 15
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-IN002E-EN-P — September 2005
Interconnect Diagrams A-23
In the figure below, the Kinetix 6000 axis module (230V) is shown connected to Y-Series (230V) servo motors.
Figure A.20
Axis Module to Y-Series Motor Interconnect Diagram
Kinetix 6000
IAM (inverter) or AM
Note 13
Y-Series (230V)
SERVO MOTORS WITH
INCREMENTAL FEEDBACK
12
13
14
15
8
9
10
11
6
7
4
5
2
3
0
1
Cable Shield
Clamp
Note 9
Motor Power
(MP) Connector
Motor Feedback
(MF) Connector
Motor/Resistive
Brake (BC) Connector
W
V
U
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
4
3
2
1
6
5
4
3
2
1
Green/Yellow
3/Black
2/Black
1/Black
2090-XXNPY-xxSxx
Motor Power and Brake Cable
Note 14
BR-
BR+
Black
Black
4
3
2
1
9
7
User Supplied
24V dc (1.2A max.)
Resistive Brake
Connections
Pigtail
W
V
U
GND
Three-Phase
Motor Power
BR-
BR+
Motor
Feedback
Motor
Brake
Pigtail
13
14
15
17
19
–
22
23
24
9
10
11
12
BLACK
WHT/BLACK
RED
WHT/RED
GREEN
WHT/GREEN
WHT/BLUE
BLUE
BROWN
WHT/BROWN
GRAY
WHT/GRAY
AM+
AM-
BM+
BM-
IM+
IM-
S1
S2
S3
–
+5VDC
ECOM
DRAIN
Motor Feedback
(MF) Connector
(IAM/AM)
5
10
12
13
3
4
1
2
8
14
6
Refer to Low Profile Connector illustration (below) for proper grounding technique.
2090-XXNFY-Sxx
(flying-lead) Feedback Cable
Notes 14, 15, 16
Grounding Technique for
Feedback Cable Shield
Low Profile Connector
(2090-K6CK-D15M shown)
Clamp
Exposed shield and drain wire secured under clamp.
Clamp screws (2)
Turn clamp over to hold small cables secure.
Publication 2094-IN002E-EN-P — September 2005
A-24
Interconnect Diagrams
Controlling a Brake
Example
The relay output of the Kinetix 6000 (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.
Maximum Brake Current Rating Kinetix 6000 IAM/AM
2094-AC05-Mxx, -AC09-Mxx,
2094-AMP5, -AM01, -AM02
2094-BC01-Mxx, -BC02-Mxx,
2094-BMP5, -BM01, -BM02
2094-AC16-Mxx, -AC32-Mxx,
2094-AM03, -AM05
2094-BC04-Mxx, -BC07-Mxx,
2094-BM03, -BM05
1.0A
1.3A
3.0A
IMPORTANT
For brake requirements outside of these limits, an external relay must be used (refer to Figure A.21 for an example).
H-3007 and -3016
H-4030, -4050, and -4075
N-2302, and -2304
N-3406, -3412, -4214, and -4220
N-5630, -5637, and -5647
Y-1002 and -1003
Y-2006 and -2012
Y-3023
TL-A110P-H, -A120P-H, and -A130P-H
TL-A220P-H and -A230P-H
TL-A2530P-H and -A2540P-H
TL-A410P-H
The following tables list Allen-Bradley motors and brake coil current ratings.
Coil Currents Rated at
<
1.0A
Compatible Brake Motors Coil Current
F-4030, -4050, and -4075 0.69A
0.60A
0.69A
0.28A
0.36A
0.71A
0.26A
0.31A
0.37A
0.208A
0.375A
0.396A
0.746A
Coil Currents Rated at
<
1.0A
Coil Current Compatible Brake Motors
MPL/MPF/MPS-x310, -x320, -x330
1
MPL-x420, -x430, -x4520, -x4530, -x4540
1
MPF-x430, -x4530, -x4540
1
MPG-x004
1
MPG-x010
1
MPG-x025
1
MPG-x050
1
MPG-x110
1
0.50A
0.64A
0.33A
0.45A
0.50A
1.0A
1326AB-B4xxx 0.88A
1
Applies to 230V and 460V motors.
Publication 2094-IN002E-EN-P — September 2005
Interconnect Diagrams A-25
Coil Currents Rated
>
1.0A and
≤
1.3A
Compatible Brake Motors Coil Current
F-6100, -6200, and -6300
H-6100, -6200, and -6300
1.30A
1.13A
Coil Currents Rated
>
1.3A and
≤
3.0A
Compatible Brake Motors
H-8350 and -8500
Coil Current
2.20A
Coil Currents Rated
>
1.0A and
≤
1.3A
Compatible Brake Motors
MPL-x520, -x540, -x560, -x580
1
Coil Current
1.05 to 1.28A
MPF-B540
1326AB-B5xxx, and -B7xxx
1
Applies to 230V and 460V motors.
1.20A
Coil Currents Rated
>
1.3A and
≤
3.0A
Compatible Brake Motors Coil Current
MPL-B640, -B660, -B680, -B860, -B880,
-B960, -B980
1.91 to 2.19A
Figure A.21 shows an example configuration using MBRK± and an external relay to control a motor brake which exceeds the drive (IAM/
AM) internal relay rating.
Figure A.21
Example Configuration Controlling a Motor Brake
Kinetix 6000
IAM (inverter) or AM
Note 13
MBRK -
MBRK +
COM
PWR
DBRK -
DBRK +
Motor/Resistive
1
Brake (BC) Connector
6
5
4
3
2
1
CR1
User Supplied
24V dc (3.0A max.)
CR1
BR-
BR+
Brake
Feedback
Power
SERVO
MOTOR
1
For Motor/Resistive Brake (BC) connector specifications, refer to the Kinetix 6000 Installation Manual (publication
2094-IN001).
ATTENTION
To avoid damage to the brake contactor, surge suppression (flyback diode or MOV, rated at appropriate voltage), must be used when controlling a brake coil.
Publication 2094-IN002E-EN-P — September 2005
A-26
Interconnect Diagrams
System Block Diagrams
This section provides block diagrams of the Kinetix 6000 modules.
IAM/AM Inverter Block Diagram
Figure A.22
Inverter Block Diagram
Publication 2094-IN002E-EN-P — September 2005
IAM Converter Block Diagram
Figure A.23
Converter Block Diagram
Interconnect Diagrams A-27
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A-28
Interconnect Diagrams
Safe-Off Feature Block Diagram
The Kinetix 6000 Safe-Off drives ship with the wiring header and motion allowed jumper installed, as shown in the figure below. With the motion allowed jumper installed, the safe-off feature is not used.
Figure A.24
Safe-Off Feature Block Diagram
Safe-Off Option
8
9
Safe-Off (SO)
9-pin Connector
+24V
+24V_COM
K1-C
3
4
FDBK1+
FDBK1-
7
ENABLE1+
6
ENABLE-
5
ENABLE2+
1
2
FDBK2+
FDBK2-
K1
K2
K1-A
K2-A
K2-C
Motion Allowed Jumper
(2090-XNSS-MA)
Wiring Header
(2090-XNSS-WP)
+24V
DRIVE ENABLE
+24V_COM
Gate Control
Power Supply
Safety Monitor uC
Gate Control
Circuit (CCP)
Gate Control
Enable Signal
M
DC+
SYSOK
GSHUNT (2)
POWER
RAIL
DC-
CTRL 1
CTRL 2
SM Block Diagram
Figure A.25
Shunt Module Block Diagram
SMPS
+5V (Control)
+/-15V (IGBT)
24V (Control)
Chassis
Publication 2094-IN002E-EN-P — September 2005
Shunt Circuit
Internal or External
Shunt
Resistor
LIM Block Diagrams
Figure A.26
LIM Block Diagram (2094-AL75S)
Interconnect Diagrams A-29
Publication 2094-IN002E-EN-P — September 2005
A-30
Interconnect Diagrams
Figure A.27
LIM Block Diagram (2094-BL75S)
Publication 2094-IN002E-EN-P — September 2005
Figure A.28
LIM Block Diagram (2094-XL75S-Cx)
Interconnect Diagrams A-31
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A-32
Interconnect Diagrams
Figure A.29
LIM Block Diagram (2094-AL09)
9
18
26
1
10
19
Publication 2094-IN002E-EN-P — September 2005
Figure A.30
LIM Block Diagram (2094-BL02)
Interconnect Diagrams A-33
9
18
26
1
10
19
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A-34
Interconnect Diagrams
RBM Block Diagrams
Figure A.31
RBM Block Diagram (2090-XB33-xx)
Publication 2094-IN002E-EN-P — September 2005
Figure A.32
RBM Block Diagram (2090-XB120-xx)
Interconnect Diagrams A-35
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A-36
Interconnect Diagrams
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1
Appendix
B
Upgrade Your Kinetix 6000 Firmware
Chapter Objectives
This appendix provides a procedure for upgrading the Kinetix 6000 firmware using DriveExplorer.
Upgrade Drive Firmware
Using DriveExplorer
Upgrading axis module firmware using DriveExplorer (via the DPI port) involves setting the Axes to Flash parameter, configuring a
HyperTerminal session, and flashing the firmware.
Before You Begin
Before you begin this procedure, make sure you have the following:
Description Catalog Numbers
DriveExplorer Software
1
9306-4EXP02ENE
Smart Self-Powered (DPI) Serial Converter 1203-SSS (Series B)
Firmware upgrade file for Kinetix 6000 N/A
2
Personal computer with HyperTerminal N/A
Minimum Firmware
Revision
2.01
3.004
N/A
N/A
2
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Contact Rockwell Automation Technical Support at (440) 646-5800 for firmware upgrade file.
Select Axis Modules to Upgrade
In this procedure you will use DriveExplorer software to set the Axes to Flash parameter (x708) and allow selective axis module upgrading.
Note: You will save time by selecting only the axis module(s) that require a firmware upgrade.
Publication 2094-IN002E-EN-P — September 2005
B-2
Upgrade Your Kinetix 6000 Firmware
To set the Axes to Flash parameter:
1. Apply 95-264V AC to the IAM control power (CPD) connector.
ATTENTION
To avoid injury or damage to equipment due to unpredictable motor activity, do not apply AC input (three-phase) power or establish communications with the 1756-MxxSE SERCOS interface module.
2. Connect the 1203-SSS serial cable to the appropriate COM port on your personal computer.
3. Connect the 1203-SSS DPI cable to the DPI connector on your
IAM.
4. Verify that the 1203-SSS has power by observing the LED indicated in Figure B.1.
Figure B.1
1203-SSS DPI Adapter
DPI communication
5. Start the DriveExplorer software. Click on Explore\Connect.
DriveExplorer proceeds to read your system.
Publication 2094-IN002E-EN-P — September 2005
Upgrade Your Kinetix 6000 Firmware B-3
6. Double-click on 2094D SERVO Config 0000. The linear list of parameters appears, as shown in the window 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
7. Scroll down to parameter x:x.30 (Version Data) and record the version (VERS: xx.xxx) of each axis module.
8. Double-click on Configuration. The following window opens.
9. Double-click on Axes to Flash. The Axis to Flash window opens.
10. Check each axis to flash (example above shows two axes to flash).
11. Select OK. The Axes to Flash parameter is set.
12. Close DriveExplorer.
Publication 2094-IN002E-EN-P — September 2005
B-4
Upgrade Your Kinetix 6000 Firmware
HyperTerminal Configuration
To open and begin a new HyperTerminal session:
1. From the Windows Start menu, select Programs\Accessories\
HyperTerminal\HyperTerminal. The New Connection window opens.
• Name the new HyperTerminal file
• Choose an icon for the connection
2. Select OK. The following window opens.
Publication 2094-IN002E-EN-P — September 2005
Select the appropriate COM port
3. Select OK. The following window opens. Select the following properties as shown or as appropriate for your 1203-SSS DPI adapter.
IMPORTANT
Bits per second of HyperTerminal must match the 1203-SSS DPI adapter setting for connection to occur.
Upgrade Your Kinetix 6000 Firmware B-5
4. Select OK. HyperTerminal configuration is complete.
Flash Your Firmware
This procedure assumes you have identified which axis module(s) 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.
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B-6
Upgrade Your Kinetix 6000 Firmware
2. Enter 3. The following window opens.
3. Enter 0. The following window opens.
4. Enter Y. As indicated in the text, the program begins displaying the character C.
Note: Program times-out after 60 seconds. If program times-out before you complete steps 5 - 7, return to step 1.
5. Go to the Transfer menu and select Send File. The Send File window opens. Browse for your firmware upgrade file.
Firmware upgrade file, as provided by Rockwell
Automation Technical Support at (440) 646-5800.
Publication 2094-IN002E-EN-P — September 2005
Upgrade Your Kinetix 6000 Firmware
6. Select Xmodem protocol.
7. Select Send. The flash upgrade operation begins and the following window opens.
B-7
ATTENTION
To avoid unrecoverable fault to modules, do not interrupt control power to IAM, power to the
1203-SSS DPI adapter, or power to your PC while the flash upgrade operation is in progress.
8. The flash operation completes and the following window opens.
9. Close the HyperTerminal session.
10. Verify that parameter 30 for each axis module is now upgraded to the new firmware revision. Return to DriveExplorer (refer to Select
Axis Modules to Upgrade, step 6) to see the linear list of parameters.
Publication 2094-IN002E-EN-P — September 2005
B-8
Upgrade Your Kinetix 6000 Firmware
Publication 2094-IN002E-EN-P — September 2005
Chapter Objectives
Before You Begin
Integrate Resistive Brake Modules with Kinetix 6000 Drives
Appendix
C
This appendix provides Bulletin 2090 Resistive Brake Module (RBM) integration procedures specific to the Allen-Bradley Kinetix 6000 multi-axis servo drive systems using drive firmware v1.071 (or above).
The procedure involves setting the time delay parameter using
RSLogix 5000.
These procedures assume you have mounted and wired your RBM with your Kinetix 6000 drive system. The following publications are available to assist you with RBM installation:
Title
Kinetix 6000 Installation Manual
Resistive Brake Module Installation Instructions
Publication Number
2094-IN001
2090-IN009
1
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C-2
Understand Safety
Precautions
Integrate Resistive Brake Modules with Kinetix 6000 Drives
The following precautions apply to resistive brake module installation 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
• 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.
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Integrate Resistive Brake Modules with Kinetix 6000 Drives C-3
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.
Publication 2094-IN002E-EN-P — September 2005
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Integrate 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-IN002E-EN-P — September 2005
Integrate Resistive Brake Modules with Kinetix 6000 Drives C-5
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
Interconnect Diagram
Notes
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 example RBM interconnect 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.
2
3
4
5
6
Note Information
1 Cable shield clamp must be used in order to meet CE requirements. No external connection to ground required.
For motor cable specifications, refer to the Kinetix Motion Control Selection Guide (publication GMC-SG001).
The BRKTMP0 signal can be wired to a ControlLogix input as overtemp warning in user program.
Firmware version 1.071 (or higher) is required to use the DBRK outputs on the Kinetix 6000 IAM or AM.
The safety relay time delay should be set beyond the time required to stop and disable the axis when running at full speed.
Drive Enable Input Checking must be selected in Axis Properties.
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Integrate Resistive Brake Modules with Kinetix 6000 Drives
Resistive Brake Module
Interconnect Diagrams
The example diagram below shows Kinetix 6000 IAM, AM, and LIM
(2094-AL75S, -BL75S, and -XL75S) wired with the Bulletin 2090 RBM.
Figure C.1
Example RBM Interconnection Diagram (Category 2 Configuration per EN954-1)
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Integrate Resistive Brake Modules with Kinetix 6000 Drives C-7
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C-8
Integrate 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.
Figure C.2
Example RBM Interconnection Diagram (Category 2 Configuration per EN954-1)
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Integrate Resistive Brake Modules with Kinetix 6000 Drives C-9
Publication 2094-IN002E-EN-P — September 2005
C-10
Integrate Resistive Brake Modules with Kinetix 6000 Drives
The example diagram below shows Kinetix 6000 IAM and LIM
(2094-AL75S, -BL75S, and -XL75S) wired with the Bulletin 2090 RBM.
Figure C.3
Example RBM Interconnection Diagram (Category 3 Configuration per EN954-1)
Publication 2094-IN002E-EN-P — September 2005
Integrate Resistive Brake Modules with Kinetix 6000 Drives C-11
Publication 2094-IN002E-EN-P — September 2005
C-12
Integrate 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.
Figure C.4
Example RBM Interconnection Diagram (Category 3 Configuration per EN954-1)
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Integrate Resistive Brake Modules with Kinetix 6000 Drives C-13
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C-14
Integrate Resistive Brake Modules with Kinetix 6000 Drives
Set 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.
If you are using this version of RSLogix 5000 software
Then
v11 or v12 v13 or above
Proceed with these instructions using DriveExplorer to set the RBM delay time parameter.
Go to Configure Axis Properties on page 1-24 and use
RSLogix 5000 to set the RBM delay time parameter.
The following hardware and software tools are required to provide the necessary communication link between your PC and the Kinetix
6000 drive system running RSLogix 5000.
Description
DriveExplorer Software
1, 3
Catalog Numbers
9306-4EXP02ENE
Serial to SCANport Adapter
2, 3
RSLogix 5000
Software
1203-SSS (Series B)
9324-RLD300NE
Personal computer with HyperTerminal N/A
Version
2.01 or above
3.004 or above
11.0 or 12.0
N/A
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Refer to 1203-SSS (Series B) FRN 3.xxx User Manual (publication 20COMM-UM001) for instructions.
3
Additional information regarding these communication and software tools is available at www.ab.com/
support/abdrives.
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 made to the time delay parameter.
Remove SERCOS Communication
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-IN002E-EN-P — September 2005
Integrate Resistive Brake Modules with Kinetix 6000 Drives C-15
Set the RBM Delay Time Parameter
To set the RBM delay time parameter:
1. Start the DriveExplorer software.
2. Click on Explore\Connect\Local in the menu bar or enter
Ctrl-L from the keyboard. DriveExplorer 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. Click on Devices\Node\Product\Axis x Group\Config and navigate to the Config parameters as shown below.
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Integrate Resistive Brake Modules with Kinetix 6000 Drives
5. Double-click on the x:x:x641 RBM Delay parameter. The command window for parameter x641 - RBM Delay opens.
6. Click on the Value Edit tab and enter the delay time Value (ms).
The recommended RBM delay time is 71 ms.
7. Select OK. The RBM delay time is changed, but not saved in non-volatile memory.
Save the Delay Time Parameter to Non-Volatile Memory
To save the delay time parameter to non-volatile memory:
1. Click on Actions\Non-Volatile Memory in the menu bar. The following message window opens.
Publication 2094-IN002E-EN-P — September 2005
2. Click on Save. The changes are saved to non-volatile memory and the following cautionary message window opens.
Integrate Resistive Brake Modules with Kinetix 6000 Drives C-17
3. Click on Yes to complete saving changes to non-volatile memory.
The following confirmation message window opens.
4. Click OK.
5.
If you
Have another RBM in the
Kinetix 6000 system
Then
Go to Set the RBM Delay Time
Parameter (step 4).
Do not have another RBM in the Kinetix 6000 system
1. Close DriveExplorer.
2. Go to Reconnect SERCOS
Communication.
Reconnect SERCOS Communication
To reconnect SERCOS communication:
1. Remove three-phase and control power from the Kinetix 6000 drive system.
2. Replace the SERCOS fiber-optic cable(s) 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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Integrate Resistive Brake Modules with Kinetix 6000 Drives
Publication 2094-IN002E-EN-P — September 2005
1
Chapter Objectives
Before You Begin
Appendix
D
DC Common Bus Applications
This appendix provides integration procedures specific to the Kinetix
6000 multi-axis servo drive systems configured for DC common bus and using drive firmware v1.85 (or above). The procedure involves calculating capacitance values and setting the Add Bus Cap parameter using DriveExplorer software.
These procedures assume you have mounted and wired your Kinetix
6000 DC common bus system. Refer to the Kinetix 6000 Installation
Manual (publication 2094-IN001) for mounting and wiring information.
Before you set the Additional Bus Capacitance (Add Bus Cap) parameter in DriveExplorer, you need to calculate the following values using the tables provided:
• Total Bus Capacitance
• Additional Bus Capacitance
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D-2
DC Common Bus Applications
Calculate 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 the following 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 D-3 for IAM/AM/
SM capacitance values.
IMPORTANT
When total bus capacitance exceeds the Leader IAM maximum value given in the table below, the IAM seven-segment LED displays error code E90
(pre-charge timeout fault) and the drive is disabled.
Leader IAM (230V)
2094-
AC05-MP5
AC05-M01
AC09-M02
AC16-M03
AC32-M05
Maximum Bus
Capacitance
µF
7145
15295
34400
62825
Leader IAM (460V)
2094-
BC01-MP5
BC01-M01
BC02-M02
BC04-M03
BC07-M05
Maximum Bus
Capacitance
µF
4585
8955
8955
17915
IMPORTANT
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.
Publication 2094-IN002E-EN-P — September 2005
DC Common Bus Applications D-3
Calculate Additional Bus Capacitance
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 the following modules:
• Each Follower IAM (converter and inverter)
• Each AM on the Follower IAM power rails
Enter the additional bus capacitance value in step 6 of Set the
Additional Bus Capacitance Parameter.
Kinetix 6000 Capacitance Values
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
AC05-M01
AC09-M02
AC16-M03
AC32-M05
Capacitance
µF
270
540
1320
1980
AM Inverter (230V)
2094-
AMP5
AM01
AM02
AM03
AM05
Capacitance
µF
390
660
780
1320
2640
IAM/AM (460V) Modules
IAM Converter (460V)
2094-
BC01-MP5
BC01-M01
BC02-M02
BC04-M03
BC07-M05
Capacitance
µF
110
220
940
1410
SM (230/460V) Module
SM (230-460V)
2094-
BSP2
Capacitance
µF
470
AM Inverter (460V)
2094-
BMP5
BM01
BM02
BM03
BM05
Capacitance
µF
75
150
270
840
1175
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D-4
Three-Phase
Input Power
DC Common Bus Applications
Common Bus Capacitance Example
In the figure below, the sum of the Leader IAM power rail modules capacitance (6530 µF) and the Follower IAM power rail modules capacitance (5280 µF) equals 11810 µF Total Bus Capacitance.
The sum of the Follower IAM power rail modules equal 5280 µF
Additional Bus Capacitance.
Figure D.1
Calculating Common Bus Capacitance
AC Line
Filter
MAIN VAC
Kinetix 6000 (230V)
Leader IAM
11810 µF Total Bus Capacitance
Line Interface
Module
(optional component)
DC Common Bus
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
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
Publication 2094-IN002E-EN-P — September 2005
Set the Additional Bus
Capacitance Parameter
DC Common Bus Applications D-5
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 PC and the Kinetix
6000 drive system running DriveExplorer.
Description
DriveExplorer Software
1, 3
Serial to SCANport Adapter
2, 3
RSLogix 5000
Software
Catalog Numbers
9306-4EXP02ENE
1203-SSS (Series B)
9324-RLD300NE
Version
2.01 or above
3.004 or above
15.0 or above
1
Refer to DriveExplorer Getting Results Manual (publication 9306-GR001) for instructions.
2
Refer to 1203-SSS (Series B) FRN 3.xxx User Manual (publication 20COMM-UM001) for instructions.
3
Additional information regarding these communication and software tools is available at www.ab.com/
support/abdrives.
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 made to the
Add Bus Cap parameter.
Remove SERCOS Communication
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-IN002E-EN-P — September 2005
D-6
DC Common Bus Applications
Set the Additional Bus Capacitance Parameter
To set the Additional Bus Capacitance parameter:
1. Start the DriveExplorer software.
2. Click on Explore\Connect\Local in the menu bar or enter
Ctrl-L from the keyboard. DriveExplorer 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. Click on Devices\Node\Product\ and navigate to the parameter
x:x:x599 as shown below.
Publication 2094-IN002E-EN-P — September 2005
DC Common Bus Applications
5. Double-click on the x:x:x599 Add Bus Cap parameter. The command window for parameter x599 - Add Bus Cap opens.
D-7
6. Click on the Value Edit tab and enter the Add Bus Cap Value (
µF).
7. Select OK. The Add Bus Cap parameter is changed, but not saved in non-volatile memory.
8. Go to Save the Add Bus Cap Parameter to Non-Volatile Memory.
Save the Add Bus Cap Parameter to Non-Volatile Memory
To save the Add Bus Cap parameter to non-volatile memory:
1. Click on Actions\Non-Volatile Memory in the menu bar. The following message window opens.
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D-8
DC Common Bus Applications
2. Click on Save. The changes are saved to non-volatile memory and the following cautionary message window opens.
3. Click on Yes to complete saving changes to non-volatile memory.
The following confirmation message window opens.
4. Click OK. Close DriveExplorer.
5. Go to Reconnect SERCOS Communication.
Reconnect SERCOS Communication
To reconnect SERCOS communication:
1. Remove three-phase and control power from the Kinetix 6000 drive system.
2. Replace the SERCOS fiber-optic cable(s) 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-IN002E-EN-P — September 2005
1
Index
Numerics
1203-SSS serial cable
B-2
,
B-4
16 axis SERCOS interface PCI card installation instructions
P-3
1756 module properties
1-18
1756-MxxSE interface module
1-9
,
1-16
1784-PM16SE PCI card
1-9
24V power LED
2-12
26-pin I/O connector
2-20
A
acronyms
P-4 additional bus capacitance calculating
D-3 example
D-4 analog test points
DAC0
2-20
DAC1
2-20 applying power
1-26 with LIM
1-26 without LIM
1-30 atune fault
2-6 aux fdbk noise fault
2-6 aux feedback AQB
2-6 aux feedback loss
2-6 auxiliary encoder error,
see troubleshooting axis module connector designators
1-2 connector locations
1-4 axis properties
1-24 axis unstable
2-14
B
backplane comm
2-7 bandwidth
1-37 base node address
1-10 example with two
ControlLogix chassis
1-12
,
1-13 example with two power rails
1-11 baud rate
1-14
,
1-15 block diagrams converter
A-27 inverter
A-26
LIM
A-29
,
A-30
,
A-31
,
A-32
,
A-33
RBM
A-34
,
A-35 safe-off feature
A-28 shunt module
A-28 blown fuse
2-3 brake
A-24 brake power LED
1-27
,
2-12 bus overvoltage
2-4 undervoltage
2-4 bus overcurrent
2-7 bus regulator
1-22 bus status LED
1-29
,
1-32
,
2-9
,
2-11
C
cables fiber optic cable length
1-9
CAD files
P-3 can init
2-7
CB1, CB2, CB3
1-26 certifications
Rockwell Automation Product
Certification
P-3 changing parameters
DriveExplorer
2-19
HIM
2-20 circuit breakers
1-26 comm status LED
1-29
,
1-31
,
2-8 commissioning your Kinetix 6000
1-1 common bus (see DC common bus)
Common Bus FLT
2-7 component removal and replacement
2-22 configuring
AM
1-15 base node address
1-10 baud rate, AM
1-15 baud rate, IAM
1-14 feedback only axis
1-21
IAM
1-10
Kinetix 6000
1-9 optical power level
1-14
,
1-15
SERCOS module
1-16 connector designators axis module
1-2 integrated axis module
1-2 line interface module
1-6
Publication 2094-IN002E-EN-P — September 2005
I-2
Index
Publication 2094-IN002E-EN-P — September 2005 shunt module
1-5 connector locations axis module
1-4 integrated axis module
1-3 line interface module
1-6
,
1-8 shunt module
1-5 contents of manual
P-2 control reliability
C-5 controller properties
1-16 controlling a brake
A-24
Controllogix Motion Module
Programming Manual
P-3 conventions used in this manual
P-4 conversion tab
1-24 converter
A-27 coordinated system time master
1-17
CPLD FLT
2-7 cycle time
1-19 erratic operation
2-15 error codes
2-3 establishing communications
2-8
F
fault action
2-16 fault action, programmable
2-16 fault actions tab
1-25 feedback only axis
1-21 feedback tab
1-24 fiber optic cables receive and transmit connectors
1-9
Fiber-Optic Cable Installation
Instructions
P-3 firmware upgrade file
B-6 flyback diodes
A-25 follow error
2-4
D
DAC0
2-20
DAC1
2-20 data rate
1-19 data type
1-20 date and time tab
1-17
DC common bus configuring
1-22 interconnect diagram
A-8
,
A-9
,
A-10
,
A-12 setting the add bus cap parameter
D-5 digital I/O not working correctly
2-3 dip switches
1-19 disable drive
2-16 documentation files
P-3 download program
1-25 drive enable fault
2-5 drive overcurrent
2-3 drive overtemp
2-5
,
2-7 drive status LED
1-29
,
1-31
,
2-8 drive tab
1-24 drive undervoltage
2-5
DriveExplorer
2-19
,
B-1
,
C-14
,
D-5
E
encoder communication fault
2-5
G
ground fault
2-5
H
hardware overtravel
2-4
HIM
2-19 hookup fault
2-6 hookup tab
1-34 human interface module (HIM)
2-19 hyperterminal
B-4
I
I/O connector
2-20
I/O power LED
1-27
,
2-12
Ifbk HW Fault
2-6 illegal hall state
2-4 integrated axis module configuring
1-10 connector designators
1-2 connector locations
1-3 interconnect diagram
A-3
,
A-4
,
A-6
,
A-7
,
A-8
,
A-9
,
A-10
,
A-12 interconnect diagrams
2094 with H-Series motor
A-21
2094 with MPG-A motor
A-17
,
A-18
,
A-19
Index I-3
2094 with MPG-B motor
A-16
2094 with MPL-A motor
A-17
,
A-18
,
A-19
2094 with MPL-B motor
A-16
2094 with N-Series motor
A-22
2094 with Y-Series motor
A-23
2094 with1326AB motor
A-20 controlling a brake example
A-25 notes
A-1
,
C-5 power, DC common bus
A-8
,
A-9
,
A-10
,
A-12 power, IAM with LIM
A-3
,
A-4 power, IAM without LIM
A-6
,
A-7
RBM
C-6 shunt module
A-13
,
A-14
,
A-15 introduction
P-1 inverter
A-26
IPM fault, see troubleshooting seven segment
1-28 shunt fault
2-11 status
1-28
,
1-31
,
1-33
,
2-2 temperature fault
2-11
LIM
1-26 line interface module brake power LED
1-27 connector designators
1-6 connector locations
1-6
,
1-8
I/O power LED
1-27 interconnect diagram
A-3
,
A-4
,
A-6
,
A-7 removing
2-27 replacing
2-28 system block diagram
A-29
,
A-30
,
A-31
,
A-32
,
A-33
Literature Library
P-3 logic power
1-30
,
2-2 logic power LED
1-28
Logix5000 Controllers Motion
Instructions Reference Manual
P-3
Logix5000 Motion Modules User
Manual
P-3
,
1-16
,
1-33 loop configuration
1-24
K
Kinetix 6000 axis properties
1-24 configuring
1-9
Installation Manual
P-3
Line Interface Module
Installation Instructions
P-3 module properties
1-20 troubleshooting
2-1 user documentation and CAD files CD
P-3
Kinetix Motion Control Selection
Guide
P-3
Kinetix Safe-Off Feature
Reference Manual
P-3
L
LED
24V power, LIM
2-12 brake power, LIM
1-27
,
2-12 bus status
1-29
,
1-32
,
2-9
,
2-11 comm status
1-29
,
1-31
,
2-8 drive status
1-29
,
1-31
,
2-8
I/O power, LIM
1-27
,
2-12 logic power
1-28
,
1-30
,
2-2
RBM 230V status
2-13
RBM 24V status
2-12
SERCOS 1756 module
1-32
SERCOS interface module
1-29
M
maintenance
2-2 memory init
2-6 module mismatch
2-7 module properties
1756 SERCOS interface
1-18
IAM
1-20
Motion Analyzer CD
P-3
Motion Control Selection Guide
P-3 motion group properties
1-23 motor accel/decel problems
2-14 motor and feedback tab
1-24 motor encoder error
2-4 motor feedback loss
2-4 motor jumps when first enabled
2-3 motor overheating
2-15 motor overtemp
2-3 motor velocity
2-14 motors interconnect diagram
1326AB
A-20
H-Series
A-21
Publication 2094-IN002E-EN-P — September 2005
I-4
Index
Publication 2094-IN002E-EN-P — September 2005
MPG-A
A-17
,
A-18
,
A-19
MPG-B
A-16
MPL-A
A-17
,
A-18
,
A-19
MPL-B
A-16
N-Series
A-22
Y-Series
A-23 testing
1-33 tuning
1-33
MOV
A-25 mtr fdbk noise fault
2-6
N
National Electrical Code
P-3 no communication
2-8 no rotation
2-15 node address
1-20 noise abnormal
2-15 feedback
2-15
NV mem init
2-6
O
objects init
2-6 optical power level
1-14
,
1-15
,
1-19 overspeed fault
2-4
P
parameters, changing
2-19 power indicator not on
2-3 power phase loss
2-5 power rail removing
2-25 removing modules
2-23 replacing
2-26 power up
1-26 precautions general startup
1-1 precharge fault
2-5 purpose of this manual
P-1
R
related documentation
P-3 relay output
A-24 removing components
2-22
LIM
2-27 modules
2-23 replacing components
2-22
LIM
2-28 power rail modules
2-24 resistive brake module interconnect diagrams
C-6 setting the RBM delay time
C-14 system block diagram
A-34
,
A-35
Resistive Brake Module
Installation Instructions
P-3 risk assessment
C-4
Rockwell Automation Product
Certification
P-3
RSLogix 5000 software
1-16
,
2-19
,
C-14
,
D-5
S
safe-off block diagram
A-28 safe-off HW fault
2-6 safety control reliability
C-5 risk assessment
C-4 standards
C-2 stop categories
C-3 safety reference manual
P-3
SCANport comm
2-6
SCANport/DPI adapter
C-14
,
D-5 self sense fault
2-5
SERCOS init
2-7
SERCOS interface module installation instructions
P-3
SERCOS ring fault
2-5
SERCOS same addr
2-6 setting the add bus cap parameter
D-5 seven segment status LED
1-28
,
1-30 shunt fault LED
2-11 shunt module
A-28 connector designators
1-5 connector locations
1-5 interconnect diagram
A-13
,
A-14
,
A-15 shunt module troubleshooting
2-10 shunt time fault
2-7 shunt time out
2-7
Index I-5 shutdown
2-16
SoftLogix Motion Card Setup and
Configuration Manual
P-3
,
1-16
,
1-33 software
RSLogix 5000
1-16
,
2-19 software overtravel
2-4 start-up procedure
1-1 status LEDs
1-28
,
1-31
,
1-33
,
2-2 status only
2-16 stop categories
C-3 stop motion
2-16 storage
P-2 supplemental troubleshooting information
2-19 surge suppression
A-25 switches base node address
1-10 baud rate
1-14
,
1-15 optical power level
1-14
,
1-15 system block diagrams converter
A-27 inverter
A-26
LIM
A-29
,
A-30
,
A-31
,
A-32
,
A-33
RBM
A-34
,
A-35 safe-off feature
A-28 shunt module
A-28
System Design for Control of
Electrical Noise
P-3
T
task init
2-6 temperature fault LED
2-11 testing axes hookup tab
1-34 total bus capacitance calculating
D-2 example
D-4 troubleshooting
2-2
24V power LED
2-12 brake power LED
2-12 bus status LED
2-9
,
2-11 comm status
2-8 disable drive
2-16 drive status LED
2-8 error codes
2-3 fault action
2-16 general atune fault
2-6 aux fdbk noise fault
2-6 aux feedback AQB
2-6 aux feedback loss
2-6 auxiliary encoder error
2-4 backplane comm
2-7 blown fuse
2-3 bus overcurrent
2-7 bus undervoltage
2-4 can init
2-7
Common Bus FLT
2-7
CPLD FLT
2-7 digital I/O not working correctly
2-3 drive enable fault
2-5 drive overcurrent
2-3 drive overtemp
2-5
,
2-7 drive undervoltage
2-5 encoder communication fault
2-5 follow error
2-4 ground fault
2-5 hardware overtravel
2-4 hookup fault
2-6
Ifbk HW Fault
2-6 illegal hall state
2-4
IPM fault
2-3 memory init
2-6 module mismatch
2-7 motor encoder error
2-4 motor feedback loss
2-4 motor jumps when first enabled
2-3 motor overtemp
2-3 mtr fdbk noise fault
2-6
NV mem init
2-6 objects init
2-6 overspeed fault
2-4 power indicator not on
2-3 power phase loss
2-5 precharge fault
2-5 safe-off HW fault
2-6
SCANport comm
2-6 self sense fault
2-5
SERCOS init
2-7
SERCOS ring fault
2-5
SERCOS same addr
2-6 shunt module fault
2-7 shunt time out
2-7 software overtravel
2-4
Publication 2094-IN002E-EN-P — September 2005
I-6
Index task init
2-6 unknown axis
2-6 general system problems
2-14 abnormal noise
2-15 axis unstable
2-14 erratic operation
2-15 feedback noise
2-15 motor accel/decel problems
2-14 motor overheating
2-15 motor velocity
2-14 no rotation
2-15
I/O power LED
2-12
Logix/drive fault behavior
2-16 programmable fault action
2-16
RBM 230V status LED
2-13
RBM 24V status LED
2-12 shunt fault LED
2-11 shunt module
2-10 shutdown
2-16 status only
2-16 stop motion
2-16 supplemental troubleshooting information
2-19 changing parameters
2-19 using analog test points
2-20 temperature fault LED
2-11 troubleshooting your Kinetix
6000
2-1 tuning axes bandwidth
1-37 tune tab
1-36
U
units tab
1-24 unknown axis
2-6 user manuals
P-3
W
who should use this manual
P-1
X
Xmodem
B-7
Publication 2094-IN002E-EN-P — September 2005
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
Outside United
States
1.440.646.3223
Monday – Friday, 8am – 5pm EST
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 and needs to be returned:
United States
Outside 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.
Please contact your local Rockwell Automation representative for return procedure.
Publication 2094-IN002E-EN-P — September 2005
Supersedes Publication 2094-IN002D-EN-P — July 2005 Copyright © 2005 Rockwell Automation. All rights reserved. Printed in USA.

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Key features
- Modular design
- Versatile applications
- High performance
- Flexibility
- Easy to configure
- SERCOS communication protocol
- Integration with ControlLogix and SoftLogix systems