Allen-Bradley 2094-AL15S Installation Instructions Manual
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Allen-Bradley 2094-AL15S Installation Instructions Manual

Allen-Bradley 2094-AL15S Installation Instructions Manual

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Installation Instructions
Line Interface Module
Catalog Numbers 2094-AL15S, 2094-AL25S, 2094-AL50S, 2094-AL75S, 2094-BL10S, 2094-BL25S, 2094-BL50S,
2094-BL75S, 2094-XL75S-C1, 2094-XL75S-C2, 2094-AL09, 2094-BL02
About the Line Interface Module
Topic
About the Line Interface Module
Important User Information
Catalog Number Explanation
Before You Begin
Connector Data
Understanding Signal Specifications
Install the Line Interface Module
Wiring Diagrams
Block Diagrams
Post-installation
Status Indicators
Specifications
Additional Resources
The Bulletin 2094 line interface module is designed to replace many of the
common-input power devices required for your servo drive system. Use these
instructions when mounting your module to the panel or wiring your module
into the system.
For installation information regarding equipment and accessories excluded here,
see
Additional Resources
products.
on
page 56
or the information available for those
Page
1
2
3
3
9
17
27
43
45
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56

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  • Page 1 Installation Instructions Line Interface Module Catalog Numbers 2094-AL15S, 2094-AL25S, 2094-AL50S, 2094-AL75S, 2094-BL10S, 2094-BL25S, 2094-BL50S, 2094-BL75S, 2094-XL75S-C1, 2094-XL75S-C2, 2094-AL09, 2094-BL02 Topic Page About the Line Interface Module Important User Information Catalog Number Explanation Before You Begin Connector Data Understanding Signal Specifications...

  • Page 2: Important User Information

    2 Line Interface Module 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.

  • Page 3: Catalog Number Explanation

    Catalog numbers and descriptions for the line interface module are listed in the table below. Input Current Cat. No. Description Voltage Rating 2094-AL15S 15 A 2094-AL25S 25 A 230V • 230V AC auxiliary power output. 2094-AL50S 50 A • Customer-configurable branch-circuit •...
  • Page 4 4 Line Interface Module Mounting Requirements The following requirements apply when preparing to mount your line interface module: ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it.
  • Page 5 Line Interface Module 5 Figure 1 - Minimum Clearance Requirements (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Clearance for Airflow and Installation 50.8 mm (2.0 in.) min Line Interface Module (catalog number 2094-ALxxS is shown) MAIN VAC Clearance left of Clearance right of module module is not required.
  • Page 6 6 Line Interface Module Establishing Noise Zones Observe these guidelines when a 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx line interface module is used in the system and mounted left of the drive with the AC (EMC) line filter mounted above the module: •...
  • Page 7 Line Interface Module 7 Observe these guidelines when a 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx line interface module is used in the system and mounted right of the drive with the AC (EMC) line filter mounted behind the line interface module: • The clean zone (C) is to the left and beneath the drive system (gray wireway).
  • Page 8 8 Line Interface Module Observe these guidelines when a 2094-AL09 or 2094-BL02 line interface module is used in the drive system: • The clean zone (C) is to the right and beneath the drive system (gray wireway). • The dirty zone (D) is to the left and above the drive, and above and below the line interface module (black wireway).

  • Page 9: Connector Data

    Line Interface Module 9 Connector Data Use the figures below to locate the line interface module connectors and indicators. Figure 6 - Connectors and Indicators (catalog numbers 2094-AL S, 2094-BL7 S, and 2094-XL75S-C ) Auxiliary Power Input (APL) Connector L2/N Control Power Output (CPL) Connector CTRL2 CTRL1...
  • Page 10 10 Line Interface Module Figure 7 - Connectors and Indicators (catalog numbers 2094-AL09 and 2094-BL02) Line Interface Module, Top View (catalog number 2094-AL09 is shown) Control Power Output L2/N (CPL) Connector VAC Line MBRK PWR VAC Load MBRK COM (IPL) Connector MBRK PWR (OPL) Connector MBRK COM...
  • Page 11 Line Interface Module 11 Line Interface Module Connectors Table 1 - Connectors (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Designator Description Connector Status I/O 21-pin (plugable) terminal block VAC LINE input power 4-position plug/header VAC LOAD output power 4-position plug/header Brake and I/O power output (24V DC) 6-position plug/header...

  • Page 12: Table Of Contents

    12 Line Interface Module Your IOL connector terminals may be staggered, as in Figure 8, or straight, as in Figure Figure 8 - Pin Orientation for the IOL (21-pin) Connector, Staggered I/O (IOL) Connector Access Door (door open) IO_PWR1 IO_PWR1 IO_COM1 IO_PWR1 IO_COM1...
  • Page 13 Line Interface Module 13 Figure 10 - IOL (26-pin) Connector Pinouts (catalog numbers 2094-AL09 and 2094-BL02) IOL Pin Description Signal IOL Pin Description Signal Reserved – Reserved – Reserved – Contactor auxiliary contact (NC) #1 IN CONSTAT_11 Reserved – Contactor auxiliary contact (NC) #2 IN CONSTAT_21 24V contactor coil negative COIL_A2...
  • Page 14 14 Line Interface Module Control Power Output Connector These tables provide signal descriptions and pinouts for the control power (2-pin) CPL connector. Table 4 - CPL (2-pin) Connector Pinouts (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) CPL Pin Description Signal CTRL 2...
  • Page 15 Line Interface Module 15 VAC LINE Connector These tables provide signal descriptions and pinouts for the 3-phase input power (4-pin) IPL connector. Table 8 - IPL (4-pin) Connector Pinouts (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) IPL Pin Description Signal Chassis ground...
  • Page 16 16 Line Interface Module VAC LOAD Connector These tables provide signal descriptions and pinouts for the 3-phase output power (4-pin) OPL connector. Table 10 - OPL (4-pin) Connector Pinouts (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) OPL Pin Description Signal Chassis ground...

  • Page 17: Block Diagrams

    Line Interface Module 17 Understanding Signal A description of the I/O (IOL), brake power (P1L/PSL), control power (CPL), and auxiliary power (P2L) signals and circuit specifications is provided on the Specifications following pages. See the Block Diagrams beginning on page 45 for your line interface modules schematic.

  • Page 18: Specifications

    18 Line Interface Module For more information regarding the Bulletin 100S-C85x-14 contactor, see the Safety Products Catalog, website http://www.ab.com. The 2094-AL09 and 2094-BL02 line interface module I/O (IOL) signals include the contactor coil, status contacts, and I/O power supply. Table 14 - IOL (26-pin) Signal Specifications (catalog numbers 2094-AL09 and 2094-BL02) IOL Pin Signal...

  • Page 19: Rockwell Automation Publication 2094-In005H-En-P - October

    Line Interface Module 19 Contactor Coil For safety reasons, the internal wiring is arranged so that if the control power (CPL) circuit breaker (CB2) trips, the opening contact will interrupt the coil voltage and remove main input power to the drive. The 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-Cx line interface modules use an AC coil and a DC interface module allows the contactor coil to be controlled by the 24V DC output of the drive.

  • Page 20: Constat

    20 Line Interface Module Safety Contactor The safety contactor includes three main contacts (normally-open) that close when coil power is applied. The three auxiliary (safety) contacts (used in 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-Cx line interface modules) are volt-free, positively-guided, and mechanically-latched. A fourth volt-free normally-open contact is also available, but is not safety rated and IMPORTANT should not be used in a safety string.

  • Page 21: Constat

    Line Interface Module 21 The four auxiliary (safety) contacts (used in 2094-AL09 and 2094-BL02 line interface modules) are volt-free, positively-guided, and mechanically-latched. Figure 16 - IOL Contactor Status (catalog numbers 2094-AL09 and 2094-BL02) IOL-15 IOL-6 CONSTAT_12 CONSTAT_11 IOL-16 IOL-7 CONSTAT_21 CONSTAT_22 IOL-17 IOL-8...
  • Page 22 22 Line Interface Module Figure 17 - IOL Power Supply (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Line Interface Module IOL-1 IOL-3 IO_PWR1 IOL-5 24V+ AC Line Filter 480 W, 20 A Power Supply IOL-2 24V- IOL-4 IO_COM1 IOL-6 P1L-1 P1L-3...
  • Page 23 Line Interface Module 23 I/O Power Supply (catalog numbers 2094-AL09 and 2094-BL02) The I/O power supply on 2094-AL09 and 2094-BL02 line interface modules is capable of supplying 24V @ 5.7 A for PLC I/O functions and switches. It is available to the user via the IOL (26-pin) D-sub connector. A single-phase filter is placed on the input to the supply to provide conditioning.
  • Page 24 24 Line Interface Module Brake Power Supply (catalog numbers 2094-AL09 and 2094-BL02) A +24V DC supply is provided on the PSL connector of the 2094-AL09 and 2094-BL02 line interface modules for mechanical motor brakes and the Bulletin 2090 resistive-brake module I/O. The supply has over-current protection and is isolated from all other supplies.
  • Page 25 Line Interface Module 25 Control Power Supply The control power supply on 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-C2 line interface modules is protected by FB1 and one 2-pole circuit breaker (CB2). The control power supply on 2094-AL09 and 2094-BL02 line interface modules is protected by one 3-pole circuit breaker (CB2).
  • Page 26 26 Line Interface Module Auxiliary Power Output An auxiliary 230V AC output is provided for use with the Bulletin 2090 resistive-brake module (RBM) or other customer requirement as needed on the P2L connector. This supply is present with 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-C2 line interface modules.
  • Page 27 Line Interface Module 27 Install the Line Interface This procedure assumes that you have prepared your panel and understand how to bond your system. Module See the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001, for information on high-frequency bonding and reducing electrical noise.

  • Page 28: Product Dimensions

    28 Line Interface Module Product Dimensions Figure 24 - Mounting Dimensions (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) 259.8 (10.23) CTRL2 CTRL1 AUX2 AUX2 AUX1 AUX1 Dimensions are in millimeters (inches) I/O_COM (catalog number 2094-XL75S-Cx is shown) I/O_PWR I/O_COM I/O_PWR I/O_COM...
  • Page 29 Line Interface Module 29 Figure 25 - Mounting Dimensions (catalog number 2094-AL09) (12.8) 184.7 Dimensions are in millimeters (inches) 187.7 (7.27) (7.39) (7.75) 3x Ø 16 6x Ø 7.9 12.7 187.7 (0.63) (0.31) (0.87) (0.5) (7.39) 3x 28.7 (1.13) (0.35) (8.86) 253.1 (9.97)
  • Page 30 30 Line Interface Module Figure 26 - Mounting Dimensions (catalog number 2094-BL02) (15.75) (3.9) 2x 206 (8.11) Dimensions are in millimeters (inches) (11.02) (10.9) 2x 28.5 (1.2) 2x 40.4 27.6 (1.59) (1.09) (11.02) 6x Ø 7.9 3x Ø 16 (0.31) (0.63) 12.7 (11.37)
  • Page 31 Line Interface Module 31 Wire the Line Interface Module This section provides wiring requirements for each connector on the line interface module. The National Electrical Code and local electrical codes take precedence over the values IMPORTANT and methods provided. Wire should be copper with 75 °C (167 °F) minimum rating. Phasing of main AC power is arbitrary and earth-ground connection is required for safe and proper operation.
  • Page 32 32 Line Interface Module Figure 28 - Wiring Requirements (catalog numbers 2094-AL09 and 2094-BL02) Connects to Terminals Recommended Strip Length Torque Value Wire Size Cat. No. Description mm (in.) N•m (lb•in) Signal (AWG) IPL-1 IPL-2 VAC LINE IPL-3 IPL-4 2094-AL09 10.0 0.5…0.6 (230V)
  • Page 33 Line Interface Module 33 Wiring Guidelines Use these guidelines as a reference when wiring the connectors on your line interface module. Connector Data page 9 for the connector locations of your line interface IMPORTANT module. When tightening screws to secure the wires, see the tables beginning on page 31 torque values.
  • Page 34 34 Line Interface Module Wiring the Auxiliary-input Power (APL) Connector The auxiliary-input power (APL) connector is present only on the 2094-XL75S-Cx line interface modules. Figure 29 - Line Interface Module (APL connector) Line Interface Module, Top View (catalog number 2094-XL75S-Cx is shown) Table 15 - Auxiliary Input Power (APL) Connector Recommended...
  • Page 35 Line Interface Module 35 Wiring the VAC LINE (IPL) Connector Figure 30 - Line Interface Module (IPL connector) Line Interface Module, Top View (catalog number 2094-XL75S-Cx is shown) ATTENTION: The input power for Bulletin 2094 line interface modules must come from a grounded configuration.
  • Page 36 36 Line Interface Module Wiring the VAC LOAD (OPL) Connector Figure 31 - Line Interface Module (OPL connector) Line Interface Module, Top View (catalog number 2094-XL75S-Cx is shown) The 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-Cx line interface modules are capable IMPORTANT of connecting to multiple drives, providing each drive has its own line filter and the maximum current specification is not exceeded.
  • Page 37 Line Interface Module 37 Wiring the Control Power Output (CPL) Connector Figure 32 - Line Interface Module (CPL connector) Line Interface Module, Top View (catalog number 2094-XL75S-Cx is shown) Table 21 - Control Power Output (CPL) Connector (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Recommended Wire Size Strip Length...
  • Page 38 38 Line Interface Module Wiring the Auxiliary Power Output (P2L) Connector Figure 33 - Line Interface Module (P2L connector) Line Interface Module, Top View (catalog number 2094-XL75S-Cx is shown) Table 23 - Auxiliary Power Output (P2L) Connector (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Recommended Wire Size Strip Length...
  • Page 39 Line Interface Module 39 Wiring the Brake Power Output (24V DC) Connector Figure 34 - Line Interface Module (24V connector) Line Interface Module, Top View (catalog number 2094-XL75S-Cx is shown) Table 24 - Brake Power Output (24V DC) Connector (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Recommended Wire Size Strip Length...
  • Page 40 Figure 36 - Branch-circuit Operation (catalog numbers 2094-AL S and 2094-BL S) Cat. No. Branch-circuit Protection Configurations Module Operation • 2094-AL15S, 2094-AL25S, 2094-AL50S, Closing CB1 removes 3-phase power to the device (servo Input VAC to CB2 and CB3 before CB1 2094-AL75S...

  • Page 41: Constat

    Line Interface Module 41 2. Allow five minutes for the 24V power supplies 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.
  • Page 42 42 Line Interface Module 9. Move the CB2/CB3 wiring harness (P4) to the J4_B (optional) connection. 10. Fully insert the P4 connector into the J4_B housing until latched. CB2/CB3 Wiring Harness in Default (before CB1) Configuration Line Interface Module (catalog number 2094-ALxxS is shown) CB2/CB3 Wiring Harness in Optional (after CB1) Configuration...

  • Page 43: Io_Com1

    Line Interface Module 43 Wiring Diagrams In this example configuration, the servo drive has input power, brake power, and the start/stop string wired from 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx line interface modules. These modules do not contain an AC line filter, so an external filter is added between the module and the drive.

  • Page 44: Io_Pwr1

    44 Line Interface Module In the example configuration below, the servo drive has input power, brake power, and the start/stop string wired from a 2094-AL09 or 2094-BL02 line interface module. These modules contain an AC line filter, so an external filter is not required.
  • Page 45 Line Interface Module 45 Block Diagrams These are block diagrams for the Bulletin 2094 line interface modules. Figure 39 - Block Diagram (catalog number 2094-AL S) Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 46 46 Line Interface Module Figure 40 - Block Diagram (catalog number 2094-BL S) Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 47 Line Interface Module 47 Figure 41 - Block Diagram (catalog number 2094-XL75S-C ) Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 48 48 Line Interface Module Figure 42 - Block Diagram (catalog number 2094-AL09) Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 49 Line Interface Module 49 Figure 43 - Block Diagram (catalog number 2094-BL02) Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 50 Removing and Replacing line interface Module Internal Components Installation Instructions, publication 2094-IN009. Table 26 - Field-Replaceable Components (catalog numbers 2094-AL S, 2094-BL S, and 2094-XL75S-C ) Reference Allen-Bradley Bussmann Cat. No. Quantity Description Designator...
  • Page 51 Line Interface Module 51 Table 28 - Accessories Cat. No. Description Accessory Cat. No. Connector Set. Includes I/O (IOL), VAC LINE (IPL), VAC LOAD (OPL), control power (CPL), 230V auxiliary output (P2L), 24V brake power (P1L), and 230V auxiliary input (APL) 2094-XNLIM-2 replacement connectors for these catalog numbers.

  • Page 52: Coil_E1

    52 Line Interface Module Specifications This section provides power, fuse, weight, and environmental specifications for the line interface modules. Power Specifications Table 30 - Power Specifications (catalog numbers 2094-AL S and 2094-BL S) 2094-AL S (230V) 2094-BL S (460V) Designators Attribute AL15S AL25S...

  • Page 53: Coil_E2

    Line Interface Module 53 Table 31 - Power Specifications (catalog numbers 2094-XL75S-C ) Designators Attribute 2094-XL75S-C1 (230/460V) 2094-XL75S-C2 (230/460V) AC input voltage 195…520V rms 3-phase (230…460V nom) VAC LINE (IPL) Connector AC input frequency 47…63 Hz VAC LOAD Main AC output current (rms) 75 A (OPL) connector Auxiliary AC input voltage...
  • Page 54 54 Line Interface Module Table 33 - Power Dissipation Specifications Dissipation at 100% of Rated Power Output Cat. No. (watts) 2094-AL09 2094-ALxxS 52.5 2094-BL02 2094-BLxxS 42.9 2094-XL75S-Cx 52.5 Fuse Specifications Use Class CC, J, L, or R fuses with current rating as indicated in the table below. The table below lists fuse examples recommended for use with 2094-AL09 and 2094-BL02 line interface modules.

  • Page 55: General Specifications

    Line Interface Module 55 General Specifications Table 35 - Environmental Specifications Attribute Value (operational range) Value (storage range) 0…50 °C (32…122 °F) -40…70 °C (-40…158 °F) Temperature Humidity 5…95% noncondensing 5…95% noncondensing 1000 m (3281 ft) 3000 m (9843 ft) during transport The line interface module can operate at elevations up to 1000 m (3300 ft) without derating;...

  • Page 56: Additional Resources

    National Electrical Code, published by the National Fire Protection Association of An article on wire sizes and types for grounding electrical equipment. Boston, MA Allen-Bradley® Industrial Automation Glossary, publication AG-7.1 A glossary of industrial automation terms and abbreviations. You can view or download publications at http://www.rockwellautomation.com/literature.
  • Page 57 Line Interface Module 57 Notes: Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 58 58 Line Interface Module Notes: Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 59 Line Interface Module 59 Notes: Rockwell Automation Publication 2094-IN005H-EN-P - October 2012...
  • Page 60 Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/. Allen-Bradley, Kinetix, RSLogix, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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