Page 1 Kinetix 6000 Multi-axis Servo Drive Catalog Numbers 2094-AC05-MP5, 2094-AC05-M01, 2094-AC09-M02, 2094-AC16-M03, 2094-AC32-M05, 2094-BC01-MP5, 2094-BC01-M01, 2094-BC02-M02, 2094-BC04-M03, 2094-BC07-M05 2094-AC05-MP5-S, 2094-AC05-M01-S, 2094-AC09-M02-S, 2094-AC16-M03 -S, 2094-AC32-M05-S, 2094-BC01-MP5-S, 2094-BC01-M01-S, 2094-BC02-M02-S, 2094-BC04-M03-S, 2094-BC07-M05-S 2094-AMP5, 2094-AM01, 2094-AM02, 2094-AM03, 2094-AM05, 2094-BMP5, 2094-BM01, 2094-BM02, 2094-BM03, 2094-BM05 2094-AMP5-S, 2094-AM01-S, 2094-AM02-S, 2094-AM03-S, 2094-AM05-S, 2094-BMP5-S, 2094-BM01-S, 2094-BM02-S,...
Page 2 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.
Page 3: Table Of Contents
Table of Contents Preface About This Publication......9 Who Should Use this Manual ......9 Conventions Used in This Manual .
Page 4 Table of Contents Understanding IAM/AM Signal Specifications... . 60 Digital Inputs ....... . 60 SERCOS Connections .
Page 5 Table of Contents Wiring Feedback and I/O Connectors....108 Connecting Premolded Motor Feedback Cables ..108 Wiring Panel-mounted Breakout Board Kits ..109 Wiring Low-profile Connector Kits .
Page 6 Table of Contents Appendix A Specifications and Dimensions Introduction........169 Power Specifications .
Page 7 Table of Contents Appendix D DC Common Bus Applications Introduction ........231 Before You Begin .
Page 8 Table of Contents Publication 2094-UM001A-EN-P — September 2006...
Page 9: Preface
Kinetix 6000 drive with a SERCOS interface module. If you do not have a basic understanding of the Kinetix 6000 drive, contact your local Rockwell Automation sales representative before using this product, for information on available training courses. Conventions Used in This The conventions starting below are used throughout this manual.
Page 10: Additional Resources
A glossary of industrial automation terms and abbreviations Rockwell Automation Industrial Automation Glossary AG-7.1 You can view or download publications at http://literature.rockwellautomation.com. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. Publication 2094-UM001A-EN-P — September 2006...
Page 11: Start
Chapter Start Introduction Use this chapter to become familiar with the Kinetix 6000 drive components. This chapter also reviews design and installation requirements for Kinetix 6000 drive systems. Topic Page Introduction About the Kinetix 6000 Drive System Catalog Number Explanation Agency Compliance Publication 2094-UM001A-EN-P —...
Page 12: About The Kinetix 6000 Drive System
Start About the Kinetix 6000 The Kinetix 6000 multi-axis servo drive is designed to provide a Kinetix Integrated Motion solution for applications with output power Drive System requirements between 3 and 45 kW (4 and 49 A). Kinetix 6000 Drive System Overview Kinetix 6000 Catalog Numbers Description...
Page 13 Start Typical Kinetix 6000 system installations include three-phase ac configurations, with and without the line interface module (LIM), and dc common bus configurations. To avoid personal injury due to electrical shock, place a slot SHOCK HAZARD filler module (catalog number 2094-PRF) in all empty slots on the power rail.
Page 14 Start Typical Kinetix 6000 System Installation (without LIM) Three-phase Logix Controller Programming Network Input Power Logix SERCOS interface Module Logix Platform Line (ControlLogix is shown) Disconnect Device RSLogix 5000 Software Input Kinetix 6000 Multi-axis Servo Drive System Fusing Single-phase Control Power Magnetic SERCOS Fiber-optic Ring Contactor...
Page 15: Appendix D
Start Typical DC Common Bus System Installation Logix Controller Programming Network Kinetix 6000 Multi-axis Servo Drive System Logix SERCOS interface Module Three-phase AC Line Filter SERCOS interface Input Power 2090-XXLF-xxxx Logix Platform RSLogix 5000 (ControlLogix is shown) Software Tx (rear) Rx (front) SERCOS Fiber-optic Ring 115/230V Control Power...
Page 16: Catalog Number Explanation
Start Catalog Number Kinetix 6000 drive catalog numbers and descriptions are listed in the Explanation table below. Kinetix 6000 Drive Catalog Numbers Catalog Number Catalog Number Integrated Axis Modules (230V (with safe-off feature) (without safe-off feature) Kinetix 6000, IAM, 230V, 3 kW converter, 5 A inverter 2094-AC05-MP5-S 2094-AC05-MP5 Kinetix 6000, IAM, 230V, 3 kW converter, 9 A inverter...
Page 17: Ce Requirements (System Without Lim)
Start For more information on electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001. CE Requirements (System without LIM) To meet CE requirements when your Kinetix 6000 system does not include the line interface module (LIM), the following requirements apply.
Page 18 Start Publication 2094-UM001A-EN-P — September 2006...
Page 19: Planning The Kinetix 6000 Drive System Installation
Chapter Planning the Kinetix 6000 Drive System Installation Introduction This chapter describes system installation guidelines used in preparation for mounting your Kinetix 6000 drive components. Topic Page Introduction System Design Guidelines Minimizing Electrical Noise Plan the installation of your system so that you can perform all ATTENTION cutting, drilling, tapping, and welding with the system removed from the enclosure.
Page 20: System Design Guidelines
Planning the Kinetix 6000 Drive System Installation System Design Guidelines Use the information in this section when designing your enclosure and planning to mount your system components on the panel. For on-line product selection and system configuration tools, including AutoCAD (DXF) drawings of the product, refer to http://www.ab.com/e-tools.
Page 21: Transformer Selection
Planning the Kinetix 6000 Drive System Installation Transformer Selection The integrated axis module (IAM) does not require an isolation transformer for three-phase input power. However, a transformer may be required to match the voltage requirements of the controller to the available service.
Page 22: Circuit Breaker/Fuse Selection
Planning the Kinetix 6000 Drive System Installation Circuit Breaker/Fuse Selection The Kinetix 6000 system utilizes internal short circuit output protection and is suitable for use on a circuit capable of delivering up to 100,000 amperes, when protected by class CC, J, L, and R fuses. Circuit breakers with adequate widthstand and interrupt ratings, as defined in NEC 2002, article 110.9 and 110.10, are also permitted.
Page 23: Enclosure Selection
Planning the Kinetix 6000 Drive System Installation Enclosure Selection The following example is provided to assist you in sizing an enclosure for your Kinetix 6000 system. The example system consists of the following components: • 6-axis Kinetix 6000 servo drive system •...
Page 24 Planning the Kinetix 6000 Drive System Installation ControlLogix System Heat Dissipation Example Backplane Power Enclosure Heat Dissipation Description Component Load watts watts 1756-M08SE 8-axis SERCOS interface module 1756-L55M12 5555 ControlLogix processor 1756-IB16D 16 -point input module 0.84 1756-OB16D 16 -point output module 4.64 1756-ENBT Ethernet communications module...
Page 25 Planning the Kinetix 6000 Drive System Installation The maximum ambient rating of the Kinetix 6000 system is 50 °C (122 °F) and if the maximum environmental temperature is 30 °C (86 °F) then Q=606 and T=20 in the equation below. 0.38 606 6.59m 2 ≈...
Page 26: Minimum Clearance Requirements
Planning the Kinetix 6000 Drive System Installation Minimum Clearance Requirements This section provides information to assist you in sizing your cabinet and positioning your Kinetix 6000 system components. Mount the module in an upright position. Do not mount the IMPORTANT module on its side.
Page 27: Minimizing Electrical Noise
Planning the Kinetix 6000 Drive System Installation Minimizing Electrical This section outlines best practices which minimize the possibility of noise-related failures as they apply specifically to Kinetix 6000 system Noise installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001.
Page 28 Planning the Kinetix 6000 Drive System Installation The illustrations that follow show details of recommended bonding practices for painted panels, enclosures, and mounting brackets. Recommended Bonding Practices for Painted Panels Stud-mounting the Subpanel Stud-mounting a Ground Bus to the Enclosure Back Wall or Chassis to the Subpanel Subpanel Back Wall of...
Page 29: Bonding Multiple Subpanels
Planning the Kinetix 6000 Drive System Installation Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path.
Page 30: Establishing Noise Zones
Planning the Kinetix 6000 Drive System Installation Establishing Noise Zones Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or -XL75S-Cx) is used in the Kinetix 6000 system and mounted left of the IAM with the ac (EMC) line filter mounted above the LIM: •...
Page 31 Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or -XL75S-Cx) is used in the Kinetix 6000 system and mounted right of the IAM with the ac (EMC) line filter mounted behind the IAM: •...
Page 32 Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when a LIM (2094-ALxxS or -XLxxS-Cx) is used in the Kinetix 6000 system and mounted right of the drive with the ac (EMC) line filter mounted behind the LIM: •...
Page 33 Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when a LIM (2094-ALxxS, -BLxxS, or -XL75S-Cx) is used in a dc common bus configuration and the follower IAM is mounted below the leader IAM: Keep the dc common bus cable (very dirty) segregated from all other cables (not in a wireway).
Page 34 Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when a LIM (2094-AL09 or -BL02) is used in the Kinetix 6000 system and mounted left of the IAM: This layout is preferred due to the reduced size of the very dirty zone. •...
Page 35 Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when a LIM (2094-AL09 or -BL02) is used in the Kinetix 6000 system and mounted above the IAM: • The clean zone (C) is to the right and beneath the Kinetix 6000 system (grey wireway).
Page 36 Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when individual input power components are used in the Kinetix 6000 system and the LIM (2094-xLxx or -xLxxS-xx) is not used: • The clean zone (C) is beneath the Kinetix 6000 system and includes the I/O wiring, feedback cable, and dc filter (grey wireway).
Page 37: Cable Categories For Kinetix 6000 Systems
Planning the Kinetix 6000 Drive System Installation Observe the following guidelines when installing your 1756-MxxSE SERCOS interface module: • The clean zone (C) is beneath the less noisy modules (I/O, analog, encoder, registration, etc. (grey wireway). • The dirty zone (D) is above and below the power supply and noisy modules (black wireway).
Page 38 Planning the Kinetix 6000 Drive System Installation Integrated Axis Module or Axis Module (inverter side) Zone Method Wire/Cable Connector Very Ferrite Shielded Dirty Clean Dirty Sleeve Cable U, V, W (motor power) MBRK-, MBRK+ (motor brake) MBRK-, MBRK+ (motor brake) 1326AB motors with resolver feedback DBRK-, DBRK+ (resistive brake) COM, PWR (24V dc), filtered...
Page 39: Noise Reduction Guidelines For Drive Accessories
Planning the Kinetix 6000 Drive System Installation Resistive Brake Module Zone Method Wire/Cable Connections Very Ferrite Shielded Dirty Clean Dirty Sleeve Cable Resistive brake module coil power TB3-6 and TB3-7 TB1-1...-5 Resistive brake module I/O and TB3-8 Resistive brake module TB1 and TB2 drive and motor power 230V power...
Page 40 Planning the Kinetix 6000 Drive System Installation External Shunt Resistor Observe the following guidelines when mounting your external shunt resistor outside the enclosure: • Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI.
Page 41 Planning the Kinetix 6000 Drive System Installation When mounting your shunt module inside the enclosure, follow these additional guidelines: • Metal-clad modules can be mounted anywhere in the dirty zone, but as close to the Kinetix 6000 system as possible. •...
Page 42 Planning the Kinetix 6000 Drive System Installation Resistive Brake Modules Observe the following guidelines when mounting your resistive brake module (RBM): • Mount circuit components and wiring in the dirty zone or in an external shielded enclosure. If mounting the RBM in a separate ventilated shielded enclosure, run wiring inside metal conduit to minimize the effects of EMI and RFI.
Page 43: Mounting The Kinetix 6000 Drive System
Chapter Mounting the Kinetix 6000 Drive System Introduction This chapter provides the system installation procedures for mounting your Kinetix 6000 drive components to the panel. Topic Page Introduction Determining Mounting Order Mounting the Modules Mounting the External Shunt Module The procedures in this chapter assume you have prepared your panel and understand how to bond your system.
Page 44: Installing The 2094 Power Rail
Mounting the Kinetix 6000 Drive System Installing the 2094 Power Rail The Kinetix 6000 power rail comes in lengths to support one integrated axis module (IAM), and up to seven additional axis modules (AM) or shunt module (SM). The connector pins for each slot are covered by a protective boot.
Page 45: Mounting The Modules
Mounting the Kinetix 6000 Drive System The integrated axis module (IAM) must be positioned in the IMPORTANT leftmost slot of the power rail. Position your axis modules (AM), shunt module (SM), and slot fillers (PRF) to the right of the IAM. The SM must be installed to the right of the last AM.
Page 46 Mounting the Kinetix 6000 Drive System 4. Hang the mounting bracket from the slot on the power rail. Mounting Bracket Power Rail Slot Slots for additional axis modules, shunt module, or slot filler. Integrated Axis Module Power Rail 5. Pivot module downward and align the guide pins on the power rail with the guide pin holes in the back of the module.
Page 47 Mounting the Kinetix 6000 Drive System 6. Gently push the module against the power rail connectors and into the final mounting position. Bracket secured in slot. Power Rail Integrated Axis Module 7. Use 2.26 Nm (20 lb-in.) torque to tighten the mounting screws. Bottom front view of Bottom front view of single-wide AM, SM, or PRF...
Page 48: Mounting The External Shunt Module
Mounting the Kinetix 6000 Drive System Mounting the External If your Kinetix 6000 drive requires a means of dissipating regenerative energy that exceeds the capacity of the 2094 shunt module, install a Shunt Module Bulletin 1394 external shunt module. To avoid the hazard of shock or burn and ignition of flammable BURN HAZARD material, appropriate guarding must be provided.
Page 49: Kinetix 6000 Connector Data
Chapter Kinetix 6000 Connector Data Introduction This chapter provides power, feedback, and I/O connector locations and signal descriptions for your Kinetix 6000 drive. Topic Page Introduction Locating IAM/AM Connectors and Indicators Understanding IAM/AM Signal Specifications Understanding Feedback Specifications Locating Shunt Module Connectors and Indicators Publication 2094-UM001A-EN-P —...
Page 50: Locating Iam/Am Connectors And Indicators
Kinetix 6000 Connector Data Locating IAM/AM Although the physical size of the 460V modules is larger than the 230V Connectors and Indicators modules, the location of the connectors and indicators is identical. Integrated Axis Module Connectors and Indicators Integrated Axis Module, Top View (2094-AM05-MP5-S is shown) Motor Cable Shield Clamp...
Page 51 Kinetix 6000 Connector Data Axis Module Connectors and Indicators Axis Module, Top View (2094-AMP5-S is shown) Motor Cable Shield Clamp Motor Power (MP) Connector MBRK - MBRK + Safe-off Motor/Resistive Brake (SO) Connector (BC) Connector DBRK - (present only on the 2094-xMxx-S) DBRK + BAUD RATE...
Page 52: Safe-Off Connector Pinout
Kinetix 6000 Connector Data Integrated Axis Module/Axis Module Connectors Present on Designator Description Connector IAM or AM User I/O (drive) 26-pin high-density D-shell IAM/AM Motor feedback 15-pin high-density D-shell (female) IAM/AM Auxiliary feedback 15-pin high-density D-shell (male) IAM/AM Control input power (drive) 2-position plug/header VAC Input Power (drive) 230V and 6-position plug/header...
Page 53 Kinetix 6000 Connector Data Headers in this table extend the safe-off (SO) connector signals for use in wiring single and multiple safe-off drive configurations, or to jumper around (not use) the safe-off feature. IAM/AM Safe-off 9-pin (SO) Connector Safe-off (SO) Also Applies to These Description Signal...
Page 54: I/O Connector Pinout
Kinetix 6000 Connector Data I/O Connector Pinout IAM/AM I/O 26-pin (IOD) Connector IOD Pin Description Signal IOD Pin Description Signal Hardware enable 24V dc power supply +24V_PWR High speed registration 1 input REG1 Hardware enable input ENABLE Common for registration REG_COM Common +24V_COM...
Page 55: Motor Feedback Connector Pinouts
Kinetix 6000 Connector Data Motor Feedback Connector Pinouts Stegmann Hiperface (SRS/SRM) MF Pin Description Signal MF Pin Description Signal Sine differential input+ SINE+ Reserved — Sine differential input- SINE- Hiperface data channel DATA- Cosine differential input+ COS+ Motor thermal switch (normally closed) Cosine differential input- COS- Reserved...
Page 56 Kinetix 6000 Connector Data Resolver Transmitter (transformation ratio = 0.25) MF Pin Description Signal MF Pin Description Signal Sine differential input+ Reserved — Sine differential input- Resolver excitation Motor thermal switch Cosine differential input+ (1) (2) (normally closed) Cosine differential input- Reserved —...
Page 57: Auxiliary Feedback Connector Pinouts
Kinetix 6000 Connector Data Auxiliary Feedback Connector Pinouts For TTL devices, the position count will increase when A leads B. For sinusoidal devices, the position count will increase when cosine leads sine. Stegmann Hiperface (SRS and SRM only) AF Pin Description Signal AF Pin...
Page 58: Iam Input Connector Pinouts
Kinetix 6000 Connector Data IAM Input Connector Pinouts Control Power Connector CPD Pin Description Signal CTRL 2 Control power VAC input CTRL 1 DC Bus and Input Power Connector IPD Pin Description Signal An integral, unregulated power supply, consisting of ac line input, three-phase bridge rectifier, and filter capacitors.
Page 59: Iam And Am Motor Power And Brake Connector Pinouts
Kinetix 6000 Connector Data IAM and AM Motor Power and Brake Connector Pinouts Motor Power Connector MP Pin Description Signal Chassis ground Three-phase motor power To meet CE requirements, combined motor power cable length IMPORTANT for all axes on the same dc bus must not exceed 240 m (787 ft) with 460V systems or 160 m (525 ft) with 230V systems.
Page 60: Understanding Iam/Am Signal Specifications
Kinetix 6000 Connector Data Understanding IAM/AM A description of the Kinetix 6000 IAM/AM input/output (IOD), SERCOS, contactor enable (CED), brake (BC), and control power Signal Specifications (CPD) connectors is provided on the following pages. Digital Inputs Two fast registration inputs and four other inputs are available for the machine interface on the integrated sxis module (IAM) and axis module (AM).
Page 61: Sercos Connections
Kinetix 6000 Connector Data Enable, Home, and Overtravel Digital Input Circuits 24V dc IOD-1, -4, -7, -10 I/O SUPPLY IOD-2, -5, -8, -11 INPUT 3k Ω CTRL_INPUT 0.1 μF 511 Ω IOD-3, -6, -9, -12 IO_COM 1k Ω Customer-supplied Input Device Kinetix 6000 IAM/AM 24V dc source (range) = 21.6V - 26.4V (supplied by drive, not to exceed 500 mA total).
Page 62: Analog Outputs
Kinetix 6000 Connector Data Analog Outputs The integrated axis module (IAM) and axis module (AM) include two analog outputs (IOD-23 and -25) that can be configured through software to represent drive variables. Analog Output Circuit Oscilloscope 2.5V = 0 ref Kinetix 6000 IAM/AM 2.5V (second channel not shown)
Page 63: Contactor Enable Relay
Kinetix 6000 Connector Data Contactor Enable Relay Contactor enable is a relay-driven contact used in the safety control string to protect the drive electronics during certain fault conditions. It is capable of handling 120V ac or 24V dc at 1 A or less. Contactor enable is a function of the converter and is not available in the axis modules.
Page 64: Motor/Resistive Brake Relay
Kinetix 6000 Connector Data Motor/Resistive Brake Relay Two connections are required for the (customer-supplied) motor/ resistive brake input power (BC-3 and -4) and two connections each for the motor and resistive brake output, as shown in the figure below. Connections are rated for +24V and current as shown in the table below.
Page 65: Control Power Input
Kinetix 6000 Connector Data Control Power Input The integrated axis module (IAM) requires ac input power for logic circuitry. The control power input requires an ac (EMC) line filter for CE IMPORTANT certification. For wiring examples, refer to Power Wiring Examples beginning on page 193.
Page 66: Understanding Feedback Specifications
Kinetix 6000 Connector Data Understanding Feedback The integrated axis module (IAM) and axis module (AM) can accept motor and auxiliary feedback signals from the following types of Specifications encoders: • Stegmann Hiperface • TTL or Sine/Cosine with index pulse and Hall commutation •...
Page 67: Feedback Power Supply
Kinetix 6000 Connector Data AM, BM, and IM Input Specifications for TTL Encoders Parameter Description AM, BM, and IM Input voltage difference between the plus (+) input and +1.0V +7.0V On-state input voltage the minus (-) input that is detected as an on-state. AM, BM, and IM Input voltage difference between the plus (+) input and -1.0V...
Page 68: Locating Shunt Module Connectors And Indicators
Kinetix 6000 Connector Data Locating Shunt Module The Kinetix 6000 shunt module (2094-BSP2) is suitable for both 230V and 460V applications. Connectors and Indicators Locating Shunt Module Connectors and Indicators Shunt Module, Front View (2094-BSP2) Motor Cable Shield Clamp External Shunt Resistor (RC) Connector Shunt Module, Front View External Thermal Switch...
Page 69: Connecting The Kinetix 6000 Drive System
Chapter Connecting the Kinetix 6000 Drive System Introduction This chapter provides procedures for wiring your Kinetix 6000 system components and making cable connections. Topic Page Introduction Understanding Basic Wiring Requirements Determining Your Type of Input Power Setting the Ground Jumper in Ungrounded Power Configurations Grounding Your Kinetix 6000 System Power Wiring Requirements Wiring Guidelines...
Page 70: Building Your Own Cables
Connecting the Kinetix 6000 Drive System This section contains common PWM servo system wiring IMPORTANT configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.
Page 71: Determining Your Type Of Input Power
Connecting the Kinetix 6000 Drive System Determining Your Type of Before wiring input power to your Kinetix 6000 system, you must determine the type of input power you are connecting to. The IAM is Input Power designed to operate in both grounded and ungrounded environments. When using a LIM with your Kinetix 6000 drive, the VAC LINE ATTENTION input power must come from a grounded configuration (refer to...
Page 72 Connecting the Kinetix 6000 Drive System Grounded (B-Phase) Power Configuration (Delta Secondary) Integrated Axis Module, Top View (2094-BCxx-Mxx-S is shown) CTRL 2 CTRL 1 Transformer (Delta) Secondary Transformer MBRK - MBRK + CONT EN- DBRK - CONT EN+ DBRK + BAUD RATE Connect to power rail ground stud.
Page 73: Ungrounded Power Configurations
Connecting the Kinetix 6000 Drive System Ungrounded Power Configurations Ungrounded power configurations are allowed, but you must jumper across a 120 kΩ resistor (internal to the IAM) to prevent high electrostatic build-up. The ungrounded power configuration (shown below) does not provide a neutral ground point. The IAM has a ground jumper set for grounded power distribution (default configuration).
Page 74: Dc Common Bus Configurations
Connecting the Kinetix 6000 Drive System DC Common Bus When an integrated axis module (IAM) is used in a dc common bus configuration, the IAM is known as a leader IAM or follower IAM. The Configurations IAM (non-common bus) and leader IAM have identical three-phase input power connections.
Page 75: Common Bus Fusing Requirements
Connecting the Kinetix 6000 Drive System Common Bus Fusing Requirements When using a Kinetix 6000 leader IAM, dc bus fuses are only required when wiring to more than one Kinetix 6000 follower IAM. When wiring multiple follower IAMs, terminal blocks are required to extend the dc common bus power to additional drives.
Page 76: Setting The Ground Jumper
Connecting the Kinetix 6000 Drive System When using ungrounded input power in common bus configurations, use the table below to determine where to set the ground jumper. Ground Jumper to Set Then Set the Jumper in This When Leader Drive is And Follower Drive is Drive Kinetix 6000 IAM...
Page 77 Connecting the Kinetix 6000 Drive System Setting the Ground Jumper (460V IAM) Top Screw Integrated Axis Module (460V) 2094-BCxx-Mxx-S Ground jumper set for ungrounded configuration. Ground jumper set for grounded configuration (default setting) Front Panel (opened) Bottom Screw 2. Swing the front panel open to the right, as shown, and locate the ground jumper.
Page 78: Grounding Your Kinetix 6000 System
Connecting the Kinetix 6000 Drive System Grounding Your All equipment and components of a machine or process system should have a common earth ground point connected to chassis. A Kinetix 6000 System grounded system provides a ground path for short circuit protection. Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized...
Page 79: Grounding Multiple Subpanels
Connecting the Kinetix 6000 Drive System For power rail dimensions, refer to the Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003. For mounting bracket dimensions, refer to the 2094 Mounting Brackets Installation Instructions, publication 2094-IN008. When 2094 mounting brackets are used to mount the power rail IMPORTANT or LIM over the ac line filter, the braided ground strap must be removed from the power rail and attached to a mounting...
Page 80: Power Wiring Requirements
Connecting the Kinetix 6000 Drive System Wire should be copper with 75 °C (167 °F) minimum rating. Phasing Power Wiring of main ac power is arbitrary and earth ground connection is required Requirements for safe and proper operation. The National Electrical Code and local electrical codes take IMPORTANT precedence over the values and methods provided.
Page 81 Connecting the Kinetix 6000 Drive System IAM/AM Power Wiring Requirements Connects to Terminals Recommended Module Catalog Number Description Wire Size Strip Length Torque Value Signal (AWG) mm (in.) Nm (lb-in) 2094-AC05-Mxx-S 2094-AC09-Mxx-S 2094-BC01-Mxx-S Motor power 0.5 - 0.6 2094-BC02-Mxx-S 10 (0.38) cable depends (4.4 - 5.3) 2094-AMP5-S, -AM01-S,...
Page 82 Connecting the Kinetix 6000 Drive System Refer to Power Specifications on page 170 for additional information. Refer to Power Wiring Examples on page 193 for interconnect diagrams. This drive contains ESD (Electrostatic Discharge) sensitive parts ATTENTION and assemblies. You are required to follow static control precautions when you install, test, service, or repair this assembly.
Page 83: Wiring Guidelines
Connecting the Kinetix 6000 Drive System Wiring Guidelines Use these guidelines as a reference when wiring the connectors on your Kinetix 6000 drive modules or line interface module (LIM). Refer to page 50 for the connector locations of the Kinetix 6000 IMPORTANT drive modules.
Page 84: Wiring The Lim Connectors
Connecting the Kinetix 6000 Drive System Wiring the LIM Connectors This section provides examples and wiring tables to assist you in making connections to the line interface module (LIM) connectors. Wiring the Auxiliary Input Power (APL) Connector The Auxiliary Input Power (APL) connector is present only on the 2094-XL75S-Cx models.
Page 85: Wiring The Vac Line (Ipl) Connector
Connecting the Kinetix 6000 Drive System Wiring the VAC LINE (IPL) Connector Line Interface Module (IPL connector) Line Interface Module, Top View (2094-XL75S-Cx is shown) VAC LINE (IPL) Connector 2094-AL09, -ALxxS, -BLxxS, and -XL75S-Cx Recommended Wire Size Three-phase Supply IPL Pin Signal Strip Length Torque Value...
Page 86: Wiring The Vac Load (Opl) Connector
Connecting the Kinetix 6000 Drive System Wiring the VAC LOAD (OPL) Connector Line Interface Module (OPL connector) Line Interface Module, Top View (2094-XL75S-Cx is shown) Line interface modules (2094-ALxxS, -BLxxS, and -XL75S-Cx) IMPORTANT are capable of connecting to two IAMs, providing each IAM has its own line filter and the maximum current specification is not exceeded.
Page 87: Wiring The Control Power Output (Cpl) Connector
Connecting the Kinetix 6000 Drive System Wiring the Control Power Output (CPL) Connector Line Interface Module (CPL connector) Line Interface Module, Top View (2094-XL75S-Cx is shown) Control Power Output (CPL) Connector 2094-ALxxS, -BLxxS, -XL75S-Cx Recommended Wire Size CPL Pin Signal Strip Length Torque Value (AWG)
Page 88: Wiring The Auxiliary Power Output (P2L) Connector
Connecting the Kinetix 6000 Drive System Wiring the Auxiliary Power Output (P2L) Connector Line Interface Module (P2L connector) Line Interface Module, Top View (2094-XL75S-Cx is shown) Auxiliary Power Output (P2L) Connector 2094-ALxxS, -BLxxS, -XL75S-Cx Recommended Wire Size P2L Pin Signal Strip Length Torque Value (AWG)
Page 89: Wiring The Brake Power Output (24V Dc) Connector
Connecting the Kinetix 6000 Drive System Wiring the Brake Power Output (24V dc) Connector Line Interface Module (24V connector) Line Interface Module, Top View (2094-XL75S-Cx is shown) Brake Power Output (24V dc) Connector 2094-ALxxS, -BLxxS, -XL75S-Cx Recommended Wire Size P1L Pin Signal Strip Length Torque Value...
Page 90: Wiring The Iam/Am Connectors
Connecting the Kinetix 6000 Drive System Wiring the IAM/AM This section provides examples and wiring tables to assist you in making connections to the integrated axis module (IAM) connectors. Connectors Wiring the Control Power (CPD) Connector This example applies to an integrated axis module (IAM), leader IAM, or follower IAM.
Page 91: Wiring The Input Power (Ipd) Connector
Connecting the Kinetix 6000 Drive System Wiring the Input Power (IPD) Connector This example applies to an integrated axis module (IAM) or leader IAM (dc common bus). Integrated Axis Module (IPD connector) Integrated Axis Module, Top View (2094-BC02-M02-S is shown) Input Power (IPD) Connections OPL Connector (LIM) or Other Three-phase Input IPD Connector...
Page 92 Connecting the Kinetix 6000 Drive System This example applies to a follower IAM (dc common bus). Integrated Axis Module (IPD connector) Integrated Axis Module, Top View (2094-BC02-M02-S is shown) Input Power (IPD) Connections IPD Connector (IAM or follower IAM) IPD Pin Signal N.C.
Page 93: Wiring The Contactor Enable (Ced) Connector
Connecting the Kinetix 6000 Drive System Wiring the Contactor Enable (CED) Connector This example applies to any integrated axis module (IAM), leader IAM, or follower IAM. Integrated Axis Module (CPD connector Integrated Axis Module, Top View (2094-BC02-M02-S is shown) Wiring the contactor enable relay is required. To avoid personal ATTENTION injury or damage to the drive, wire the contactor enable relay into your safety control string.
Page 94: Wiring The Safe-Off (So) Connector
Connecting the Kinetix 6000 Drive System Wiring the Safe-off (SO) Connector This example applies to any integrated axis module (IAM) or axis module (AM) equipped with the safe-off (SO) connector. Integrated Axis Module (CED connector) Kinetix 6000 IAM/AM (Kinetix 6000 AM is shown) Motion Allowed Jumper Safe-off Wiring Plug Header...
Page 95: Wiring The Motor Power (Mp) Connector
Connecting the Kinetix 6000 Drive System Wiring the Motor Power (MP) Connector This example applies to axis modules (AM) and the inverter section of integrated axis modules (IAM). Integrated Axis Module/Axis Module (MP connector) Integrated Axis Module, Top View (2094-BC02-M02-S is shown) Cable Shield Clamp Cable Shield Terminations Factory supplied motor power cables for MP-Series, TL-Series,...
Page 96 Connecting the Kinetix 6000 Drive System Motor Power Cables with Three-phase Wires Only Motor Power Cable Motor Motor Catalog Number Catalog Number MPL-A/B3xxx, -A/B4xxx, -A/B45xxx, MP-Series Low Inertia -A/B5xxx, -B6xxx, -B8xxx, -B9xxx, S/M 2090-XXNPMP-xxSxx MP-Series Integrated Gear MPG-A/BxxxxS/M 1326AB (M2L/S2L) 1326AB-Bxxxx-M2L/S2L TL-Series TL-Axxxx-H...
Page 97 Connecting the Kinetix 6000 Drive System Motor Power Cables with Three-phase and Brake Wires Motor Power Cable Motor Motor Catalog Number Catalog Number MP-Series Low Inertia MPL-A/B15xxx and MPL-A/B2xxx V/E MP-Series Food Grade MPF-A/BxxxxS/M 2090-XXNPMF-xxSxx MP-Series Stainless Steel MPS-A/BxxxxS/M Y-Series Y-xxxx 2090-XXNPY-16Sxx These MP-Series brake wires have a shield braid (shown below as...
Page 98 Connecting the Kinetix 6000 Drive System Motor Power Cables with Three-phase, Brake, and Thermal Switch Wires Motor Power Cable Motor Motor Catalog Number Catalog Number 1326AB (resolver) 1326AB-Bxxxx-21 1326-CPx1-xxx The 1326AB (resolver) power cable contains the three-phase wires, brake wires, and thermal switch wires. To improve the EMC performance of your system, route the wires as shown.
Page 99 Connecting the Kinetix 6000 Drive System Shield Clamp Cable Preparation (1326-CPx1-xxx) Cable Pinouts (2090-XXNPY-16Sxx, and 2090-XXNPMF-xxSxx) Strip Length 10 mm (0.375 in.) MPL-A/B15xx, MPL-A/B2xx, 1326AB (resolver) Motors Y-Series Motors MPF-A/B and MPS-A/B Motors (1326-CPx1-xxx cable) (2090-XXNPY-xxSxx cable) (2090-XXNPMF-xxSxx cable) Black White Thermal Spare...
Page 100 Connecting the Kinetix 6000 Drive System Pigtail Terminations TL- and Y-Series motors have a short pigtail cable which connects to the motor, but is not shielded. The preferred method for grounding the TL- and Y-Series motor power cable on the motor side is to expose a section of the cable shield and clamp it directly to the machine frame.
Page 101: Wiring The Motor/Resistive Brake (Bc) Connector
Connecting the Kinetix 6000 Drive System Wiring the Motor/Resistive Brake (BC) Connector This example applies to axis modules (AM) and the inverter section of integrated axis modules (IAM). Integrated Axis Module/Axis Module (BC connector) Integrated Axis Module, Top View (2094-BC02-M02-S is shown) Motor/Resistive Brake (BC) Connector Wiring 24V dc Brake Input Power Connections...
Page 102 Connecting the Kinetix 6000 Drive System Wiring the Motor Brake Connections The procedure for wiring your motor brake varies slightly, depending on the motor series you are using. Refer to the table below to determine where the brake wires for your servo motor are located and for the appropriate brake cable or connector kit catalog number.
Page 103: Applying The Motor Cable Shield Clamp
Connecting the Kinetix 6000 Drive System Applying the Motor Cable This procedure assumes you have completed wiring your motor power (MP) connector and are ready to apply the motor cable shield Shield Clamp clamp. Follow these steps to apply the motor cable shield clamp. 1.
Page 104: Understanding Feedback And I/O Cable Connections
Connecting the Kinetix 6000 Drive System Understanding Feedback Factory made cables with premolded connectors are designed to minimize EMI and are recommended over hand-built cables to and I/O Cable Connections improve system performance. However, other options are available for building your own feedback and I/O cables. Options for Connecting Motor Feedback and I/O Connector Kit Connection Option...
Page 105: Flying-Lead Feedback Cable Pin-Outs
Connecting the Kinetix 6000 Drive System Flying-lead Feedback Cable Pin-outs 2090-XXNFMP-Sxx Feedback Cable Motors with Incremental Motors with High Resolution Feedback Encoder Feedback Motor Drive MF MPL-A3xxx-M/-S MPL-A3xxx-H Connector Connector MPL-Bxxx-M/-S MPL-A4xxx-M/-S MPL-A4xxx-H MPL-A5xxx-M/-S MPL-A45xxx-M/-S MPL-A45xxx-H 1326AB-Bxxx-M2L/-S2L MPG-A/Bxxx-M/-S MPL-A5xxx-H Sine+ Sine+ Sine- Sine-...
Page 106: Publication 2094-Um001A-En-P — September
Connecting the Kinetix 6000 Drive System 2090-XXNFMF-Sxx Feedback Cable Motors with Incremental Motors with High Resolution Feedback Encoder Feedback MPL-A15xxx-V/-E Motor Drive MF MPL-B15xxx-V/-E MPL-A2xxx-V/-E MPL-A15xxx-H Connector Connector MPL-B2xxx-V/-E MPF/MPS-A3xx-M/-S MPL-A2xxx-H MPF/MPS-Bxxx-M/-S MPF/MPS-A4xx-M/-S MPL-B15xxx-H MPF-A5xx-M/-S MPF/MPS-A45xx-M/-S MPL-B2xxx-H MPS-A5xx-M/-S Sine+ Sine+ Sine- Sine- Cos+...
Page 107 Connecting the Kinetix 6000 Drive System 2090-XXNFHF-Sxx Feedback Cable 2090-XXNFY-Sxx Feedback Cable Incremental Encoder Incremental Encoder Motor Drive MF Motor Drive MF Feedback Feedback Connector Connector Connector Connector F-Series Motors Y-Series Motors Reserved – Reserved – EPWR_5VM EPWR_5VM EPWR_5VM ECOMM ECOMM ECOMM Connector...
Page 108: Wiring Feedback And I/O Connectors
Connecting the Kinetix 6000 Drive System Wiring Feedback and I/O These procedures assume you have mounted your Kinetix 6000 system, completed all power wiring, and are ready to connect your Connectors feedback and I/O cables. For This Connection Go to Premolded cable Connecting Premolded Motor Feedback Cables on page 108.
Page 109: Wiring Panel-Mounted Breakout Board Kits
Connecting the Kinetix 6000 Drive System Wiring Panel-mounted Breakout Board Kits The panel-mounted breakout board kit (catalog number 2090-UXBK-D15xx) includes a (DIN rail) breakout board and cable. The cable connects between the breakout board and the motor feedback (MF) connector. Wires from your flying-lead motor feedback cable connect to the terminals.
Page 110: Wiring Low-Profile Connector Kits
Connecting the Kinetix 6000 Drive System Wiring Low-profile Connector Kits Low-profile connector kits (2090-K6CK-Dxxx) are suitable for motor feedback (MF), auxiliary feedback (AF), and I/O connections (IOD) on any IAM or AM. They also apply to I/O connections (IOL) on the 2094-AL09 and 2094-BL02 line interface module (LIM).
Page 111 Connecting the Kinetix 6000 Drive System Wiring (15-Pin) Flying-lead Feedback Cable Connections 1326-CCUx-xxx Motor Feedback Cable 15-pin (male) Motor Feedback 15-pin (female) Auxiliary Feedback Bare Wires Low-profile Connector Low-profile Connector Drain Wire Wire Insulation Pin 10 Pin 6 Foil Shield Pin 5 Pin 15 Pin 1...
Page 112 Connecting the Kinetix 6000 Drive System Wiring (26-Pin) I/O Cable Connections Pin 18 Pin 9 Pin 26 Mounting Screws Pin 19 Pin 1 Pin 10 26-pin (male) I/O Low Profile Connector Tie Wrap Slot Turn clamp over to hold small wires secure. Discrete I/O Wire Three Conductor I/O Cables...
Page 113: Understanding External Shunt Module Connections
Connecting the Kinetix 6000 Drive System Understanding External Follow these guidelines when wiring your external active or passive shunt resistor kit. Shunt Module Connections When tightening screws to secure the wires, refer to the tables IMPORTANT beginning on page 80 for torque values. To ensure system performance, run wires and cables in the IMPORTANT wireways as established in Chapter 2.
Page 114: Understanding Resistive Brake Module Connections
Connecting the Kinetix 6000 Drive System Understanding Resistive Follow these guidelines when wiring your Bulletin 2090 Resistive Brake Module (RBM). Brake Module Connections To ensure system performance, run wires and cables in the IMPORTANT wireways as established in Chapter 2. If your application requires an RBM and you are wiring to a Kinetix 6000 IAM/AM drive, then refer to the following: •...
Page 115: Connecting Your Sercos Fiber-Optic Cables
Connecting the Kinetix 6000 Drive System Connecting Your SERCOS This procedure assumes you have your Logix SERCOS interface module/PCI card and Kinetix 6000 IAM/AM modules mounted and are Fiber-optic Cables ready to connect the fiber-optic cables. The SERCOS fiber-optic ring is connected using the SERCOS receive (Rx) and transmit (Tx) connectors.
Page 116 Connecting the Kinetix 6000 Drive System The CompactLogix platform (1768-M04SE) is limited to four IMPORTANT axes per module. In this example, two Logix modules are installed in separate Logix chassis. Fiber-optic Cable Example 2 (two Logix chassis) 1756-MxxSE SERCOS interface Modules SERCOS interface SERCOS interface Logix Platform...
Page 117 Connecting the Kinetix 6000 Drive System In this example, the second Kinetix 6000 system is located in a separate cabinet and connected with bulkhead adapters. To avoid signal loss, do not use bulkhead adapters to connect IMPORTANT glass cables. Only use bulkhead adapters for making plastic-to-plastic cable connections.
Page 118 Connecting the Kinetix 6000 Drive System Publication 2094-UM001A-EN-P — September 2006...
Page 119: Configure And Startup The Kinetix 6000 Drive System
Chapter Configure and Startup the Kinetix 6000 Drive System Introduction This chapter provides procedures for configuring your Kinetix 6000 system components with your Logix SERCOS module. Topic Page Introduction Configure the IAM/AM Configure the Logix SERCOS interface Module Apply Power to the Kinetix 6000 Drive Test and Tune the Axes Publication 2094-UM001A-EN-P —...
Page 120: Configure The Iam/Am
Configure and Startup the Kinetix 6000 Drive System Configure the IAM/AM Follow these steps to configure the IAM/AM. 1. Verify that there is no power applied to the IAM/AM and that the SERCOS fiber-optic cables are plugged into the Tx and Rx connectors.
Page 121 Configure and Startup the Kinetix 6000 Drive System 4. Set the SERCOS baud rate using DIP switches 2 and 3. For This Baud Rate Set Switch 2 Set Switch 3 4 Mbps 8 Mbps 5. Set the SERCOS optical power level to High using DIP switch 1. For This Optical Power Level Set Switch 1 High...
Page 122 Configure and Startup the Kinetix 6000 Drive System Node Addressing Example 1 1756-MxxSE SERCOS interface Module SERCOS interface Logix Platform (ControlLogix is shown) Tx (rear) Rx (front) Transmit Receive SERCOS Fiber-optic Ring Receive Transmit Kinetix 6000 System 2 Receive Transmit (2-axis power rail) Kinetix 6000 System 1...
Page 123 Configure and Startup the Kinetix 6000 Drive System Node Addressing Example 2 1756-MxxSE SERCOS 1756-MxxSE SERCOS interface Module 1 interface Module 2 SERCOS interface SERCOS interface ControlLogix Chassis ControlLogix Chassis Tx (rear) Tx (rear) Rx (front) Rx (front) Transmit Receive Transmit Receive SERCOS Fiber-Optic rings...
Page 124 Configure and Startup the Kinetix 6000 Drive System Node Addressing Example 3 1756-MxxSE SERCOS interface Module SERCOS interface Logix Platform (ControlLogix is shown) Tx (rear) Rx (front) Transmit Receive SERCOS Fiber-optic Ring Transmit Receive Kinetix 6000 (8-axis power rail) 08 = Slot Filler Node Address 07 = AM (axis 4) Node Address 06 = Not Used (AM Rightmost Slot) 05 = AM (axis 3) Node Address...
Page 125: Configure The Logix Sercos Interface Module
Configure and Startup the Kinetix 6000 Drive System Configure the Logix This procedure assumes that you have wired your Kinetix 6000 system SERCOS interface Module and have configured the baud rate and optical power switches. In order for the Kinetix 6000 drive to communicate with the IMPORTANT SERCOS interface module (indicated by the three LED indicators on the module going solid green), your RSLogix 5000 software...
Page 126: Configure The Logix Module
Configure and Startup the Kinetix 6000 Drive System 6. Select the Date and Time tab. 7. Check the box Make this controller the Coordinated System Time master. Only one ControlLogix processor can be assigned as the IMPORTANT Coordinated System Time master. 8.
Page 127 Configure and Startup the Kinetix 6000 Drive System The New Module dialog opens. Your new module appears under the I/O Configuration folder in the explorer dialog. 4. Configure the new module. a. Name the module. b. Select the slot where your module resides (leftmost slot = 0). c.
Page 128: Configure The Kinetix 6000 Modules
Configure and Startup the Kinetix 6000 Drive System 7. Verify that the Data Rate setting matches DIP switches 2 and 3 (baud rate) as set on the IAM and AMs, or use the Auto Detect setting. 8. Set the Cycle Time according to the table below. Data Rate Number of Axes Cycle Time...
Page 129 Configure and Startup the Kinetix 6000 Drive System 3. Click OK. The New Module dialog opens. a. Name the module. b. Set the Node address. Set the node address in the software to match the node setting on the drive. Refer to Configure the IAM/AM, Step 2, on page 120. c.
Page 130 Configure and Startup the Kinetix 6000 Drive System With drive firmware revision 1.80 or later, and RSLogix 5000 software revision 13 or later, it is possible to configure the auxiliary axis feedback port as a Feedback Only axis. With this feature, each IAM (inverter) or AM can be configured to appear as two axes/nodes on the SERCOS ring.
Page 131: Appendix D
Configure and Startup the Kinetix 6000 Drive System 11. Select the Bus Regulator Catalog Number or other as appropriate for your actual hardware configuration. And your hardware configuration includes this shunt If your IAM is Then select option Internal shunts only Internal or <none>...
Page 132: Configure The Motion Group
Configure and Startup the Kinetix 6000 Drive System Configure the Motion Group Follow these steps to configure the motion group. 1. Right-click Motion Groups in the explorer dialog and select New Motion Group. The New Tag dialog opens. 2. Name the new motion group. 3.
Page 133: Configure Axis Properties
Configure and Startup the Kinetix 6000 Drive System Configure Axis Properties Follow these steps to configure axis properties. 1. Right-click on an axis in the explorer dialog and select Properties. The Axis Properties dialog opens. 2. Select the Drive/Motor tab and edit the default values as appropriate for your application.
Page 134: Download The Program
Configure and Startup the Kinetix 6000 Drive System The Custom Stop Action Attributes dialog opens. The Custom Stop Action Attributes window lets you set delay times for servo motors and resistive brake modules. For recommended motor brake delay times, refer to the Kinetix Motion Control Selection Guide, publication GMC-SG001.
Page 135: Apply Power To The Kinetix 6000 Drive
Configure and Startup the Kinetix 6000 Drive System Apply Power to the This procedure assumes that you have wired and configured your Kinetix 6000 Drive Kinetix 6000 system (with or without the LIM) and your SERCOS interface module. To avoid hazard of electrical shock, perform all mounting and SHOCK HAZARD wiring of IAM, AM, SM, LIM, RBM, or power rail prior to applying power.
Page 136 Configure and Startup the Kinetix 6000 Drive System 3. Observe the IAM/AM logic power LED indicator. Seven-segment Fault Status LED Indicator Logic Power LED Indicator If the Logic Power LED Indicator is Then Go to Step 4. 1. Check your control power connections. Not ON 2.
Page 137 Configure and Startup the Kinetix 6000 Drive System 5. Observe the IAM/AM fault status LED indicator. The status LED indicator will first flash the SERCOS node address, then cycle through phases until final configuration (phase 4) is reached. IAM/AM Fault Status LED Indicator Status Do This The drive is looking for a closed SERCOS ring.
Page 138: Test And Tune The Axes
Configure and Startup the Kinetix 6000 Drive System Test and Tune the Axes This procedure assumes that you have configured your Kinetix 6000 drive, your SERCOS interface module, and applied power to the system. Before proceeding with testing and tuning your axes, verify that IMPORTANT the IAM and AM seven-segment and status LED indicators are as described in Step 6 on page 137.
Page 139 Configure and Startup the Kinetix 6000 Drive System 4. Select 2.0 as the number of revolutions for the test (or another number more appropriate for your application). This Test Performs this Test Verifies marker detection capability as you rotate the Test Marker motor shaft.
Page 140 Configure and Startup the Kinetix 6000 Drive System 9. Determine if your test completed successfully. Then Your test completes successfully, this dialog appears. 1. Click OK. 2. Remove Hardware Enable Input signal (IOD-2). 3. Go to Tune the Axes. 1. Click OK. Your test failed, this dialog appears.
Page 141: Tune The Axes
Configure and Startup the Kinetix 6000 Drive System Tune the Axes Follow these steps to tune the axes. 1. Verify the load is still removed from the axis being tuned. To reduce the possibility of unpredictable motor response, ATTENTION 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 142 Configure and Startup the Kinetix 6000 Drive System The Online Command - Tune Servo dialog opens. When the test completes, the Command Status changes from Executing to Command Complete. 8. Click OK. The Tune Bandwidth dialog opens. Actual bandwidth values (Hz) depend on your application and may require adjustment once motor and load are connected.
Page 143 Configure and Startup the Kinetix 6000 Drive System 11. Determine if your test completed successfully. Then Your test completes successfully, this dialog appears. 1. Click OK. 2. Remove the Hardware Enable Input signal (IOD-2) applied earlier. 3. Go to Step 12. Your test failed, this dialog appears.
Page 144 Configure and Startup the Kinetix 6000 Drive System Publication 2094-UM001A-EN-P — September 2006...
Page 145: Troubleshooting The Kinetix 6000 Drive System
Chapter Troubleshooting the Kinetix 6000 Drive System Introduction This chapter provides troubleshooting tables and for your Kinetix 6000 system components. Topic Page Introduction Safety Precautions Interpreting Status Indicators Supplemental Troubleshooting Information Safety Precautions Observe the following safety precautions when troubleshooting your Kinetix 6000 drive.
Page 146: Interpreting Status Indicators
If the fault Indicators persists after attempting to troubleshoot the system, please contact your Rockwell Automation sales representative for further assistance. Error Codes The following list of problematic symptoms (no error code shown) and faults with assigned error codes is designed to help you resolve anomalies.
Page 147 Troubleshooting the Kinetix 6000 Drive System Error Fault Message Problem or Symptom Potential Cause Possible Resolution Code RSLogix (HIM) Verify continuity of motor power cable and Motor cables shorted. connector. Disconnect motor power cables from the Motor winding shorted internally. motor.
Page 148 Troubleshooting the Kinetix 6000 Drive System Error Fault Message Problem or Symptom Potential Cause Possible Resolution Code RSLogix (HIM) Softovertravel • Verify motion profile. Fault Axis position exceeded maximum software setting. • Verify overtravel settings are (+/- Software appropriate. Overtravel) •...
Page 149 (Safe-off HW Flt) allow motion. • Safe-off circuit missing +24V dc. • If error persists, return the drive to Rockwell Automation. SERCOSFault Verify that each SERCOS drive is assigned Duplicate node address detected on SERCOS ring. a unique node address.
Page 150 Troubleshooting the Kinetix 6000 Drive System Error Fault Message Problem or Symptom Potential Cause Possible Resolution Code RSLogix (HIM) • Check motor power/feedback wiring. No Fault Message • Refer to on-screen message for (condition indicated resolution. by on-screen Autotune procedure failed Motor or feedback device malfunction.
Page 151 Follower IAM detected ac input power being applied. follower IAM. (Common Bus Flt) DriveHardFault Pre-charge resistor power exceeds the resistor rating. Allow resistor to cool. (Pre-charge Timeout Flt) Call your local Rockwell Automation sales RESERVED others representative. Publication 2094-UM001A-EN-P — September 2006...
Page 152: Iam/Am Status Indicators
Troubleshooting the Kinetix 6000 Drive System IAM/AM Status Indicators Drive Status LED Indicator Drive Status LED Status Potential Cause Possible Resolution Indicator Normal, no faults Refer to seven-segment error code and Error Steady Red Drive faulted Seven-segment LED displays error code Codes section beginning on page 146.
Page 153: Sm Status Indicators
Troubleshooting the Kinetix 6000 Drive System SM Status Indicators Each of the shunt module LED indicators provide specific troubleshooting information. General Shunt Module Troubleshooting Module Status Under These Conditions Fault is latched Until fault condition is corrected and cleared. • Using RSLogix MASR, MAFR, MGSR commands or the HIM (red stop button).
Page 154 Troubleshooting the Kinetix 6000 Drive System Bus Status LED Indicator Bus Status LED Status Potential Cause Possible Resolution Normal condition when control power is applied and bus voltage is less than Flashing 60V dc. Normal condition when control power is applied and bus voltage is greater Steady Green than 60V dc.
Page 155: Troubleshooting General System Problems
Troubleshooting the Kinetix 6000 Drive System Troubleshooting General Use the tables below for troubleshooting general system faults. System Problems Condition Potential Cause Possible Resolution The position feedback device is incorrect or open. Check wiring. Check to see what primary operation mode was Unintentionally in torque mode.
Page 156 Troubleshooting the Kinetix 6000 Drive System Condition Potential Cause Possible Resolution • Verify grounding. • Route wire away from noise sources. Recommended grounding per installation instructions have not been followed. • Refer to System Design for Control of Electrical Noise, publication GMC-RM001. Presence of noise on command •...
Page 157: Understanding Logix/Drive Fault Behavior
Troubleshooting the Kinetix 6000 Drive System Understanding Logix/Drive Fault Behavior This section provides the drive fault actions and indicates whether the fault action is programmable. Drive Fault Action Definitions Drive Fault Action Definition The drive disables and the contactor enable relay opens. Uncontrolled Shutdown stop, motor coasts to a stop.
Page 158 Troubleshooting the Kinetix 6000 Drive System RSLogix Fault Message RSLogix Error Drive Fault Description Programmable (HIM) Code Action Fault Action? MotFeedbackFault Motor encoder has encountered an illegal state transition. DISABLE (Mtr Fdbk AQB) AuxFeedbackFault Communication was not established with an intelligent (Stegmann) STOP encoder on the Auxiliary feedback port.
Page 159 Troubleshooting the Kinetix 6000 Drive System RSLogix Fault Message RSLogix Error Drive Fault Description Programmable (HIM) Code Action Fault Action? No Fault Message (condition indicated by Autotune procedure failed. DISABLE on-screen message) (Atune Flt) DriveHardFault Operating system failed. SHUTDOWN (Task init) DriveHardFault DPI communication failed.
Page 160: Supplemental Troubleshooting Information
Troubleshooting the Kinetix 6000 Drive System Supplemental This section provides information for accessing and changing parameters not accessible through RSLogix 5000 software. Troubleshooting Information Tools for Changing Parameters Most parameters are accessible through RSLogix 5000 software. Alternatives include the DPI compatible Human Interface Module (HIM) and DriveExplorer software.
Page 161: Using Analog Test Points To Monitor System Variables
Troubleshooting the Kinetix 6000 Drive System Changing Parameters Using the HIM When using the HIM to monitor or change parameters, use the up and down arrows (∧ and ∨) to arrive at selections. Refer to the instructions that came with your HIM for more information. Follow these steps to monitor or change parameters using the HIM.
Page 162 Troubleshooting the Kinetix 6000 Drive System Parameters begin with a variable to identify a specific axis by slot number, as follows: • IAM = 0 for parameters 0...999 • 1st AM = 1 for parameters 1000...1999 • 2nd AM = 2 for parameters 2000...2999 and so on... •...
Page 163: Removing And Replacing The Kinetix 6000 Drive Modules
Chapter Removing and Replacing the Kinetix 6000 Drive Modules Introduction This chapter provides remove and replace procedures for your Kinetix 6000 system components. Topic Page Introduction Before You Begin Removing Power Rail Modules Replacing Power Rail Modules Removing the Power Rail Replacing the Power Rail This drive contains ESD (Electrostatic Discharge) sensitive parts ATTENTION...
Page 164: Removing Power Rail Modules
Removing and Replacing the Kinetix 6000 Drive Modules Removing Power Rail Follow these steps to remove modules from the power rail. Modules 1. Verify that all control and input power has been removed from the system. To avoid shock hazard or personal injury, assure that all ATTENTION power has been removed before proceeding.
Page 165: Replacing Power Rail Modules
Removing and Replacing the Kinetix 6000 Drive Modules 6. Grasp top and bottom of the module with both hands and gently pull the module away from the connectors enough to clear the guide pins (module will pivot on top bracket). 7.
Page 166: Removing The Power Rail
Removing and Replacing the Kinetix 6000 Drive Modules 7. Re-apply power to the system. 8. Verify that the system is operating properly. Because IAM and AM parameters reside in the RSLogix 5000 software, you do not need to perform any tuning or setup procedures.
Page 167: Replacing The Power Rail
Removing and Replacing the Kinetix 6000 Drive Modules Replacing 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. If you need to change the location of the power rail, or if you IMPORTANT are installing a power rail designed for additional or fewer...
Page 168: Publication 2094-Um001A-En-P — September
Removing and Replacing the Kinetix 6000 Drive Modules Publication 2094-UM001A-EN-P — September 2006...
Page 169: Introduction
Appendix Specifications and Dimensions Introduction This appendix provides product specifications and mounting dimensions for your Kinetix 6000 system components. Topic Page Introduction Power Specifications Power Dissipation Specifications General Specifications AC Line Filter Specifications External Shunt Module Specifications Product Dimensions Publication 2094-UM001A-EN-P — September 2006...
Page 170: Power Specifications
Specifications and Dimensions Power Specifications This section contains power specifications for your Kinetix 6000 system components. Integrated Axis Module (converter) Power Specifications IAM (230V) Power Specifications Description Specification 2094-AC05-MP5-S 2094-AC05-M01-S 2094-AC09-M02-S 2094-AC16-M03-S 2094-AC32-M05-S AC input voltage 195...264V rms three-phase (230V nom) AC input frequency 47...63 Hz Main ac input current...
Page 171 Specifications and Dimensions IAM (460V) Power Specifications Description Specification 2094-BC01-MP5-S 2094-BC01-M01-S 2094-BC02-M02-S 2094-BC04-M03-S 2094-BC07-M05-S AC input voltage 324...528V rms three-phase (360...480V nom) AC input frequency 47...63 Hz Main ac input current Nom (rms) 10 A 24 A 44 A 71 A Max inrush (0-pk) 10 A 20 A...
Page 172: Axis Module (Inverter) Power Specifications
Specifications and Dimensions Axis Module (inverter) Power Specifications The following tables list power specifications for the Kinetix 6000 axis modules. The specifications apply to the axis module specified in the column heading by catalog number and the same axis module (inverter section) that resides within an integrated axis module.
Page 173: Shunt Module Power Specifications
Specifications and Dimensions AM (inverter) 460V Power Specifications Description Specification 2094-BMP5-S 2094-BM01-S 2094-BM02-S 2094-BM03-S 2094-BM05-S (2094-BC01-MP5-S) (2094-BC01-M01-S) (2094-BC02-M02-S) (2094-BC04-M03-S) (2094-BC07-M05-S) Bandwidth Velocity loop 500 Hz Current loop 1300 Hz PWM frequency 8 kHz 4 kHz Nominal input voltage 650V dc Continuous current (rms) 2.8 A 6.1 A...
Page 174 Specifications and Dimensions In the table below, the 230V system specifications are given for the IAM internal shunt resistors, the Kinetix 6000 (2094-BSP2) SM, and the Bulletin 1394 passive external shunt modules. Shunt Module (230V) System Specifications Shunt Module Specifications System Kinetix 6000 Number of...
Page 175 Specifications and Dimensions In the example below, the continuous shunt power is 300 W. The 50 W resistor in the IAM is disabled when used in combination with the (2094-BSP2) SM. This example is unique to the 2094-AC09-M02 IAM. 230V Shunt Power Example (2094-AC09-M02) Kinetix 6000 (230V) Shunt Power Example 300 W Continuous Shunt Power SM (2094-BSP2) 200 W Shunt Module...
Page 176 Specifications and Dimensions In the example below, the sum of the IAM, AMs, and SM equal 500 W of continuous shunt power. Shunt power adds up the same way for 460V (IAM, AM, and SM) systems too. Shunt Power Example (without external shunt) Kinetix 6000 (230V) Shunt Power Example 500 W Continuous Shunt Power SM (2094-BSP2) 200 W Shunt Module...
Page 177: Circuit Breaker/Fuse Specifications
Specifications and Dimensions Circuit Breaker/Fuse Specifications While circuit breakers offer some convenience, there are limitations for their use. Circuit breakers do not handle high current inrush as well as fuses. The Kinetix 6000 needs to be protected by a device having a short circuit interrupt current rating of the service capacity provided or a maximum of 100,000 A.
Page 178 Specifications and Dimensions Use class CC, J, L, or R fuses, with current rating as indicated in the table below. The following fuse examples and Allen-Bradley circuit breakers are recommended for use with integrated axis modules (2094-xCxx-Mxx-S) when the Line Interface Module (LIM) is not used. Line Interface Modules (2094-ALxxS, -BLxxS, and -XL75S-Cx) IMPORTANT provide branch circuit protection to the IAM.
Page 179: Contactor Ratings
Specifications and Dimensions Contactor Ratings The table below lists the recommended contactor ratings for integrated axis modules installed without a line interface module. Catalog Number Catalog Number Contactor Contactor 230V IAM 460V IAM 2094-AC05-MP5-S 2094-BC01-MP5-S 100-C23x10 (ac coil) 100-C23x10 (ac coil) 100-C23Zx10 (dc coil) 100-C23Zx10 (dc coil) 2094-AC05-M01-S...
Page 180: Power Dissipation Specifications
Specifications and Dimensions Power Dissipation Use the following table to size an enclosure and calculate required ventilation for your Kinetix 6000 drive system. Specifications Usage as % of Rated Power Output (watts) Kinetix 6000 Modules 100% Integrated axis module (IAM converter) 2094-AC05-MP5-S 2094-AC05-M01-S 2094-AC09-M02-S...
Page 181: General Specifications
Specifications and Dimensions General Specifications This section contains general specifications for your Kinetix 6000 system components. Maximum Feedback Cable Lengths Although motor feedback cables are available in standard lengths up to 90 m (295.3 ft), the drive/motor/feedback combination may limit the maximum cable length, as shown in the tables below.
Page 182: Weight Specifications
Specifications and Dimensions Weight Specifications Value, Approx. Value, Approx. Kinetix 6000 Kinetix 6000 Catalog Number Catalog Number Module Module kg (lb) kg (lb) 2094-AC05-MP5-S 2.23 (4.9) 2094-BC01-MP5-S 4.98 (11.0) 2094-AC05-M01-S 2.27 (5.0) 2094-BC01-M01-S 5.03 (11.1) 2094-AC09-M02-S 2.31 (5.1) 2094-BC02-M02-S 5.08 (11.2) (230V) (460V) 2094-AC16-M03-S...
Page 183: Ac Line Filter Specifications
Specifications and Dimensions AC Line Filter The tables below contain specifications for ac line filters available for Kinetix 6000 servo drive systems. Specifications AC Line Filter Specifications Specifications AC Line Filter Power Leakage Weight Operating Catalog Number Voltage Phase Current Loss Current Humidity...
Page 184: External Shunt Module Specifications
Specifications and Dimensions External Shunt Module External shunt modules are used with Kinetix 6000 drives when regenerative loads exceed the capacity of the internal (IAM or AM) Specifications shunt resistor. Passive shunt modules wire to the Kinetix 6000 (rail mounted) shunt module, catalog number 2094-BSP2.
Page 185: Product Dimensions
Specifications and Dimensions Product Dimensions This section contains product dimensions for your Kinetix 6000 system components. Integrated Axis Module Dimensions 2094-AC05-MP5-S, AC05-M01-S, and -AC09-M02-S (230V) 2094-BC01-MP5-S, -BC01-M01-S, and -BC02-M02-S (460V) Dimensions are in millimeters (inches) (4.9) (0.8) (0.35) 2094-AC05-M01-S (230V) (shown) 2090-XXNFxx-Sxx (flying lead) Feedback Cable with...
Page 186 Specifications and Dimensions Integrated Axis Module Dimensions 2094-AC16-M03-S and -AC32-M05-S (230V) 2094-BC04-M03-S and -BC07-M05-S (460V) Dimensions are in millimeters (inches) (0.35) 2094-BC04-M03-S (460V) shown 2090-XXNFxx-Sxx (flying lead) Feedback Cable with Power Rail 2090-K6CK-D15Mxx Low-profile Connector Kit Important: Additional clearance below the connector (2.45) is necessary to provide the recommended cable-bend radius.
Page 187 Specifications and Dimensions Axis Module Dimensions 2094-AMP5-S, -AM01-S, and -AM02-S (230V) 2094-BMP5-S, -BM01-S, and -BM02-S (460V) Dimensions are in millimeters (inches) (2.76) (0.8) (0.35) 2094-AM01-S (230V) shown 2090-XXNFxx-Sxx (flying lead) Feedback Cable with 2090-K6CK-D15Mxx Low-profile Connector Kit Power Rail Important: Additional clearance below the connector (2.45) is necessary to provide the recommended cable-bend radius.
Page 188 Specifications and Dimensions Axis Module Dimensions 2094-AM03-S and -AM05-S (230V) 2094-BM03-S and -BM05-S (460V) Dimensions are in millimeters (inches) (0.35) 2094-BM03-S (460V) shown 2090-XXNFxx-Sxx (flying lead) Feedback Cable with Power Rail 2090-K6CK-D15Mxx Low-profile Connector Kit Important: Additional clearance below the connector (2.45) is necessary to provide the recommended cable-bend This view illustrates the...
Page 189 Specifications and Dimensions Shunt Module Dimensions 2094-BSP2 (10.3) Dimensions are in millimeters (inches) (2.76) (9.8) (4.8) (1.7) (0.8) (0.8) (11.0) (10.1) Power Rail Modules are shown mounted to the power rail and the dimensions reflect that in the depth of the module. Publication 2094-UM001A-EN-P —...
Page 190 Specifications and Dimensions Publication 2094-UM001A-EN-P — September 2006...
Page 191: Interconnect Diagrams
Appendix Interconnect Diagrams Introduction This appendix provides wiring examples and system block diagrams for your Kinetix 6000 system components. Topic Page Introduction Wiring Examples Power Wiring Examples DC Common Bus Wiring Examples Shunt Module Wiring Examples Axis Module/Motor Wiring Examples Controlling a Brake Example System Block Diagrams Publication 2094-UM001A-EN-P —...
Page 192: Wiring Examples
Interconnect Diagrams Wiring Examples This appendix provides wiring examples to assist you in wiring the Kinetix 6000 system. The notes below apply to the wiring examples on the pages that follow. Note Information For power wiring specifications, refer to Power Wiring Requirements on page 80. For input fuse and circuit breaker sizes, refer to Circuit Breaker/Fuse Specifications on page 177.
Page 193: Power Wiring Examples
Interconnect Diagrams Power Wiring Examples Single IAM Wiring Example with LIM (2094-AL09 or -BL02) Kinetix 6000 Integrated Axis Module 2094-ACxx-Mxx or -BCxx-Mxx Power Rail Note 10 Ground Stud Bonded Cabinet Cable Shield Ground Bus* Clamp Line Interface Module Three-phase 2094-AL09 or -BL02 Motor Power Motor Power Connections...
Page 194 Interconnect Diagrams Multiple IAM Wiring Example with LIM (2094-ALxxS, -BLxxS, or -XL75S) Kinetix 6000 Integrated Axis Module 2094-ACxx-Mxx or -BCxx-Mxx (IAM_1) Note 10 Bonded Cabinet Power Rail Ground Bus* Ground Stud Cable Shield Clamp Line Interface Module Three-phase 2094-ALxxS, -BLxxS, or Motor Power Motor Power -XL75S-Cx...
Page 195 Interconnect Diagrams Kinetix 6000 Integrated Axis Module 2094-ACxx-Mxx or -BCxx-Mxx (IAM_2) Power Rail Note 10 Ground Stud Bonded Cabinet Cable Shield Ground Bus* Clamp Three-phase Motor Power Motor Power Connections (MP) Connector Note 16 CTRL 2 Control Power From CPL connector, LIM (CPD) Connector CTRL 1 DC Bus...
Page 196 Interconnect Diagrams The configuration on this page does not include a LIM. You must supply input power components. The single-phase and three-phase line filters are wired downstream of fusing and the M1 contactor. Wiring the contactor enable (CED) relay is required. To avoid ATTENTION injury or damage to the drive, wire the contactor enable relay into your safety control string.
Page 197: Dc Common Bus Wiring Examples
Interconnect Diagrams DC Common Bus Wiring Examples Leader IAM Wiring Example with Single Follower IAM Publication 2094-UM001A-EN-P — September 2006...
Page 198 Interconnect Diagrams Leader IAM Wiring Example with Multiple Follower IAM To Follower DC Bus Connections To Follower Control Power Connections Kinetix 6000 Common Bus Leader IAM 2094-ACxx-Mxx or -BCxx-Mxx Bonded Cabinet Ground Bus * Power Rail Ground Stud Note 10 Cable Shield Clamp Single-phase Input...
Page 199 Interconnect Diagrams Kinetix 6000 Common Bus Follower IAM 2094-ACxx-Mxx or -BCxx-Mxx Bonded Cabinet Ground Bus * Power Rail Ground Stud Note 10 Cable Shield Clamp Note 4 From Leader Control Power CTRL 2 Control Power (CPD) Connector CTRL 1 Connections Three-phase Note 4 Motor Power...
Page 200 Interconnect Diagrams 8720MC-RPS Leader Drive Wiring Example with Single Follower IAM Publication 2094-UM001A-EN-P — September 2006...
Page 201: Shunt Module Wiring Examples
Interconnect Diagrams Shunt Module Wiring Examples Shunt Module Wired for Internal Operation (default configuration) Kinetix 6000 Shunt Module 2094-BSP2 External Shunt Resistor (RC) Connector External Thermal Switch (TS) Connector Shunt Module Wiring Example with External Passive Shunt External Passive Kinetix 6000 Shunt Module Shunt Module 2094-BSP2...
Page 202 Interconnect Diagrams IAM Wiring Example with Single External Active Shunt External Active Kinetix 6000 Shunt Module (1336-MOD-Kxxxx) Integrated Axis Module 2094-xCxx-Mxx (+) Slave In (–) Slave In (–) Master Out (+) Master Out DC Bus (–) DC Bus Connections (+) DC Bus Input Fusing* Note 23 Three-phase...
Page 203 Interconnect Diagrams IAM Wiring Example with Multiple External Active Shunts Kinetix 6000 External Active Integrated Axis Module Shunt Module (1336-MOD-Kxxxx) 2094-xCxx-Mxx (+) Slave In (–) Slave In (–) Master Out (+) Master Out Note 4 DC Bus (–) DC Bus Connections (+) DC Bus Three-phase...
Page 204: Axis Module/Motor Wiring Examples
Interconnect Diagrams Axis Module/Motor Wiring Examples AM (460V) Wiring Example with MP-Series (MPL-B and MPG-B) Motors Kinetix 6000 MPL-B3xx, -B4xx, -B45xx, IAM (inverter) or AM -B5xx, -B6xx, -B8xx, -B9xx, and MPG-B Note 15 (460V) Servo Motors with Motor Feedback High Resolution Feedback Cable Shield (MF) Connector Clamp...
Page 205 Interconnect Diagrams AM (230V) Wiring Example with MP-Series (MPL-A and MPG-A) Motors Kinetix 6000 MPL-A3xx, -A4xx, -A45xx, IAM (inverter) or AM -A5xx, and MPG-Axxx (230V) Servo Motors with Note 15 High Resolution Feedback Motor Feedback Cable Shield (MF) Connector Clamp (IAM/AM) Note 10 SIN+...
Page 206 Interconnect Diagrams AM Wiring Example with MP-Series (MPL-A/B, MPF-A/B, and MPS-A/B) Motors Kinetix 6000 MPL-A/B15xx and -A/B2xx, IAM (inverter) or AM MPF-A/Bxxx and MPS-A/Bxxx Servo Motors with Motor Feedback Note 15 High Resolution Feedback (MF) Connector Cable Shield (IAM/AM) Clamp Shield Note 10 SIN+...
Page 207 Interconnect Diagrams AM (230V) Wiring Example with TL-Series Motors Kinetix 6000 TL-Series (230V) Servo Motors IAM (inverter) or AM with Incremental Feedback Note 15 Motor Feedback (MF) Connector Cable Shield Clamp (IAM/AM) Note 10 Green/Yellow BLACK WHT/BLACK Blue Motor Power Black (MP) Connector Three-phase...
Page 208 Interconnect Diagrams AM (460V) Wiring Example with 1326AB Motors Kinetix 6000 1326AB (M2L/S2L) IAM (inverter) or AM Servo Motors with High Resolution Feedback Note 15 Motor Feedback Cable Shield (MF) Connector Clamp (IAM/AM) Note 10 Green/Yellow SIN+ BLACK WHT/BLACK SIN- 1/Blue Motor Power COS+...
Page 209 Interconnect Diagrams AM (230V) Wiring Example with F-Series Motors Kinetix 6000 F-Series (230V) IAM (inverter) or AM Servo Motors with Incremental Feedback Note 15 Cable Shield Clamp Note 10 Green/Yellow Motor Feedback 1/Blue Motor Power (MF) Connector 2/Black (MP) Connector (IAM/AM) Three-phase 3/Brown...
Page 210: Controlling A Brake Example
Interconnect Diagrams AM (230V) Wiring Example with Y-Series Motors Kinetix 6000 Y-Series (230V) IAM (inverter) or AM Servo Motors with Incremental Feedback Note 15 Motor Feedback Cable Shield (MF) Connector Clamp (IAM/AM) Note 10 Green/Yellow BLACK 3/Black WHT/BLACK Motor Power 2/Black (MP) Connector Three-phase...
Page 211 Interconnect Diagrams For brake requirements outside of these limits, an external relay IMPORTANT must be used. < Coil Currents Rated at 1.0 A Compatible Brake Motors Coil Current Compatible Brake Motors Coil Current MPL-x15xx 0.48 A 1326AB-B4xxx 0.88 A MPL-x2xx 0.51 A F-4030, -4050, and -4075 0.69 A...
Page 212: System Block Diagrams
Interconnect Diagrams System Block Diagrams This section provides block diagrams of the Kinetix 6000 modules. For block diagrams of the line interface module (LIM) and resistive brake module (RBM), refer to Additional Resources on page 10 for the documentation available for those products. IAM/AM (inverter) Block Diagram Publication 2094-UM001A-EN-P —...
Page 213 Interconnect Diagrams IAM (converter) Block Diagram Publication 2094-UM001A-EN-P — September 2006...
Page 214 Interconnect Diagrams Kinetix 6000 drives with the safe-off feature ships with the wiring header and motion allowed jumper installed. In this configuration, as illustrated below, the safe-off feature is not used. Safe-off Feature Block Diagram Safe-Off Option Gate Control Safe-Off (SO) Power Supply 9-pin Connector K1-C...
Page 215: Upgrading Firmware
Appendix Upgrading Firmware Introduction This appendix provides procedures for upgrading firmware using either ControlFLASH or DriveExplorer software. Topic Page Introduction Using ControlFLASH Software to Upgrade Drive Firmware Using DriveExplorer Software to Upgrade Drive Firmware Publication 2094-UM001A-EN-P — September 2006...
Page 216: Using Controlflash Software To Upgrade Drive Firmware
Upgrading Firmware Using ControlFLASH Upgrading axis module firmware using ControlFLASH software involves selecting the drive to flash, configuring your Logix Software to Upgrade Drive communications, and flashing the firmware. Firmware Before You Begin You will need the following software and information before you begin.
Page 217: Selecting The Drive To Upgrade
Upgrading Firmware Selecting the Drive to Upgrade Follow these steps to upgrade (flash) your drive firmware. 1. Open your ControlFLASH software. The Welcome to ControlFLASH dialog opens. 2. Click Next. The Catalog Number dialog opens. 3. Select the catalog number of your drive module to flash. 4.
Page 218: Configuring Logix Communications
Upgrading Firmware Configuring Logix Communications This procedure assumes that your communication method to the Logix controller is using the Ethernet protocol. It is also assumed that your Logix Ethernet module has already been configured. For more information, refer to the ControlLogix System User Manual, publication 1756-UM001.
Page 219 Upgrading Firmware The Configure driver dialog opens. 6. Enter the IP address of your Logix ethernet module. The IP address shown is an example. Yours will be different. 7. Click OK. 8. Click Close in the Configure Drivers dialog. 9. Select RSWho from the Communication menu. The drive selection dialog opens.
Page 220: Flashing Firmware
Upgrading Firmware Flashing Firmware The Firmware Revision dialog opens with the current firmware revision listed. 1. Select the firmware revision for the upgrade. 2. Click Next. The Summary dialog opens. 3. Confirm the drive catalog number and firmware revision. Publication 2094-UM001A-EN-P — September 2006...
Page 221 Upgrading Firmware 4. Click Finish. This ControlFLASH warning dialog opens. 5. Click Yes (only if you are ready). This ControlFLASH warning dialog opens. 6. Acknowledge the warning and click OK. The Progress dialog opens and flashing begins. The drive module seven-segment LED indicator changes from the fixed 2, 3, or 4 to F which indicates that flashing is in progress.
Page 222: Troubleshooting Controlflash
Upgrading Firmware 7. The Update Status dialog opens and indicates success or failure as described below. Flashing 1. Update complete appears in a GREEN status dialog. Succeeded 2. Go to Step 8. 1. Update failure appears in a RED status dialog. Failed 2.
Page 223: Verifying The Firmware Upgrade
Upgrading Firmware Verifying the Firmware Upgrade Follow these steps to verify your firmware upgrade was successful. This procedure is optional. 1. Return to the RSLinx Classic software and expand the dialog tree to gain access to your drive module, as you did earlier. 2.
Page 224: Using Driveexplorer Software To Upgrade Drive Firmware
Personal computer with HyperTerminal software Refer to DriveExplorer Getting Results Manual, publication 9306-GR001, for instructions. Contact Rockwell Automation Technical Support at (440) 646-5800 for firmware upgrade file. Control power (24V dc) must be present at CPD-1 and -2 prior to IMPORTANT flashing your drive.
Page 225 Upgrading Firmware 3. Verify that the 1203-SSS has power by observing the LED indicated in the figure below. SCANport/DPI communication 4. Open the DriveExplorer software and select Connect from the Explore menu. The DriveExplorer software proceeds to read your system. 5.
Page 226: Hyperterminal Configuration
Upgrading Firmware 8. Double-click Axes to Flash. The Axis to Flash dialog opens. 9. Click (check) each axis to flash. Example above shows two axes to flash checked. 10. Select OK. The Axes to Flash parameter is set. 11. Close DriveExplorer. HyperTerminal Configuration Follow these steps to begin a new HyperTerminal session.
Page 227 Upgrading Firmware 3. Select OK. The following dialog opens. 4. Select the appropriate COM port. 5. Select OK. The following dialog opens. 6. Select the properties as shown above or as appropriate for your 1203-SSS SCANport adapter. Bits per second of HyperTerminal must match the IMPORTANT 1203-SSS SCANport adapter setting for connection to occur.
Page 228: Flashing Firmware
Upgrading Firmware Flashing Firmware This procedure assumes you have identified which axis modules require flashing, have set the Axes to Flash parameter, and have configured a HyperTerminal session. You must also know where to find your firmware upgrade file. IMPORTANT 1.
Page 229: Publication 2094-Um001A-En-P — September
Upgrading Firmware The following dialog opens. 4. Enter Y. As indicated in the text, the program begins displaying the character C. Program times-out after 60 seconds. If program times-out before you complete steps 5...8, return to Step 1. 5. From the Transfer menu select Send File. The Send File dialog opens.
Page 230 Upgrading Firmware The flash upgrade operation begins and the following dialog opens. To avoid unrecoverable fault to drive modules, do not ATTENTION interrupt control power to IAM, power to the 1203-SSS SCANport adapter, or power to your PC while the flash upgrade operation is in progress.
Page 231: Introduction
Appendix DC Common Bus Applications Introduction This appendix provides integration procedures specific to the Kinetix 6000 multi-axis servo-drive systems configured for dc common bus. The procedure involves calculating capacitance values and setting the Add Bus Cap parameter using DriveExplorer software. Topic Page Introduction...
Page 232: Calculating Total Bus Capacitance
DC Common Bus Applications Calculating Total Bus Total bus capacitance is the sum of all capacitance values for your Kinetix 6000 common bus modules. Specifically, this includes the Capacitance capacitance values for each of these modules. • Leader IAM (converter and inverter) •...
Page 233: Kinetix 6000 Capacitance Values
DC Common Bus Applications Kinetix 6000 Capacitance Use the tables below when calculating total bus capacitance and additional bus capacitance for your Kinetix 6000 common bus Values application. IAM/AM (230V) Modules Capacitance Capacitance IAM Converter (230V) AM Inverter (230V) µF µF 2094-AC05-MP5-S 2094-AMP5-S...
Page 234: Common Bus Capacitance Example
DC Common Bus Applications Common Bus Capacitance In the example below, the sum of the leader IAM power rail modules capacitance (6530 µF) and the follower IAM power rail modules Example capacitance (5280 µF) equals 11,810 µF total bus capacitance. The sum of the follower IAM power rail modules equal 5280 µF additional bus capacitance.
Page 235: Setting The Additional Bus Capacitance Parameter
DC Common Bus Applications Setting the Additional Bus In this procedure you will set the Add Bus Cap parameter using DriveExplorer software. Capacitance Parameter The following hardware and software tools are required to provide the necessary communication link between your personal computer and the Kinetix 6000 drive system running DriveExplorer software.
Page 236: Setting The Additional Bus Capacitance Parameter
DC Common Bus Applications Setting the Additional Bus Capacitance Parameter Follow these steps to set the Additional Bus Capacitance parameter. 1. Start your DriveExplorer software. 2. From the menu bar choose Explore\Connect\Local or enter Ctrl-L from the keyboard. DriveExplorer software will read your system. 3.
Page 237: Saving The Add Bus Cap Parameter To Non-Volatile Memory
DC Common Bus Applications The command dialog for parameter x599 - Add Bus Cap opens. 6. Select the Value Edit tab and enter the Add Bus Cap Value (μF). 7. Click OK. The RBM delay time is changed, but not saved in non-volatile memory.
Page 238: Reconnecting Sercos Communication
DC Common Bus Applications The save to non-volatile memory is complete and the following confirmation message dialog opens. 4. Click OK. 5. Close the DriveExplorer software. Reconnecting SERCOS Communication Follow these steps to reconnect SERCOS communication. 1. Remove three-phase and control power from the Kinetix 6000 drive system.
Page 239: Integrating Resistive Brake Modules With Kinetix 6000 Drives
Appendix Integrating Resistive Brake Modules with Kinetix 6000 Drives Introduction This appendix provides Bulletin 2090 Resistive Brake Module (RBM) integration procedures and interconnect diagrams specific to Kinetix 6000 multi-axis servo-drive systems. The procedure involves setting the time delay parameter using either RSLogix 5000 or DriveExplorer software.
Page 240: Understanding Safety Precautions
Integrating Resistive Brake Modules with Kinetix 6000 Drives Understanding Safety The following precautions apply to resistive brake module (RBM) installations as shown in the interconnect diagrams. Be sure to read Precautions and thoroughly understand them before proceeding. The interconnection diagrams should be used as a general ATTENTION recommendation on how the safety control circuit may be implemented.
Page 241: Background On Safety Design
Integrating Resistive Brake Modules with Kinetix 6000 Drives 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.
Page 242: Risk Assessment
Integrating Resistive Brake Modules with Kinetix 6000 Drives Risk Assessment The European safety standard (EN 1050) and U.S. technical report (ANSI B11.TR3) explain the process of risk assessment, which must be conducted by the machine builder. This is done by analyzing the tasks that people perform on and around the machine.
Page 243: Control Reliability
Integrating Resistive Brake Modules with Kinetix 6000 Drives 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.
Page 244 Integrating Resistive Brake Modules with Kinetix 6000 Drives The example diagram below shows Kinetix 6000 IAM, AM, and LIM (2094-ALxxS, -BLxxS, and -XL75S) wired with the Bulletin 2090 RBM in a category 2 configuration. RBM Wiring Example (Category 2 Configuration per EN954-1) Publication 2094-UM001A-EN-P —...
Page 245 Integrating Resistive Brake Modules with Kinetix 6000 Drives Publication 2094-UM001A-EN-P — September 2006...
Page 246 Integrating Resistive Brake Modules with Kinetix 6000 Drives The example diagram below shows Kinetix 6000 IAM, AM, and LIM (2094-AL09 and -BL02) wired with the Bulletin 2090 RBM in a category 2 configuration. RBM Wiring Example (Category 2 Configuration per EN954-1) Publication 2094-UM001A-EN-P —...
Page 247 Integrating Resistive Brake Modules with Kinetix 6000 Drives Publication 2094-UM001A-EN-P — September 2006...
Page 248 Integrating Resistive Brake Modules with Kinetix 6000 Drives The example diagram below shows Kinetix 6000 IAM and LIM (2094-ALxxS, -BLxxS, and -XL75S) wired with the Bulletin 2090 RBM in a category 3 configuration. RBM Wiring Example (Category 3 Configuration per EN954-1) Publication 2094-UM001A-EN-P —...
Page 249 Integrating Resistive Brake Modules with Kinetix 6000 Drives Publication 2094-UM001A-EN-P — September 2006...
Page 250 Integrating Resistive Brake Modules with Kinetix 6000 Drives The example diagram below shows Kinetix 6000 IAM and LIM (2094-AL09 and -BL02) wired with the Bulletin 2090 RBM in a category 3 configuration. RBM Wiring Example (Category 3 Configuration per EN954-1) Publication 2094-UM001A-EN-P —...
Page 251 Integrating Resistive Brake Modules with Kinetix 6000 Drives Publication 2094-UM001A-EN-P — September 2006...
Page 252: Setting The Rbm Delay Time Using Driveexplorer
Integrating Resistive Brake Modules with Kinetix 6000 Drives Setting the RBM Delay Time In this procedure you will break SERCOS ring communications, set the delay time parameter using DriveExplorer software, and re-establish Using DriveExplorer SERCOS communication. For This Revision of Do This RSLogix 5000 Software Proceed with these instructions using DriveExplorer to set...
Page 253: Setting The Rbm Delay Time Parameter
Integrating Resistive Brake Modules with Kinetix 6000 Drives Setting the RBM Delay Time Parameter Follow these steps to set the RBM delay time parameter. 1. Start your DriveExplorer software. 2. From the menu bar choose Explore\Connect\Local or enter Ctrl-L from the keyboard. DriveExplorer software will read your system.
Page 254: Saving The Delay Time Parameter To Non-Volatile Memory
Integrating Resistive Brake Modules with Kinetix 6000 Drives 5. Double-click the x:x:x641 RBM Delay parameter. The command dialog for parameter x641 - RBM Delay opens. 6. Select the Value Edit tab and enter the delay time Value (ms). The recommended RBM delay time is 71 ms. 7.
Page 255: Reconnecting Sercos Communication
Integrating Resistive Brake Modules with Kinetix 6000 Drives The changes are saved to non-volatile memory and the following cautionary message dialog opens. 3. Click Yes. The save to non-volatile memory is complete and the following confirmation message dialog opens. 4. Click OK. 5.
Page 256: Publication 2094-Um001A-En-P — September
Integrating Resistive Brake Modules with Kinetix 6000 Drives Publication 2094-UM001A-EN-P — September 2006...
Page 257 Index Numerics example with two power rails 1203-SSS serial cable baud rate 1756-MxxSE block diagrams 1768-M04SE converter 1784-PM16SE inverter 26-pin I/O connector safe-off feature shunt module blown fuse about this publication bonding ac line filters EMI (ElectroMagnetic noise reduction Interference) specifications examples acronyms...
Page 258 Index specifications converter clamp coordinated system time master comm status LED common bus (refer to DC CPLD FLT common bus) cycle time common bus flt configuration configuring DAC0 DAC1 base node address data rate baud rate, IAM data type delay times date and time tab feedback only axis DC common bus...
Page 259 Index EMI (ElectroMagnetic Interference) grounding bonding multiple subpanels enclosure requirements selection hardware enable input sizing, Kinetix 6000 hardware overtravel encoder communication fault headers motion allowed jumper environmental specifications HF bonding high frequency energy erratic operation error codes hookup fault establishing communications hookup tab external active shunt resistor human interface module (HIM)
Page 260 Index enclosure selection module properties fuse selection overview HF bonding specifications noise zones enclosure sizing system mounting requirements system overview transformer integrated axis module leader IAM catalog number configuring bus status connector designators comm status connector locations drive status dimensions logic power interconnect diagram SERCOS interface module...
Page 261 Index motor feedback loss overview motor jumps when first enabled motor overheating panel motor overtemp requirements motor velocity panel-mounted breakout kit motors parameters, changing brake wiring pin-outs feedback pin-outs auxiliary feedback connector feedback specifications ground termination I/O connector interconnect diagram IAM/AM 1326AB input connector...
Page 262 Index software RSLinx software RSLogix 5000 RSLogix 5000 software software overtravel specifications ac line filters certifications circuit breakers safe-off contactor ratings block diagram environmental motion allowed jumper external active shunt resistor pin-outs, AM pin-outs, IAM external passive shunt resistor wiring safe-off HW fault feedback safety...
Page 263 Index safe-off feature encoder communication shunt module fault system ground follow error system mounting requirements ground fault hardware overtravel system overview hookup fault DC common bus Ifbk HW fault with LIM illegal hall state without LIM IPM fault memory init module mismatch motor encoder error task init...
Page 264 Index status only stop motion BC connector supplemental troubleshooting CED connector information CPD connector changing parameters IPD connector using analog test points MP connector SO connector temperature fault LED IAM with LIM tuning axes 24V connector bandwidth APL connector tune tab CPL connector typical installation IPL connector...
Page 265 Notes: Publication 2094-UM001A-EN-P — September 2006...
Page 266 Notes: Publication 2094-UM001A-EN-P — September 2006...
Page 267 Notes: Publication 2094-UM001A-EN-P — September 2006...
Page 268 Outside United Please contact your local Rockwell Automation representative for States return procedure. Publication 2094-UM001A-EN-P — September 2006 Supersedes Publication 2094-IN001G-EN-P and 2094-IN002E-EN-P Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Rockwell Automation Allen-Bradley Kinetix 6000 User Manual

Preface

Chapter 1

Start

Appendix D

Chapter 2

Planning the Kinetix 6000 Drive System Installation

Chapter 3 Introduction

Mounting the Kinetix 6000 Drive System

Chapter 4

Kinetix 6000 Connector Data

Chapter 5

Connecting the Kinetix 6000 Drive System

Chapter 6

Configure and Startup the Kinetix 6000 Drive System

Appendix D

Chapter 7

Troubleshooting the Kinetix 6000 Drive System

Chapter 8

Removing and Replacing the Kinetix 6000 Drive Modules

Appendix A Power Specifications

Appendix B

Interconnect Diagrams

Appendix C

Upgrading Firmware

Appendix E

Integrating Resistive Brake Modules with Kinetix 6000 Drives

Quick Links

Troubleshooting

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Summary of Contents for Rockwell Automation Allen-Bradley Kinetix 6000