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Allen-Bradley Kinetix 6000M User Manual

Allen-Bradley Kinetix 6000M User Manual

Integrated drive-motor system
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User Manual
Kinetix 6000M Integrated Drive-Motor System
Catalog Numbers 2094-SEPM-B24-S, MDF-SB1003P, MDF-SB1153H, MDF-SB1304F

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  • Page 1 User Manual Kinetix 6000M Integrated Drive-Motor System Catalog Numbers 2094-SEPM-B24-S, MDF-SB1003P, MDF-SB1153H, MDF-SB1304F...
  • Page 2 IMPORTANT Identifies information that is critical for successful application and understanding of the product. Allen-Bradley, Rockwell Software, Rockwell Automation, Kinetix, On-Machine, ControlLogix, CompactLogix, SoftLogix, RSLinx, RSLogix, DriveExplorer, ControlFLASH and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

  • Page 3: Table Of Contents

    About the Kinetix 6000M System ........9...
  • Page 4 Table of Contents Chapter 4 Kinetix 6000M System Connector IPIM Module Connectors and Indicators ......38 IPIM Module Connector and Signal Descriptions .
  • Page 5 Configuring the Kinetix 6000M Configure the Kinetix 6000M Integrated Drive-motor System ..65 Understanding the IPIM Module Display ......66 System Startup Sequence .
  • Page 6 Definitions ........... . . 127 Manually Sizing the Kinetix 6000M System ..... . . 128...

  • Page 7: About This Publication

    Manual • Numbered lists provide sequential steps or hierarchical information. • Acronyms for the Kinetix 6000 and Kinetix 6200 system components and Kinetix 6000M integrated drive-motor are shown in the table below and are used throughout this manual. Acronym Kinetix Modules Cat.
  • Page 8 Preface Resource Description Kinetix 6000M IPIM Hybrid Terminator Installation Instructions, Provides detailed terminator information. publication 2090-IN035 Kinetix 6000M Network Terminator Installation Instructions, publication 2090-IN036 Kinetix 6000M Hybrid Power Coupler Installation Instructions, Provides installation information for the Hybrid publication 2090-IN038 Power Coupler.

  • Page 9: About The Kinetix 6000M System

    Typical Communication Configurations Catalog Number Explanations Component Compatibility Agency Compliance About the Kinetix 6000M The Kinetix 6000M integrated drive-motor system is designed to provide a Kinetix Integrated Motion solution for your applications. Table 1 lists the System components that can be used to build an integrated solution.
  • Page 10 Real-time Communication System (sercos) protocol over a fiber-optic cable. RSLogix 5000 Software 9324-RLD300ENE RSLogix 5000 software provides support for programming, commissioning, and maintaining the Logix family of controllers. Version 20 or later is required when using the Kinetix 6000M integrated drive- motor system. Line Interface Modules 2094-BLxxS...

  • Page 11: Typical Hardware Configurations

    2094-PRF slot-filler module in all empty slots on the power rail. Any power rail connector without a module installed will disable the 3-phase power; however, control power is still present. Figure 1 - Typical Kinetix 6000M Integrated Drive-motor System Catalog numbers are in parenthesis IPIM-to-IDM Hybrid Cable...
  • Page 12 Chapter 1 Start Figure 2 - Typical 2094 Power Rail with Kinetix 6000M System (with LIM) 2090-XXLF-xxxx 2094-BSP2 AC Line Filter 2094-SEPM-B24-S Shunt Module (required for CE) IPIM Module (optional component) 3-Phase 2094-PRF Control Power Input Power Slot-filler Module 2094 Drive System...
  • Page 13 Start Chapter 1 Figure 3 - Typical 2094 Power Rail with Kinetix 6000M System (without LIM) 3-Phase Input Power Line Disconnect Device 2090-XXLF-xxxx Input Line Filter Fusing (required for CE) Control Power Magnetic Contactor 2094-BSP2 2094-SEPM-B24-S Shunt Module IPIM Module...
  • Page 14 Chapter 1 Start In the following example, the leader IAM module is connected to the follower IAM module via the DC common-bus. When planning your panel layout, you must calculate the total bus capacitance of your DC common-bus system to be sure that the leader IAM module is sized sufficiently to pre-charge the entire system.
  • Page 15 Start Chapter 1 Figure 4 - Typical Kinetix 6000 with Kinetix 6000M System Common Bus 2090-XXLF-xxxx AC Line Filter (required for CE) 2094-BSP2 Control Power 2094-SEPM-B24-S 3-phase Shunt Module IPIM Module Input Power (optional component) 2094-BCxx-Mxx-S 2094-PRF MAIN VAC IAM Module...

  • Page 16: Typical Communication Configurations

    Configurations software. For more information on Ethernet cables, refer to the Industrial Ethernet Media Brochure, publication 1585-BR001. Figure 5 - Typical Kinetix 6000M, Kinetix 6000 and Kinetix 6200 Network Configuration Logix Controller Programming Network EtherNet/IP Module Logix Sercos Interface Module...

  • Page 17: Catalog Number Explanations

    Start Chapter 1 Catalog Number Kinetix 6000M catalog numbers and descriptions are listed in the tables below. Explanations Table 2 - Power Interface Module (IPIM) Cat. No. Description 2094-SEPM-B24-S 460V IDM Power Interface Module (IPIM) w/Safe-off Table 3 - Integrated Drive-motor (IDM) Cat.

  • Page 18: Component Compatibility

    Kinetix 6500 EtherNet/IP control modules (catalog numbers 2094-EN02D- IMPORTANT M01-Sx) are not compatible with the Kinetix 6000M IPIM or Kinetix 6000/ Kinetix 6200 IAM and AM modules on the same Bulletin 2094 power rail. The IDM system cannot be accessed with DriveExplorer™ or a human interface IMPORTANT module (HIM).

  • Page 19: Agency Compliance

    Start Chapter 1 Agency Compliance If this product is installed within the European Union and has the CE mark, the following regulations apply. ATTENTION: Meeting CE requires a grounded system, and the method of grounding the AC line filter and IDM must match. Failure to do this renders the filter ineffective and may cause damage to the filter.
  • Page 20 Chapter 1 Start Notes: Rockwell Automation Publication 2094-UM003A-EN-P - May 2012...

  • Page 21: Cable Length Restrictions And System Sizing

    240 m (787 ft). • The number of IDM units also depends on the use of the safe-off function. Refer to Using the Safe Torque-off Feature with the Kinetix 6000M System page 103 for details.

  • Page 22: Ipim Module Design Guidelines

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

  • Page 23: Circuit Breaker/Fuse Options

    Planning the Kinetix 6000M System Installation Chapter 2 • Combined motor power cable lengths for all axes and hybrid cable lengths for all IDM units on the same DC bus must not exceed 240 m (787 ft) with 400V-class systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft).

  • Page 24: Enclosure Selection

    Chapter 2 Planning the Kinetix 6000M System Installation Figure 6 - IPIM Fuse Location ATTENTION: Capacitors on the DC bus may retain hazardous voltages after input power has been removed. Before working on the IDM system, measure the DC bus voltage to verify it has reached a safe level or wait the full time interval as indicated in the warning on the IPIM module.

  • Page 25: Minimum Clearance Requirements

    Planning the Kinetix 6000M System Installation Chapter 2 Table 7 - Power Dissipation Specifications - Percent of DC Bus Current Power Dissipation as % of DC Bus Current Output Rating Watts 100% Heat Dissipation Formula Y = 33.95x + 3.18x (1) x is percent of DC bus current output rating: any value between 0.0 and 1.0.

  • Page 26: Idm Unit Design Guidelines

    Chapter 2 Planning the Kinetix 6000M System Installation Figure 7 - Minimum IPIM Module Clearance Requirements 50.8 mm (2.0 in.) clearance for airflow and installation 287 mm (11.3 in.) Clearance left of the Clearance right of the module is not required...

  • Page 27: Electrical Noise Reduction

    Planning the Kinetix 6000M System Installation Chapter 2 Figure 8 - Minimum IDM Unit Clearance Requirements 100.0 mm (3.9 in.) 100.0 mm (3.9 in.) 100.0 mm (3.9 in.) Refer to the Kinetix 6000 Multi-axis Servo Drives User Manual, publication Electrical Noise Reduction...

  • Page 28: Cable Categories For Kinetix 6000M System

    Chapter 2 Planning the Kinetix 6000M System Installation Figure 9 - Noise Zones (Bulletin 2094 power rail with IPIM module) Dirty Wireway Clean Wireway Very Dirty Filter/IAM Connections Segregated (not in wireway) Motor and Hybrid Cables Fiber-optic Cables and IPIM Communication Wires...
  • Page 29 Chapter Mounting the Kinetix 6000M System This chapter provides the system installation procedures for mounting your Kinetix 6000M integrated drive-motor (IDM) unit and your power interface module (IPIM). Topic Page Mounting the IPIM Module Installing the IDM Unit This procedure assumes you have prepared your panel, mounted your Bulletin 2094 power rail, and understand how to bond your system.

  • Page 30: Mounting The Ipim Module

    Chapter 3 Mounting the Kinetix 6000M System Mounting the IPIM Module Using the 2094 Mounting Brackets You can use Bulletin 2094 mounting brackets to mount the power rail or LIM module over the AC line filter. Refer to the 2094 Mounting Brackets Installation Instructions, publication 2094-IN008, when using mounting brackets with your system.
  • Page 31 Mounting the Kinetix 6000M System Chapter 3 Figure 10 - Module Mounting Order Example Highest Power Utilization Lowest Power Utilization Integrated Axis Shunt Slot Filler IPIM Module Axis Modules Module Module Module The IAM must be positioned in the leftmost slot of the power rail. Position your IMPORTANT other modules to the right of the IAM module.

  • Page 32: Mount The Ipim Module

    Chapter 3 Mounting the Kinetix 6000M System Mount the IPIM Module All modules mount to the power rail using the same technique. 1. Determine the next available slot and module for mounting. Refer to Determine Mounting Order page 2. Remove the protective covers from the power rail connectors.

  • Page 33: Installing The Idm Unit

    ATTENTION: Do not attempt to open or modify the IDM unit. This manual describes modifications that you can perform in the field. Do not attempt other changes. Only a qualified Allen-Bradley employee can service an IDM unit. Failure to observe these safety procedures could result in personal injury or damage to equipment.

  • Page 34: Aligning The Idm Unit

    Chapter 3 Mounting the Kinetix 6000M System Aligning the IDM Unit The IDM unit can be mounted in any position and has a mounting pilot that aids in aligning the unit on a machine. A shaft seal that helps protect the motor against fine dust and fluids is factory installed and should be replaced at regular intervals.
  • Page 35 Mounting the Kinetix 6000M System Chapter 3 1. Allow sufficient clearances around the IDM unit for it to stay within its specified operating temperature range. See page 27 for details. BURN HAZARD: Outer surfaces of the IDM unit can reach high temperatures, 125 °C (275 °F), during motor operation.
  • Page 36 Chapter 3 Mounting the Kinetix 6000M System Notes: Rockwell Automation Publication 2094-UM003A-EN-P - May 2012...
  • Page 37 Chapter Kinetix 6000M System Connector Data This chapter provides connector locations and signal descriptions for your Kinetix 6000M integrated drive-motor system. Topic Page IPIM Module Connectors and Indicators IPIM Module Connector and Signal Descriptions IDM Unit Connectors and Indicators IDM Unit Connector and Signal Descriptions...

  • Page 38: Ipim Module Connectors And Indicators

    Chapter 4 Kinetix 6000M System Connector Data IPIM Module Connectors and Figure 11 - Module Connectors and Indicators Indicators Item Description See page Hybrid cable DC bus connector Termination point for +/- DC and PE Hybrid cable communication signals Connection point for IDM unit power and...

  • Page 39: Ipim Module Connector And Signal Descriptions

    Kinetix 6000M System Connector Data Chapter 4 IPIM Module Connector and Hybrid Cable DC Bus Connector Signal Descriptions This connector supplies the DC bus voltage. Three wires from the hybrid power and communication cable (catalog number 2090- CHBIFS8-12AAxx) are used to extend this voltage to the first IDM unit.

  • Page 40: Safe Torque-Off Connector

    Chapter 4 Kinetix 6000M System Connector Data Safe Torque-off Connector Remove the motion- allowed jumper before connecting any safety This connector provides a termination devices. point for connecting safety devices such as: emergency stop switches, light Wiring Plug Header curtains, and floor mats. The redundant...

  • Page 41: Sercos Fiber-Optic Connectors

    Kinetix 6000M System Connector Data Chapter 4 Sercos Fiber-optic Connectors The sercos fiber-optic ring is connected by using the sercos receive (RX) and transmit (TX) connectors. Receive Transmit ATTENTION: To avoid damage to the sercos RX and TX connectors use only finger-tight torque when attaching the fiber-optic cables.

  • Page 42: Ethernet/Ip Connectors

    Chapter 4 Kinetix 6000M System Connector Data EtherNet/IP Connectors Two connectors are provided for firmware upgrades, troubleshooting, and integration with Logix. The Ethernet ports also support a web browser interface to provide access to status information for the IPIM module and IDM units.

  • Page 43: Idm Unit Connectors And Indicators

    Kinetix 6000M System Connector Data Chapter 4 IDM Unit Connectors and Figure 12 - Integrated Drive-motor Unit Features, Connectors, and Indicators Indicators Item Description See page Hybrid cable input connector (from IPIM Input and output connecting points for the module or previous IDM unit) Hybrid Power and Communication cables.

  • Page 44: Idm Unit Connector And Signal Descriptions

    Chapter 4 Kinetix 6000M System Connector Data IDM Unit Connector and Hybrid Cable Connector Signal Descriptions The information below provides connector pinouts for the IDM unit hybrid connectors. Input Connector Output Connector Hybrid Input Connector Hybrid Output Connector Description Signal Name...

  • Page 45: Idm Network Input And Output Connector Pinouts

    Kinetix 6000M System Connector Data Chapter 4 IDM Network Input and Output Connector Pinouts Pinout information is provided below for the IDM unit network connectors. Input Connector Output Connector Network Input Connector Network Output Connector Signal Name Signal Name RTN TX-...
  • Page 46 Chapter 4 Kinetix 6000M System Connector Data IDM units have three 5-pin, M12, digital input connectors. Allen-Bradley (Bulletin 889D) DC micro-style patchcords, splitters, and V-cables are available with straight and right-angle connectors for making connections from the IDM unit to input sensors.
  • Page 47 Kinetix 6000M System Connector Data Chapter 4 Single Normally Open (NO) Sensor Connection Normally open sensors are used for registration or home switches on the IDM unit. Any 4-pin or 5-pin, M12, A-code, 1-1 pass through cable can be used to connect a normally open sensor.
  • Page 48 Chapter 4 Kinetix 6000M System Connector Data Digital Input Cable Examples Figure 16 - Digital Inputs Used for Home and Overtravel Functions MDF-SBxxxxx IDM Units Digital Inputs (1, 2, 3) 889D-x4ACDx-xx Patchcords Input Assignments: 1 = Overtravel- (NC) Input Assignments:...
  • Page 49 Kinetix 6000M System Connector Data Chapter 4 Table 14 - Understanding the Digital Inputs Capture Edge/Level Pin Connector Signal Description Time Sensitive HOME Optically isolated, single-ended active high signal. Current 30 ms Level loading is nominally 10 mA. Home switch (normally open contact) inputs for each axis require 24V DC (nominal).

  • Page 50: Power Specifications

    Chapter 4 Kinetix 6000M System Connector Data Power Specifications Brake Override Input ATTENTION: To guard against personal injury and/or component damage, the brake override must only be used for machine assembly when the IPIM module is not connected to the IDM unit.
  • Page 51 Kinetix 6000M System Connector Data Chapter 4 MDF-1003 Peak Inverter Overload (T < 2.0 s) Ipk = 200% Ipk = 350% Ipk = 471% 100% % Base Current (IBase/Icont) MDF-1153 Peak Inverter Overload (T < 2.0 s) Ipk = 200%...

  • Page 52: Feedback Specifications

    Chapter 4 Kinetix 6000M System Connector Data Feedback Specifications Kinetix 6000M integrated drive-motors are available with high performance digital encoders with multi-turn high resolution feedback: • 524,288 counts per revolution • High-resolution absolute position feedback within 4096 turns. The IDM unit does not support an auxiliary feedback device.

  • Page 53: Basic Wiring Requirements

    The Sercos Fiber-optic Ring Ethernet Cable Connections Basic Wiring Requirements This section contains basic wiring information for the Kinetix 6000M integrated drive-motor system. Refer to the Kinetix 6000 user manual, publication 2094-UM001, or the Kinetix 6200 user manual, publication 2094-UM002, for specific wiring information.

  • Page 54: Routing The Power And Signal Cables

    Chapter 5 Connecting the Kinetix 6000M System IDM system wiring differs from common PWM servo system wiring IMPORTANT configurations in the following ways: • Hybrid and network cables can be tie-wrapped together and occupy the same cable run • Hybrid and network cables do not require physical segregation as a result of more effective wire shielding and improved grounding techniques.

  • Page 55: Apply The Cable Shield Clamp

    Connecting the Kinetix 6000M System Chapter 5 Signal integrity is very important for successful operation of an integrated drive- motor system. You must be sure that all cables are properly grounded through the IPIM module to the ground plane of the Kinetix drive system.

  • Page 56: General Idm System Wiring

    Chapter 5 Connecting the Kinetix 6000M System General IDM System Wiring ATTENTION: Arcing or unexpected motion can occur if cables are connected or disconnected while power is applied to the IDM system. Before working on the system, disconnect power and wait the full time interval indicated on the IPIM module warning label or verify the DC bus voltage at the IPIM module measures less than 50V DC.
  • Page 57 Connecting the Kinetix 6000M System Chapter 5 Figure 22 - IDM System Wiring IPIM to IDM Hybrid Cable (Catalog numbers are in parenthesis.) (2090-CHBIFS8-12AAxx) IPIM Module IDM to IDM Hybrid Cable (2090-CHBP8S8-12AAxx) Hybrid Terminator Last IDM Unit (2090-CTHP8) Network Cable...

  • Page 58: Network Cable

    Chapter 5 Connecting the Kinetix 6000M System Figure 24 - Hybrid Cable Installed Hybrid Cable DC Bus Connector Hybrid Cable Hybrid Cable Communication Signals Connector Network Cable The IDM system network is routed by using 2090-CNSxPxS-AAxx cables. A 2090-CNSSPRS-AAxx or 2090-CNSSPSS-AAxx cable is required for connection to the IPIM module.

  • Page 59: The Sercos Fiber-Optic Ring

    Connecting the Kinetix 6000M System Chapter 5 The Sercos Fiber-optic Ring The sercos fiber-optic ring is connected by using the sercos receive (RX) and transmit (TX) connectors. Refer to Sercos Fiber-optic Connectors page 41 for details. Refer to the documentation supplied with your Logix sercos interface module or PCI card for connector locations.
  • Page 60 IDM units be on the same sercos ring as the IPIM module they are connected to. Figure 26 - Kinetix 6000M Network Cable Example - IPIM Module to IDM Units (1 sercos ring) Sercos Fiber-optic Ring...
  • Page 61 IDM units be on the same sercos ring as the IPIM module they are connected to. Figure 27 - Kinetix 6000M Network Cable Example - IPIM Module to IDM Units (2 sercos rings) 1756-M08SE Sercos...
  • Page 62 IDM units be on the same sercos ring as the IPIM module they are connected to. Figure 28 - Kinetix 6000M Network Cable Example - IPIM Module to IDM Units (5 sercos rings) 1756-M08SE Sercos...

  • Page 63: Ethernet Cable Connections

    Connecting the Kinetix 6000M System Chapter 5 Ethernet Cable Connections This procedure assumes you have your ControlLogix or CompactLogix EtherNet/IP module and Bulletin 2094 control modules mounted and are ready to connect the Ethernet network cables. The EtherNet/IP network is connected by using the PORT 1 and/or PORT 2 connectors.

  • Page 64: Rockwell Automation Publication 2094-Um003A-En-P - May

    Chapter 5 Connecting the Kinetix 6000M System Notes: Rockwell Automation Publication 2094-UM003A-EN-P - May 2012...

  • Page 65: Configure The Kinetix 6000M Integrated Drive-Motor System

    Chapter Configuring the Kinetix 6000M System This chapter provides procedures for configuring your Kinetix 6000M system components with your Logix sercos module. Topic Page Understanding the IPIM Module Display Configuring the IPIM Module Configuring the IDM Unit Add-on Profiles Configure the Logix Sercos Interface Module...

  • Page 66: Understanding The Ipim Module Display

    Chapter 6 Configuring the Kinetix 6000M System Understanding the IPIM The IPIM module has six status indicators (see Interpret Status Indicators page 90) and a four-line LCD display. The indicators and display are used to Module Display monitor the system status, set network parameters, and troubleshoot faults. Four navigation buttons are located directly below the display and are used to select items from a soft menu.

  • Page 67: Startup Sequence

    Configuring the Kinetix 6000M System Chapter 6 Startup Sequence On initial powerup, the IPIM module performs a self test of the system. Upon successful completion, the following confirmation is displayed, followed by the firmware version and IP address. Running Self Tests .

  • Page 68: Tools Menu

    Chapter 6 Configuring the Kinetix 6000M System The following information is displayed. IPIM Information IDM Information Module - IP Address Status: Displays IDM status values. Status: - OK -Standby (OK, but no CIP connection) -Faulted -Init Fault (Requires reboot) Bus Reg Cap...

  • Page 69: Configuring The Ipim Module

    Configuring the Kinetix 6000M System Chapter 6 Configuring the IPIM Module You can include the IPIM module in your RSLogix 5000 project by connecting it to a configured Ethernet module in the Logix chassis and adding it under the Ethernet module in the I/O configuration tree. As a result, you can view the IPIM module status information in RSLogix 5000 software and use it in your Logix program.

  • Page 70: Configuring The Idm Unit

    Chapter 6 Configuring the Kinetix 6000M System Configuring the IDM Unit Setting the Node Address The node address is set by switches on each IDM unit. This address is the actual sercos node address, not an offset from the IAM module. The address is read at power up, so if the switch settings are changed while power is applied, the changes do not take effect until the next power cycle.
  • Page 71 Configuring the Kinetix 6000M System Chapter 6 In the following example (Figure 32), the Kinetix 6000 power rail contains two single-wide axis modules and one IDM system. A sercos node address is not assigned to the slot-filler or the IPIM module. However, the system identifies both modules with slot locations.
  • Page 72 Chapter 6 Configuring the Kinetix 6000M System In example 2 (Figure 33), the Kinetix 6000 power rail contains two single-wide axis modules and two IDM systems. A sercos node address is not assigned to the slot-filler or the IPIM module, but the system identifies both with slot locations.

  • Page 73: Add-On Profiles

    Configuring the Kinetix 6000M System Chapter 6 Add-on Profiles To select the IPIM module in RSLogix 5000 software, version 20, you must load an Add-on Profile from www.ab.com. To navigate to the Add-on Profiles, follow this path: • Technical Support •...
  • Page 74 Chapter 6 Configuring the Kinetix 6000M System a. From the Type pull-down menu, choose the controller type. b. From the Revision pull-down menu, choose the revision (V20). c. Type the file Name. d. From the Chassis Type pull-down menu, choose the chassis.

  • Page 75: Configure The Logix Module

    Configuring the Kinetix 6000M System Chapter 6 Configure the Logix Module Follow these steps to configure the Logix module. 1. Right-click I/O Configuration in the Controller Organizer and choose New Module. The Select Module dialog box opens. 2. Scroll to select the sercos module as appropriate for your actual hardware configuration.
  • Page 76 1 ms Up to 16 2 ms (1) The Kinetix 6000M system supports only 8 Mbps. The factory default data rate setting for all Kinetix 6000 modules is 4 Mbps. The number of axes/module is limited to the number of axes as shown in the table below.

  • Page 77: Configure The Idm Units

    Configuring the Kinetix 6000M System Chapter 6 Configure the IDM Units Follow these steps to configure the IDM units. 1. Right-click the Logix module you just created and choose New Module. The Select Module dialog box opens. 2. Scroll to select the IDM unit appropriate for your actual hardware configuration.
  • Page 78 Chapter 6 Configuring the Kinetix 6000M System 6. Click the Associated Axes tab. 7. Click New Axis. The New Tag dialog box opens. 8. Type the axis Name. AXIS_SERVO_DRIVE is the default Data Type. 9. Click Create. The axis appears under the Ungrouped Axes folder in the Controller Organizer.

  • Page 79: Configure The Motion Group

    Configuring the Kinetix 6000M System Chapter 6 Configure the Motion Group Follow these steps to configure the motion group. 1. Right-click Motion Groups in the Controller Organizer and choose New Motion Group. The New Tag dialog box opens. 2. Type the new motion group Name.

  • Page 80: Configure Axis Properties

    Chapter 6 Configuring the Kinetix 6000M System Configure Axis Properties Follow these steps to configure the Axis properties. 1. Right-click an axis in the Controller Organizer and choose Properties. The Axis Properties dialog box opens. 2. On the Drive/Motor tab, check Drive Enable Input Checking.

  • Page 81: Download The Program

    Configuring the Kinetix 6000M System Chapter 6 8. Click the Fault Actions tab. 9. Click Set Custom Stop Action. The Custom Stop Action Attributes dialog box opens and lets you set delay times for IDM units. 10. Configure the delay times.

  • Page 82: Apply Power To The System

    Chapter 7 when troubleshooting the IPIM module and IDM unit status indicators. Follow these steps to apply power to the Kinetix 6000M system. 1. Disconnect the load to the IDM units. ATTENTION: To avoid personal injury or damage to equipment, disconnect the load to the IDM units.

  • Page 83: Test And Tune The Axes

    Chapter 6 Test and Tune the Axes This procedure assumes that you have configured your Kinetix 6000M system, your Logix sercos interface module, and applied power to the system. For help using RSLogix 5000 software as it applies to testing and tuning your...
  • Page 84 Chapter 6 Configuring the Kinetix 6000M System 6. Select the desired Test (Marker/Feedback/Command & Feedback) to verify connections. The Online Command dialog box opens. Follow the on-screen test instructions. When the test completes, the Command Status changes from Executing to Command Complete.

  • Page 85: Tune The Axes

    Configuring the Kinetix 6000M System Chapter 6 Tune the Axes Follow these steps to tune the axes. 1. Verify the load is still removed from the axis being tuned. ATTENTION: To reduce the possibility of unpredictable motor response, tune your motor with the load removed first, then re-attach the load and perform the tuning procedure again to provide an accurate operational response.
  • Page 86 Chapter 6 Configuring the Kinetix 6000M System 8. Click OK. The Tune Bandwidth dialog box opens. Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected. 9. Record your bandwidth data for future reference.

  • Page 87: Safety Precautions

    Chapter Troubleshooting the Kinetix 6000M System Topic Page Safety Precautions IDM System Error Codes Interpret Status Indicators General System Anomalies IPIM Module Fault Diagnosis IDM Unit Fault Diagnosis Use a Web Browser to Monitor System Status Safety Precautions ATTENTION: Capacitors on the DC bus may retain hazardous voltages after input power has been removed.

  • Page 88: Reading The Fault Status Of The Ipim Module

    Chapter 7 Troubleshooting the Kinetix 6000M System Connecting the IPIM module into the Logix environment as an EtherNet/IP device does not disable fault reporting through the IAM module. Only the IAM fault reporting lets the Logix motion sub-system take action based on the IPIM module fault status.
  • Page 89 Troubleshooting the Kinetix 6000M System Chapter 7 Figure 34 - Message Configuration - Write 1. Set the Source field to a tag that contains the slot location for the IPIM module. The slot location valid range is 2 - 8, (assuming an 8 slot power rail). The IAM module is always in slot 1.

  • Page 90: Interpret Status Indicators

    Chapter 7 Troubleshooting the Kinetix 6000M System Interpret Status Indicators When a fault condition is detected, the appropriate status indicator will illuminate (IDM unit or IPIM module) and the IPIM module will annunciate the fault on its front panel display. Refer to...

  • Page 91: Idm Unit Status Indicators

    Troubleshooting the Kinetix 6000M System Chapter 7 Indicator Indication Description Port 1 Status of the Port is not connected Port 2 EtherNet/IP Flashing Green Port is connected and communication is occurring ports Solid Green Port is connected, but no communication is not occurring (1) A reset or cycling the power may clear a recoverable fault (depending on the state of the IDM).

  • Page 92: General System Anomalies

    Chapter 7 Troubleshooting the Kinetix 6000M System General System Anomalies These anomalies do not always result in a fault code, but may require troubleshooting to improve performance. Condition Potential Cause Possible Solution Axis or system is Unintentionally in Torque mode.

  • Page 93: Ipim Module Fault Diagnosis

    Troubleshooting the Kinetix 6000M System Chapter 7 Condition Potential Cause Possible Solution No rotation The IDM unit connections are loose or Check IDM unit wiring and connections. open. Foreign matter is lodged in the IDM unit. Remove foreign matter. The IDM unit load is excessive.

  • Page 94: Ipim Module Fault Types

    Chapter 7 Troubleshooting the Kinetix 6000M System IPIM Module Fault Types The IPIM has two fault types: resettable and non-resettable. When an IPIM module fault occurs, the fault is reported to the IAM module. The IAM module reports an IPIM fault to the Logix controller.

  • Page 95: Idm Unit Fault Diagnosis

    Troubleshooting the Kinetix 6000M System Chapter 7 IDM Unit Fault Diagnosis Logix Controller/IDM Unit Fault Behavior These RSLogix 5000 fault actions are configurable from the Axis Properties dialog box, Fault Actions tab. Table 21 - Fault Action Definitions Fault Action...
  • Page 96 Chapter 7 Troubleshooting the Kinetix 6000M System Table 22 - Exception/Fault Behavior (continued) RSLogix IPIM Display IDM Status Programmable (RSLogix Drive Fault) Indicator Potential Cause Possible Solution Fault Action Fault Behavior E06 – Positive/Negative Hard Flashing Axis moved beyond the physical travel •...

  • Page 97: Use A Web Browser To Monitor System Status

    Troubleshooting the Kinetix 6000M System Chapter 7 Table 22 - Exception/Fault Behavior (continued) RSLogix IPIM Display IDM Status Programmable (RSLogix Drive Fault) Indicator Potential Cause Possible Solution Fault Action Fault Behavior E66 – Autotune Flashing Autotune procedure failed. • Check IDM unit power/feedback wiring.
  • Page 98 Chapter 7 Troubleshooting the Kinetix 6000M System To access the web interface: 1. Using an Ethernet cable, connect your computer to one of the Ethernet ports on the IPIM module (refer to Figure 11 page 38 for location). 2. Open a web browser program and enter the IP address of the IPIM module.

  • Page 99: Before You Begin

    Chapter Removing and Replacing the Kinetix 6000M IPIM Module This chapter provides removal and replacement procedures for your Kinetix 6000M IPIM module. Refer to your Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001, or Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives User Manual, publication 2094-UM002, for other replacement procedures.

  • Page 100: Remove The Ipim Module

    Chapter 8 Removing and Replacing the Kinetix 6000M IPIM Module Remove the IPIM Module Follow these steps to remove your IPIM module from the Bulletin 2094 power rail. 1. Verify that all control and input power has been removed from the system.

  • Page 101: Replace The Ipim Module

    Removing and Replacing the Kinetix 6000M IPIM Module Chapter 8 7. Lift the bracket out of the power rail slot and remove the module from the power rail. Power Rail Guide Pin Pivot Module Upward Side View Replace the IPIM Module Follow these steps to replace the IPIM module on the Bulletin 2094 power rail.
  • Page 102 Chapter 8 Removing and Replacing the Kinetix 6000M IPIM Module Notes: Rockwell Automation Publication 2094-UM003A-EN-P - May 2012...

  • Page 103: Certification

    IDM System Safe Torque-off Example Cascading the Safe Torque-off Signal Safe Torque-off Signal Specifications The TÜV Rheinland group has approved the Kinetix 6000M integrated drive- Certification motor system for use in safety-related applications up to EN ISO 13849-1 performance level d (PLd) and category 3, SIL CL 2 per IEC EN 61508, EN 61800-5-2 and EN 62061, in which removing the motion producing power is considered to be the safe state.

  • Page 104: Category 3 Requirements According To En Iso 13849-1

    Appendix A Using the Safe Torque-off Feature with the Kinetix 6000M System Category 3 Requirements According to EN ISO 13849-1 Safety-related parts are designed with these attributes: • A single fault in any of these parts does not lead to the loss of the safety function •...

  • Page 105: Troubleshooting The Safe Torque-Off Function

    Using the Safe Torque-off Feature with the Kinetix 6000M System Appendix A ATTENTION: Permanent magnet motors may, in the event of two simultaneous faults in the IGBT circuit, result in a rotation of up to 180 electrical degrees. ATTENTION: If any of the safety enable inputs de-energize, then the SafeOffModeActiveStatus bit of the drive status word in the Axis Tag structure will be set to 1.
  • Page 106 Appendix A Using the Safe Torque-off Feature with the Kinetix 6000M System Figure 40 demonstrates when the safe torque-off mismatch is detected and a DriveHardFault is posted. Figure 40 - System Operation in the Event that the Safety Enable Inputs Mismatch...

  • Page 107: Pfd, Pfh, And Mttfd Definitions

    Using the Safe Torque-off Feature with the Kinetix 6000M System Appendix A PFD, PFH, and MTTFd Safety-related systems can be classified as operating in either a Low Demand mode, or in a High Demand/Continuous mode: Definitions • Low Demand mode: where the frequency of demands for operation made on a safety-related system is no greater than one per year or no greater than twice the proof-test frequency.

  • Page 108: European Union Directives

    Appendix A Using the Safe Torque-off Feature with the Kinetix 6000M System European Union Directives If this product is installed within the European Union or EEC regions and has the CE mark, the following regulations apply. CE Conformity Conformity with the Low Voltage Directive and Electromagnetic Compatibility (EMC) Directive is demonstrated by using harmonized European Norm (EN) standards published in the Official Journal of the European Communities.

  • Page 109: Safe Torque-Off Feature Bypass

    Using the Safe Torque-off Feature with the Kinetix 6000M System Appendix A Refer to the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002, for wiring examples. ATTENTION: This option may be suitable for performing mechanical work on the drive system or affected area of a machine only. It does not provide electrical safety.

  • Page 110: Cascading The Safe Torque-Off Signal

    Appendix A Using the Safe Torque-off Feature with the Kinetix 6000M System Figure 42 - Typical Kinetix 6000M and Kinetix 6000 Safe-off Configuration Safe-off Control Circuit Middle-drive Headers Connections (2090-XNSM-M) Last-drive Header (2090-XNSM-T) First-drive Wiring Header (2090-XNSM-W) Drive-to-Drive Safe-off Cables...

  • Page 111: Safe Torque-Off Signal Specifications

    Using the Safe Torque-off Feature with the Kinetix 6000M System Appendix A Safe Torque-off Signal This table provides specifications for the safe torque-off signals used. Specifications Attribute Value Safety inputs Input current less than10 mA Input ON voltage range 18…26.4 V DC...
  • Page 112 Appendix A Using the Safe Torque-off Feature with the Kinetix 6000M System Notes: Rockwell Automation Publication 2094-UM003A-EN-P - May 2012...
  • Page 113 Appendix Interconnect Diagram This appendix provides a wiring example for the IDM system. Topic Page IPIM Module and IDM Unit Wiring Example Rockwell Automation Publication 2094-UM003A-EN-P - May 2012...

  • Page 114: Appendix B

    Appendix B Interconnect Diagram Figure 43 - IPIM Module and IDM Unit Wiring Example 2094-SEPM-B24-S MDF-SBxxxxx-Qx8xA-S Kinetix 6000M IPIM Module Kinetix 6000M IDM Unit Cable Shield 2090-CHBIFS8-12AAxx Clamp Hybrid Cable Hybrid Cable Hybrid Cable Input Connector Output Connector Grey 2090-CTHP8 Terminator...

  • Page 115: Before You Begin

    IDM Unit Firmware Upgrade Verify the Firmware Upgrade Upgrading firmware for the Kinetix 6000M system is done by using ControlFLASH software. The procedure for upgrading the IDM units uses the sercos interface, similar to axis modules. However, upgrading firmware on the IPIM module is accomplished over the EtherNet/IP network.

  • Page 116: Configure Logix Communication

    Appendix C Upgrading the Kinetix 6000M System Firmware Configure Logix This procedure assumes that your communication method to the Logix controller is using the Ethernet protocol. It is also assumed that your Logix Communication Ethernet module has already been configured.

  • Page 117: Ipim Module Firmware Upgrade

    Upgrading the Kinetix 6000M System Firmware Appendix C 8. Click OK. The new Ethernet driver appears under Configured Drivers. 9. Click Close. 10. Minimize the RSLinx application dialog box. IPIM Module Firmware The IPIM module will not accept a firmware upgrade request when it has an...
  • Page 118 Appendix C Upgrading the Kinetix 6000M System Firmware Follow these steps to select the IPIM module to upgrade. 1. Make sure the IPIM module will accept a firmware request prior to attempting the firmware upgrade (see page 117). 2. Open your ControlFLASH software.
  • Page 119 Upgrading the Kinetix 6000M System Firmware Appendix C The Select Device to Update dialog box opens. 6. Expand your Ethernet node and EtherNet/IP network module. 7. Select the IPIM module to upgrade. 8. Click OK. The Firmware Revision dialog box opens.
  • Page 120 Appendix C Upgrading the Kinetix 6000M System Firmware The Summary dialog box opens. 11. Confirm the IPIM module catalog number and firmware revision. 12. Click Finish. This ControlFLASH warning dialog box opens. 13. Click Yes (only if you are ready).

  • Page 121: Idm Unit Firmware Upgrade

    Upgrading the Kinetix 6000M System Firmware Appendix C The Progress dialog box opens and upgrading begins. After the upgrade information is sent to the IPIM module, the module resets and performs diagnostic checking. 15. Wait for the Progress dialog box to time out.
  • Page 122 Appendix C Upgrading the Kinetix 6000M System Firmware IDM Unit Firmware Upgrade Follow these steps to select the IDM unit to upgrade. 1. Open your ControlFLASH software. You can access the ControlFLASH software by either of these methods: • From the Tools menu in RSLogix 5000 software, choose ControlFLASH.
  • Page 123 Upgrading the Kinetix 6000M System Firmware Appendix C The Select Device to Update dialog box opens. 5. Expand your Ethernet node, Logix backplane, and EtherNet/IP network module. 6. Select the IDM unit to upgrade. 7. Click OK. The Firmware Revision dialog box opens.
  • Page 124 Appendix C Upgrading the Kinetix 6000M System Firmware The Summary dialog box opens. 10. Confirm the IDM unit catalog number and firmware revision. 11. Click Finish. This ControlFLASH warning dialog box opens. 12. Click Yes (only if you are ready).

  • Page 125: Verify The Firmware Upgrade

    Upgrading the Kinetix 6000M System Firmware Appendix C The Progress dialog box opens and upgrading begins. After the upgrade information is sent to the IDM unit, the unit resets and performs diagnostic checking. 14. Wait for the Progress dialog box to time out.
  • Page 126 Appendix C Upgrading the Kinetix 6000M System Firmware Verify the Firmware Upgrade Follow these steps to verify your firmware upgrade was successful. This procedure uses an IDM unit as an example, but applies to IPIM modules too. Verifying the firmware upgrade is optional.

  • Page 127: Definitions

    If manual calculation is desired, the following procedure can be used. Topic Page Definitions Manually Sizing the Kinetix 6000M System • Control power = 120/240 single-phase AC voltage connected to the IAM Definitions unit. • IDM system control power = 42V DC (nominal) voltage from the IPIM module that is connected to all IDM units.

  • Page 128: Manually Sizing The Kinetix 6000M System

    Appendix D Kinetix 6000M System Sizing Manually Sizing the Step 1: Calculate the IDM unit control power load current for each Kinetix 6000M System IDM unit. There are three components to the control power load current for each IDM unit: •...

  • Page 129: Rockwell Automation Publication 2094-Um003A-En-P - May

    Kinetix 6000M System Sizing Appendix D Example Example System: • Common bus leader IAM module • Two AM modules • One IPIM module • Six IDM units (shown below) • 72 total meters of hybrid cable • Control power = 120V AC, 60 Hz •...
  • Page 130 Appendix D Kinetix 6000M System Sizing It is important to understand that each IDM unit passes the load current for all IDM units farther down the daisy chain. The voltage applied at each IDM unit is dependent on voltage drop in the IDM unit control power conductors of the hybrid cable.
  • Page 131 Kinetix 6000M System Sizing Appendix D • Dividing the total IDM unit load power by 42V DC assumes that all the IDM units are at the IPIM module and experience no voltage drop from the hybrid cable. This is a very liberal method that always results in an underestimate of the load current.
  • Page 132 Appendix D Kinetix 6000M System Sizing Step 3: Confirm that all IDM units connected to each IPIM module will have sufficient control power voltage. This is a complicated calculation to do accurately for the same reasons stated in step 2. The purpose of this step is to confirm that the last IDM unit in the daisy chain has sufficient voltage to operate.
  • Page 133 Kinetix 6000M System Sizing Appendix D Example The equations in step 3 are applied to augment the table from the previous step (shown below). The estimate of the voltage assuming all IDM units are at the end of the total cable length is included in the last column.
  • Page 134 Appendix D Kinetix 6000M System Sizing Table 24 - Max Cable Length per IPIM Module using Motion Analyzer (no digital inputs) Number of IDM Units   100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100...
  • Page 135 Kinetix 6000M System Sizing Appendix D Step 4: Estimate the IAM control power load current and the power dissipation for each IPIM module based on the total IDM unit control power load. See the Kinetix Rotary Motion Specifications Technical Data, publication GMC-TD001, for specifications on IPIM module dissipation and IPIM module control power loading.
  • Page 136 Appendix D Kinetix 6000M System Sizing Step 5: Sum the IAM control power load current for all devices on the power rail and confirm that the total IAM control power load current is less than the specified IAM and power rail limit.
  • Page 137 Kinetix 6000M System Sizing Appendix D Step 6: Determine if a LIM can be used to supply the IAM control power load current, or if individual discrete components must be used. In order to use a LIM for the control power interface to the IAM, the control power load current calculated in step 5 must be less than the values listed in the Line Interface Module (LIM) Installation Instructions, publication 2094-IN005.
  • Page 138 Appendix D Kinetix 6000M System Sizing Example The six IDM units in this example are listed below with the corresponding output power. The equation for bus current is used to calculate the bus current values for each IDM unit. The DC bus voltage is 675V DC. The DC bus current as a percentage of the IPIM module rating is 12.93 / 24 = 53.9%.
  • Page 139 Index communication configurations typical 16 about this publication 7 CompactLogix sercos module 115 absolute position 52 compatibility accel/decel anomalies 92 component 18 accessories DriveExplorer 18 catalog number explanation 17 human interface module (HIM) 18 acronyms 7 software 18 additional resources 7 compliance add-on profiles 73 agency 19...
  • Page 140 Index digital input cable examples 48 grounding the IDM system 54 connectors 45 sensor connections 46 specifications 49 disable drive 95 hardware configurations display typical 11 information 67 hardware enable input 83 startup 67 headers tools 68 motion-allowed jumper 40 download program 81 heat dissipation 24 drive status (D) indicator 91...
  • Page 141 Index leader IAM 14 safe torque-off low voltage directive 108 bypass 109 connector 40 feature, IDM unit 108 motion-allowed jumper 109 operation 104 manually sizing the IDM system 128 PFD, PFH and MTTFd 107 module mounting order 30 specifications 111 module properties troubleshooting 105 drive modules 77...
  • Page 142 Index troubleshooting ControlFLASH 121 disable drive 95 error code E49 105 general system anomalies 92 abnormal noise 93 accel/decel 92 axis unstable 92 IDM unit overheating 93 no rotation 93 noise 92 sercos 92 velocity 92 Logix/drive fault behavior 95 safe torque-off 105 safety precautions 87 shutdown 95...
  • Page 144 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support/, 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.

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