2094-BSP2 2094-PRF 2094-BC04-M03-S 2094-BM03-S 2094-BC07-M05-S 2094-BM05-S - Datasheet Archive

 

Kinetix 6000 Multi-axis Servo Drives Catalog Numbers 2094-ACxx-Mxx-S, 2094-BCxx-Mxx-S, 2094-AMxx-S, 2094-BMxx-S 2094-ACxx-Mxx,

 

User Manual Kinetix 6000 Multi-axis Servo Drives Catalog Numbers 2094-ACxx-Mxx-S, 2094-BCxx-Mxx-S, 2094-AMxx-S, 2094-BMxx-S 2094-ACxx-Mxx, 2094-BCxx-Mxx, 2094-AMxx, 2094-BMxx, 2094-BSP2 2094-BSP2, 2094-PRF 2094-PRF Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Allen-Bradley, CompactLogix, ControlFLASH, ControlLogix, Guardmaster, DriveExplorer, Kinetix, LDC-Series, LDL-Series, MP-Series, RSLinx, RSLogix 5000, SoftLogix, SCANport, RDD-Series, Rockwell Automation, Rockwell Software, TechConnect, and TL-Series are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Summary of Changes This manual contains new and updated information. New and Updated Information This revision includes peak-enhancement drive specifications for series B catalog numbers 2094-BC04-M03-S 2094-BC04-M03-S, 2094-BM03-S 2094-BM03-S, 2094-BC07-M05-S 2094-BC07-M05-S, and 2094-BM05-S 2094-BM05-S. Section Chapter 1 Topic Page IAM/AM Module Series Change 13 Catalog Number Explanation 19 Drive Component Compatibility 84 100 Motor Power Cable Compatibility 101 Motor Brake Cable Compatibility 107 Motor Feedback Cable Compatibility - Bayonet Connectors 110 Motor Feedback Cable Compatibility - Circular DIN/Plastic Connectors 111 Configure Axis Properties 142 IAM Module (460V) Power Specifications (series A and B) Chapter 6 69 MP-Series (Bulletin MPL) Motor Connectors Chapter 5 20 Peak Enhancement Specifications Set the Ground Jumper Chapter 4 181 Appendix A AM Module (inverter) 460V Power Specifications (series A and B) Product Dimensions Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 183 195 3 Summary of Changes Notes: 4 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Table of Contents Preface About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 12 Chapter 1 Start Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IAM/AM Module Series Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About the Kinetix 6000 Drive Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Hardware Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Component Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Requirements (system without LIM module). . . . . . . . . . . . . . . . CE Requirements (system with LIM module) . . . . . . . . . . . . . . . . . . . 13 13 14 15 18 19 20 21 21 22 Chapter 2 Planning the Kinetix 6000 Drive Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 System Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 System Installation System Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker/Fuse Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Noise Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bonding Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bonding Multiple Subpanels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Establishing Noise Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Categories for Kinetix 6000 Systems . . . . . . . . . . . . . . . . . . . . . Noise Reduction Guidelines for Drive Accessories . . . . . . . . . . . . . . . 24 25 26 27 30 31 31 33 34 41 43 Chapter 3 Mounting the Kinetix 6000 Drive Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Using the 2094 Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 System Installing the 2094 Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Determine Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Mount Modules on the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 5 Table of Contents Chapter 4 Kinetix 6000 Connector Data Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IAM/AM Module Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe-off Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Feedback Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Feedback Connector Pinout. . . . . . . . . . . . . . . . . . . . . . . . . . IAM Input Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IAM and AM Motor Power and Brake Connector Pinout . . . . . . . Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERCOS Communication Specifications. . . . . . . . . . . . . . . . . . . . . . . Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power and Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor/Resistive Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Power Cycle Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peak Enhancement Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback Power Supply Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Position Feedback Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . 53 54 56 57 58 60 61 62 63 63 64 65 66 67 67 68 69 72 73 73 75 76 Chapter 5 Connecting the Kinetix 6000 Drive System 6 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ungrounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Common Bus Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Bus Fusing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Ground Jumper in Ungrounded Power Configurations . . . Set the Ground Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding the Kinetix 6000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . Ground the Power Rail to the System Subpanel . . . . . . . . . . . . . . . . . Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring the IAM/AM Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . . Wire the Control Power (CPD) Connector . . . . . . . . . . . . . . . . . . . . Wire the Input Power (IPD) Connector. . . . . . . . . . . . . . . . . . . . . . . . Wire the Contactor Enable (CED) Connector. . . . . . . . . . . . . . . . . . Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 77 77 78 78 79 79 81 82 83 83 84 89 89 90 91 93 94 94 95 97 Table of Contents Wiring the Safe-off (SO) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Wire the Motor Power (MP) Connector . . . . . . . . . . . . . . . . . . . . . . . 99 Wire the Motor/Resistive Brake (BC) Connector . . . . . . . . . . . . . . 106 Apply the Motor Cable Shield Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Flying-lead Feedback Cable Pin-outs . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Wiring the Feedback and I/O Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 115 Connect Premolded Motor Feedback Cables. . . . . . . . . . . . . . . . . . . 115 Connect Panel-mounted Breakout Board Kits . . . . . . . . . . . . . . . . . 116 Wire Low-profile Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 RBM Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 SERCOS Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . 122 Installing the Fiber-optic Connector Bracket Kit . . . . . . . . . . . . . . . 125 Chapter 6 Configure and Start Up the Kinetix 6000 Drive System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure the Logix SERCOS interface Module . . . . . . . . . . . . . . . . . . . Configure the Logix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure the Logix Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure the Kinetix 6000 Drive Modules . . . . . . . . . . . . . . . . . . . . Configure the Motion Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Apply Power to the Kinetix 6000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . Test and Tune the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tune the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Drive Parameters and System Variables . . . . . . . . . . . . . . . . . Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitor System Variables with Analog Test Points. . . . . . . . . . . . . 127 128 133 133 135 137 141 142 146 146 148 148 150 153 153 154 Chapter 7 Troubleshooting the Kinetix 6000 Drive System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IAM/AM Module Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . Shunt Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General System Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Logix/Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 157 157 158 158 164 165 167 169 7 Table of Contents Chapter 8 Removing and Replacing the Kinetix 6000 Drive Modules Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Kinetix 6000 Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace Kinetix 6000 Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 173 174 175 176 177 Appendix A Specifications and Dimensions Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Axis Module (converter) Power Specifications . . . . . . . Axis Module (inverter) Power Specifications . . . . . . . . . . . . . . . . . . . Shunt Module Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transformer Specifications for Control Power Input . . . . . . . . . . . Power Dissipation Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Power Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Shunt Module Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 180 182 184 187 188 188 189 190 190 191 192 192 193 193 194 195 Appendix B Interconnect Diagrams 8 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Common Bus Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . Shunt Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis Module/Rotary Motor Wiring Examples. . . . . . . . . . . . . . . . . . Axis Module/Linear Motor/Actuator Wiring Examples . . . . . . . . Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 199 200 201 205 209 212 220 224 225 Table of Contents Appendix C Upgrading the Kinetix 6000 Drive Firmware Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upgrade Drive Firmware with ControlFLASH Software . . . . . . . . . . . Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configure Logix Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upgrade Drive Firmware with DriveExplorer Software . . . . . . . . . . . . . Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Axis Modules to Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HyperTerminal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 230 230 231 233 237 238 238 238 240 242 Appendix D DC Common Bus Applications Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculate Total Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculate Additional Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2094 Drive Capacitance Values. . . . . . . . . . . . . . . . . . . . . . . . . . . Common Bus Capacitance Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set the Additional Bus Capacitance Parameter with DriveExplorer Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove SERCOS Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . Set the Additional Bus Capacitance Parameter . . . . . . . . . . . . . . . . . Save the Add Bus Cap Parameter to Non-volatile Memory . . . . . . Reconnect SERCOS Communication. . . . . . . . . . . . . . . . . . . . . . . . . 245 245 246 247 247 248 249 249 250 251 252 Appendix E Changing the Default IDN Parameter Values Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change IDN Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read the Present IDN Parameter Value. . . . . . . . . . . . . . . . . . . . . . . . Calculate the New IDN Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Write the New IDN Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . 253 253 254 254 256 257 Appendix F RBM Module Interconnect Diagrams Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 RBM Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Index Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 9 Table of Contents Notes: 10 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Preface About This Publication This manual provides detailed installation instructions for mounting, wiring, and troubleshooting the Kinetix 6000 drives; and system integration for your drive/motor/actuator combination with a Logix controller. For information on wiring and troubleshooting your Kinetix 6000 servo drive with the safe-off feature, refer to the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 GMC-RM002. Who Should Use This Manual This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 6000 drives; and programmers directly involved in the operation, field maintenance, and integration of these drives with a SERCOS interface module. If you do not have a basic understanding of the Kinetix 6000 drives, contact your local Rockwell Automation sales representative for information on available training courses. Conventions Used in This Manual The conventions starting below are used throughout this manual. · Bulleted lists such as this one provide information, not procedural steps. · Numbered lists provide sequential steps or hierarchical information. · Acronyms for the Kinetix 6000 drive components are shown in the table below and are used throughout this manual. Kinetix 6000 Drive Component Cat. No. Acronym Integrated Axis Module 2094-xCxx-Mxx-x IAM Axis Module 2094-xMxx-x AM Line Interface Module 2094-xLxx and 2094-xLxxS-xx LIM Resistive Brake Module 2090-XBxx-xx RBM IMPORTANT Throughout this publication, when the IAM or AM module catalog number is followed by -x, for example 2094-BMP5-x, the variable (x) indicates that the drive module may or may not include the safe-off feature. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 11 Preface Additional Resources These documents contain additional information concerning related Rockwell Automation products. Resource Description Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003 2094-IN003 Information on the installation of your Bulletin 2094 power rail. Kinetix 6000 Shunt Module Installation Instructions, publication 2094-IN004 2094-IN004 Information on the installation of your Bulletin 2094 shunt module. Line Interface Module Installation Instructions, publication 2094-IN005 2094-IN005 Information on the installation and troubleshooting of Bulletin 2094 line interface modules (LIM). Slot-filler Module Installation Instructions, publication 2094-IN006 2094-IN006 Information on the installation of Bulletin 2094 slot-filler module. 2094 Mounting Bracket Installation Instructions, publication 2094-IN008 2094-IN008 Information on the installation of Bulletin 2094 mounting brackets. Resistive Brake Module Installation Instructions, publication 2090-IN009 2090-IN009 Information on the installation and wiring of Bulletin 2090 Resistive Brake Modules. Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010 2090-IN010 Information on proper handling, installing, testing, and troubleshooting fiber-optic cables. External Shunt Modules Installation Instructions, publication 2090-IN004 2090-IN004 Information on mounting and wiring the Bulletin 1394 shunt modules with Bulletin 2094 servo drive systems. 1336 Chopper Module Installation Instructions, publication 1336-5.65 Information on installing, configuring, and calculating the data needed to select a 1336 chopper module and external resistor. System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001 Information, examples, and techniques designed to minimize system failures caused by electrical noise. EMC Noise Management DVD, publication GMC-SP004 GMC-SP004 Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 GMC-RM002 Information on wiring and troubleshooting your Kinetix 6000 servo drives with the safe-off feature. Kinetix Motion Control Selection Guide, publication GMC-SG001 GMC-SG001 Specifications, motor/servo-drive system combinations, and accessories for Kinetix motion control products. Rockwell Automation Configuration and Selection Tools website http://www.rockwellautomation.com/en/e-tools Motion Analyzer application analysis software for drive/motor sizing. Rockwell Automation Product Certification, website For declarations of conformity (DoC) currently available from Rockwell Automation. SERCOS and Analog Motion Configuration User Manual, publication MOTION-UM001 MOTION-UM001 Information on configuring and troubleshooting your ControlLogix, CompactLogix, and SoftLogix SERCOS interface modules. Motion Coordinate System User Manual, publication MOTION-UM002 MOTION-UM002 Information to create a motion coordinate system with SERCOS or analog motion modules. Online product selection and system configuration tools, including AutoCAD (DXF) drawings. SoftLogix Motion Card Setup and Configuration Manual, publication 1784-UM003 1784-UM003 Information on configuring and troubleshooting SoftLogix PCI cards. ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-QS105 1756-QS105 For ControlFLASH information not specific to any drive family. National Electrical Code, published by the National Fire Protection Association of Boston, MA An article on wire sizes and types for grounding electrical equipment. Rockwell Automation Industrial Automation Glossary, publication AG-7.1 A glossary of industrial automation terms and abbreviations. You can view or download publications at http://www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. 12 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Chapter 1 Start Introduction Use this chapter to become familiar with the design and installation requirements for Kinetix 6000 drive systems. Topic Page Introduction 13 About the Kinetix 6000 Drive Systems 14 Catalog Number Explanation 19 Agency Compliance 21 IAM/AM Module Series Change The peak current ratings of the Kinetix 6000 AM modules (series A and B) are configured at the factory as 150% of continuous current. You can program 460V (series B) AM modules and the equivalent IAM (inverter) modules, for up to 250% of continuous inverter current. Table 1 - Kinetix 6000 Series Change IAM Module Cat. No. AM Module Cat. No. Peak Current Rating Series A (inverter) Series B (inverter) 2094-BC01-MP5-S 2094-BC01-MP5-S 2094-BMP5-S 2094-BMP5-S 150% 250% 2094-BC01-M01-S 2094-BC01-M01-S 2094-BM01-S 2094-BM01-S 150% 250% 2094-BC02-M02-S 2094-BC02-M02-S 2094-BM02-S 2094-BM02-S 150% 250% 2094-BC04-M03-S 2094-BC04-M03-S 2094-BM03-S 2094-BM03-S 150% 250% 2094-BC07-M05-S 2094-BC07-M05-S 2094-BM05-S 2094-BM05-S 150% 200% IMPORTANT Before your drive will deliver enhanced peak performance, you must enable the peak enhancement feature by configuring your drive by using DriveExplorer or RSLogix 5000 software. Refer to the interactive Peak Enhancement Configuration Utility to recalculate torque and accel/decel limit values, and paste them into the appropriate Axis Properties dialog box. To download the utility, go to http://www.ab.com/motion/software/peak.html. For more information on setting axis properties in RSLogix 5000 software, refer to Configure Axis Properties on page 142. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 13 Chapter 1 Start About the Kinetix 6000 Drive Systems The Kinetix 6000 multi-axis servo drives are designed to provide a Kinetix Integrated Motion solution for your drive/motor/actuator applications. Table 2 - Kinetix 6000 Drive System Overview System Component Cat. No. Description 2094-xCxx-Mxx-S (1) (2) Integrated Axis Modules (IAM) with the safe-off feature are available with 230V or 460V AC input power and contains an inverter and converter section. The peak enhancement feature is available on 460V (series B) IAM modules. 2094-xCxx-Mxx Integrated Axis Modules (IAM), available with 230V or 460V AC input power (does not include the safe-off or peak-enhanced feature), contains an inverter and converter section. 2094-xMxx-S (1) (2) Axis Modules (AM) with the safe-off feature are a shared DC-bus inverter rated for 230V or 460V input power. The AM module must be used with an IAM module. The peak enhancement feature is available on 460V (series B) AM modules. 2094-xMxx Axis Modules (AM) are a shared DC-bus inverter rated for 230V or 460V input power (does not include the safe-off or peak-enhanced feature). The AM module must be used with an IAM module. Shunt Module 2094-BSP2 2094-BSP2 The Bulletin 2094 shunt module mounts to the power rail and provides additional shunting capability in regenerative applications. Power Rail 2094-PRSx 2094-PRx The Bulletin 2094 power rail consists of copper bus bars and a circuit board with connectors for each module. The power rail provides power and control signals from the converter section to adjacent inverters. The IAM and AM power modules, shunt module, slot-filler modules mount to the power rail. Integrated Axis Module Axis Module Power Rail Slot-filler Module 2094-PRF 2094-PRF The Bulletin 2094 slot-filler module is used when one or more slots on the power rail are empty after all the other power rail modules are installed. One slot-filler module is required for each empty slot. Logix Controller Platform 1756-MxxSE module 1768-M04SE 1768-M04SE module 1784-PM16SE 1784-PM16SE PCI card The SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix platform and the Kinetix 6000 drive system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (SERCOS) protocol over a fiber-optic cable. RSLogix 5000 Software 9324-RLD300ENE 9324-RLD300ENE RSLogix 5000 software provides support for programming, commissioning, and maintaining the Logix family of controllers. Rotary Servo Motors MP-Series, TL-Series, RDD-Series, 1326AB 1326AB, F-Series Compatible rotary motors include the MP-Series (Bulletin MPL, MPM, MPF, and MPS) 230 and 460V motors; RDD-Series; TL-Series; 1326AB 1326AB (M2L/S2L) and 1326AB 1326AB (resolver); and F-Series motors. Linear Motors LDC-Series, LDL-Series Compatible motors include LDC-Series iron core (230/460V 230/460V) and LDL-Series ironless (230V) linear motors. Linear Actuators MP-Series Compatible actuators include MP-Series (230/460V 230/460V) Bulletin MPAS single-axis and Bulletin MPMA multi-axis integrated linear stages, and MP-Series (230/460V 230/460V) Bulletin MPAR and MPAI electric cylinders. Cables Motor Power, Feedback, and Brake cables Bulletin 2090 motor power/brake and feedback cables are available with bayonet, threaded, and SpeedTec connectors. Power/brake cables have flying leads on the drive end and straight connectors that connect to servo motors. Feedback cables have flying leads that wire to low-profile connector kits on the drive end and straight connectors on the motor end. Communication Bulletin 2090 SERCOS fiber-optic cables are available as enclosure only, PVC, nylon, and glass with connectors at both ends. AC Line Filters 2090-XXLF-xxxx Bulletin 2090-XXLF-xxxx three-phase AC line filters are required to meet CE and available for use in all Kinetix 6000 (230V and 460V) drive systems. Line Interface Modules 2094-xLxx 2094-xLxxS 2094-XL75S-Cx Line interface modules (LIM) include the circuit breakers, AC line filter (catalog numbers 2094-AL09 2094-AL09 and 2094-BL02 2094-BL02 only), power supplies, and safety contactor required for Kinetix 6000 operation. The LIM module does not mount to the power rail. You can purchase individual components separately in place of the LIM module. 1394-SRxxxx You can use Bulletin 1394 external passive shunt modules when the IAM/AM power module internal shunt and power rail mounted 2094-BSP2 2094-BSP2 shunt module capability is exceeded. 1336-Wxxxx You can use Bulletin 1336 external active shunt modules when the IAM/AM power module internal shunt resistor capability is exceeded. Bulletin 1336-Wxxxx chopper modules require an external resistor. 2090-XBxx-xx Resistive Brake Modules (RBM) include a safety contactor for use in a control circuit. Contactors and resistors reside in this module such that the motor leads can be disconnected from the drive with the permanent magnet motor brought to an immediate stop. This module does not mount to the power rail. External Shunt Modules Resistive Brake Module (1) Refer to the Kinetix Safe-off Feature Safety Reference Manual, publication GMC-RM002 GMC-RM002, for more information. (2) Refer to Peak Enhancement Specifications on page 69 for more information on drive performance in the Peak-enhanced mode. 14 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Start Typical Hardware Configurations Chapter 1 Typical Kinetix 6000 system installations include three-phase AC configurations, with and without the line interface module (LIM), and DC common-bus configurations. SHOCK HAZARD: To avoid personal injury due to electrical shock, place a 2094-PRF 2094-PRF slot-filler module in all empty slots on the power rail. Any power rail connector without a module installed will disable the Kinetix 6000 three-phase power; however, control power is still present. Figure 1 - Typical Kinetix 6000 System Installation (with LIM) Logix Controller Programming Network Logix SERCOS interface Module RSLogix 5000 Software SERCOS interface CP OK Logix Platform (ControlLogix is shown) Kinetix 6000 Multi-axis Servo Drive System Tx (rear) Rx (front) 2090-XXLF-xxxx AC Line Filter (required for CE) Three-phase Input Power 2090-SCxxx-x SERCOS Fiber-optic Cable 2094-BSP2 2094-BSP2 Shunt Module (optional component) 115/230V 115/230V Control Power 2094-xCxx-Mxx-x Integrated Axis Module 2094-PRF 2094-PRF Slot-filler Module (required to fill any unused slots) MAIN VAC 2094-PRSx Power Rail 2094-xLxxS Line Interface Module (optional component) 2094-xMxx-x Axis Modules (5) I/O Connections To Input Sensors and Control String Bulletin 2090 Motor Feedback Cable 2090-K6CK-xxxxx Low-profile Connector Kits for I/O, Motor Feedback, and Aux Feedback MP-Series, TL-Series, 1326AB 1326AB (M2L/S2L), and F-Series Rotary Motors (MPL-Bxxxx motors shown) Bulletin 2090 Motor Power Cable MP-Series Integrated Linear Stages (MPAS-B9xxx ballscrew shown) RDD-Series Direct Drive Motors (1) (RDB-Bxxxx motor shown) LDC-Series and LDL-Series Linear Motors (LDC-Cxxxxxx linear motor shown) MP-Series Electric Cylinders (MPAR-Bxxxx electric cylinder shown) (1) RDD-Series direct-drive motors require the 2090-K6CK-KENDAT 2090-K6CK-KENDAT low-profile feedback module. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 15 Chapter 1 Start Figure 2 - Typical Kinetix 6000 System Installation (without LIM) Logix Controller Programming Network Three-phase Input Power Logix SERCOS interface Module Logix Platform (ControlLogix is shown) Line Disconnect Device RSLogix 5000 Software Input Fusing Kinetix 6000 Multi-axis Servo Drive System Single-phase Control Power Magnetic Contactor 2090-SCxxx-x SERCOS Fiber-optic Cable 2090-XXLF-xxxx AC Line Filter (required for CE) 2094-BSP2 2094-BSP2 Shunt Module (optional component) 2094-xCxx-Mxx-x Integrated Axis Module 2094-PRF 2094-PRF Slot-filler Module (required to fill any unused slots) I/O Connections 2094-PRSx Power Rail To Input Sensors and Control String 2094-xMxx-x Axis Modules (5) Bulletin 2090 Motor Feedback Cable 2090-K6CK-xxxxx Low-profile Connector Kits for I/O, Motor Feedback, and Aux Feedback MP-Series, TL-Series, 1326AB 1326AB (M2L/S2L), and F-Series Rotary Motors (MPL-Bxxxx motors shown) Bulletin 2090 Motor Power Cable MP-Series Integrated Linear Stages (MPAS-B9xxx ballscrew shown) RDD-Series Direct Drive Motors (1) (RDB-Bxxxx motor shown) LDC-Series and LDL-Series Linear Motors (LDC-Cxxxxxx linear motor shown) MP-Series Electric Cylinders (MPAR-Bxxxx electric cylinder shown) (1) RDD-Series direct-drive motors require the 2090-K6CK-KENDAT 2090-K6CK-KENDAT low-profile feedback module. 16 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Start Chapter 1 Figure 3 - Typical DC Common Bus System Installation Logix Controller Programming Network Logix SERCOS interface Module Three-phase Input Power 2090-XXLF-xxxx AC Line Filter (required for CE) SERCOS interface CP OK Logix Platform (ControlLogix is shown) Tx (rear) Rx (front) Kinetix 6000 Multi-axis Servo Drive System 2090-SCxxx-x SERCOS Fiber-optic Cable 115/230V 115/230V Control Power 2094-BSP2 2094-BSP2 Shunt Module (optional component) 2094-xCxx-Mxx-x Integrated Axis Module 2094-xLxxS Line Interface Module (optional component) RSLogix 5000 Software 2094-PRF 2094-PRF Slot-filler Module (required to fill any unused slots) 2094-PRSx Power Rail DC Common Bus Motors and other details common to both three-phase AC and DC common-bus configurations are removed. 2094-xMxx-x Axis Modules (5) 2090-SCxxx-x SERCOS Fiber-optic Cable 2094-xCxx-Mxx-x Integrated Axis Module 2094-PRF 2094-PRF Slot-filler Module (required to fill any unused slots) 2094-PRSx Power Rail 2094-xMxx-x Axis Modules (6) In the example above, the leader IAM module is connected to the follower IAM module via the DC common-bus. When planning your panel layout, you must calculate the total bus capacitance of your DC common-bus system to be sure that the leader IAM module is sized sufficiently to pre-charge the entire system. Refer to Appendix D, beginning on page 245, for more information. IMPORTANT If total bus capacitance of your system exceeds the leader IAM module pre-charge rating and input power is applied, the IAM module seven-segment status indicator will display error code E90 (pre-charge timeout fault). To correct this condition, you must replace the leader IAM module with a larger module or decrease the total bus capacitance by removing AM modules. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 17 Chapter 1 Start Typical Communication Configurations In this example, drive-to-drive SERCOS cables and catalog numbers are shown when Kinetix 6000 and Kinetix 6200 drive modules exist on the same power rail. The Kinetix 6200 control modules use SERCOS interface for configuring the Logix module and the EtherNet/IP network for diagnostics and configuring safety functions. An Ethernet cable is connected to each control module during safety configuration. Figure 4 - Typical Kinetix 6000 and Kinetix 6200 Communication (SERCOS) Logix Controller Programming Network Logix SERCOS interface Module SERCOS interface CP OK Logix Platform (ControlLogix is shown) RSLogix 5000 Software Tx (rear) Rx (front) Ethernet cable connections are required only for programming the 2094-SE02F-M00-S1 2094-SE02F-M00-S1 control module safety configurations. 2090-SCxxx-x) SERCOS Fiber-optic Cable 0.2 m (7.0 in.) 0.1 m (5.1 in.) 2094-BCxx-Mxx-S IAM Module 6200 6200 SAFE SPEED SAFE SPEED Ethernet Cables (1585J-M8CBJM-x) 2094-BMxx-S AM Modules 2094-BMxx-M Axis Modules (5) with 2094-SE02F-M00-Sx Control Modules (5) 0.1 m (5.1 in.) 0.2 m (7.0 in.) 0.1 m (5.1 in.) Drive-to-Drive SERCOS Cable Selection 2094-BCxx-Mxx-M or 2094-BMxx-M to 2094-BMxx-M = 2090-SCEP0-2 2090-SCEP0-2 2094-BCxx-Mxx-S IAM Module 6200 2094-BCxx-Mxx-M or 2094-BMxx-M to 2094-BMxx-S = 2090-SCEP0-1 2090-SCEP0-1 6200 SAFE SPEED SAFE SPEED 2094-BCxx-Mxx-S or 2094-BMxx-S to 2094-BMxx-S = 2090-SCEP0-1 2090-SCEP0-1 2094-BCxx-Mxx-S or 2094-BMxx-S to 2094-BMxx-M = 2090-SCEP0-2 2090-SCEP0-2 2094-BMxx-S AM Module 2094-BMxx-S AM Module 2094-BMxx-M AM Power Modules with 2094-SE02F-M00-Sx Control Modules 18 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Start Catalog Number Explanation Chapter 1 Kinetix 6000 (Bulletin 2094) drive catalog numbers and descriptions are listed in the tables below. IMPORTANT Throughout this publication, when the IAM or AM module catalog number is followed by -x, for example 2094-BMP5-x, the variable (x) indicates that the drive module may or may not include the safe-off feature. Table 3 - Kineitx 6000 Drive Catalog Numbers Integrated Axis Modules (230V) Cat. No. (with safe-off feature) Cat. No. (without safe-off feature) Kinetix 6000, IAM, 230V, 3 kW converter, 5 A inverter 2094-AC05-MP5-S 2094-AC05-MP5-S 2094-AC05-MP5 2094-AC05-MP5 Kinetix 6000, IAM, 230V, 3 kW converter, 9 A inverter 2094-AC05-M01-S 2094-AC05-M01-S 2094-AC05-M01 2094-AC05-M01 Kinetix 6000, IAM, 230V, 6 kW converter, 15 A inverter 2094-AC09-M02-S 2094-AC09-M02-S 2094-AC09-M02 2094-AC09-M02 Kinetix 6000, IAM, 230V, 11 kW converter, 24 A inverter 2094-AC16-M03-S 2094-AC16-M03-S 2094-AC16-M03 2094-AC16-M03 Kinetix 6000, IAM, 230V, 23 kW converter, 49 A inverter 2094-AC32-M05-S 2094-AC32-M05-S 2094-AC32-M05 2094-AC32-M05 Kinetix 6000, IAM, 460V, 6 kW converter, 4 A inverter 2094-BC01-MP5-S 2094-BC01-MP5-S (1) 2094-BC01-MP5 2094-BC01-MP5 Kinetix 6000, IAM, 460V, 6 kW converter, 9 A inverter 2094-BC01-M01-S 2094-BC01-M01-S (1) 2094-BC01-M01 2094-BC01-M01 Kinetix 6000, IAM, 460V, 15 kW converter, 15 A inverter 2094-BC02-M02-S 2094-BC02-M02-S (1) 2094-BC02-M02 2094-BC02-M02 Kinetix 6000, IAM, 460V, 28 kW converter, 30 A inverter 2094-BC04-M03-S 2094-BC04-M03-S (1) 2094-BC04-M03 2094-BC04-M03 Kinetix 6000, IAM, 460V, 45 kW converter, 49 A inverter 2094-BC07-M05-S 2094-BC07-M05-S (2) 2094-BC07-M05 2094-BC07-M05 Kinetix 6000, AM, 230V, 5 A 2094-AMP5-S 2094-AMP5-S 2094-AMP5 2094-AMP5 Kinetix 6000, AM, 230V, 9 A 2094-AM01-S 2094-AM01-S 2094-AM01 2094-AM01 Kinetix 6000, AM, 230V, 15 A 2094-AM02-S 2094-AM02-S 2094-AM02 2094-AM02 Kinetix 6000, AM, 230V, 24 A 2094-AM03-S 2094-AM03-S 2094-AM03 2094-AM03 Kinetix 6000, AM, 230V, 49 A 2094-AM05-S 2094-AM05-S 2094-AM05 2094-AM05 Kinetix 6000, AM, 460V, 4 A 2094-BMP5-S 2094-BMP5-S (1) 2094-BMP5 2094-BMP5 Kinetix 6000, AM, 460V, 9 A 2094-BM01-S 2094-BM01-S (1) 2094-BM01 2094-BM01 Kinetix 6000, AM, 460V, 15 A 2094-BM02-S 2094-BM02-S (1) 2094-BM02 2094-BM02 Kinetix 6000, AM, 460V, 30 A 2094-BM03-S 2094-BM03-S (1) 2094-BM03 2094-BM03 Kinetix 6000, AM, 460V, 49 A 2094-BM05-S 2094-BM05-S (2) 2094-BM05 2094-BM05 Integrated Axis Modules (460V) Axis Modules (230V) Axis Modules (460V) (1) You can configure the peak inverter current rating of this 460V (series B) IAM or AM module for 250% of continuous inverter current. (2) You can configure the peak inverter current rating of this 460V (series B) IAM or AM module for 200% of continuous inverter current. Refer to Peak Enhancement Specifications on page 69, for more information on drive performance in the peak-enhanced mode. Table 4 - Kinetix 6000 Drive Component Catalog Numbers Drive Components Cat. No. Kinetix 6000 shunt module, 230/460V 230/460V, 200 W 2094-BSP2 2094-BSP2 Kinetix 6000 slot-filler module, 230/460V 230/460V 2094-PRF 2094-PRF Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 19 Chapter 1 Start Drive Component Compatibility The 2094-BCxx-Mxx-M and 2094-BMxx-M power modules contain the same power structure as the 2094-BCxx-Mxx-S and 2094-BMxx-S drive modules. Because of this, the 2094-BSP2 2094-BSP2 shunt module, 2094-PRF 2094-PRF slot-filler module, and 2094-PRSx power rails are supported by both drive families. In addition, 2094-BMxx-M AM power modules with SERCOS interface are supported on power rails with a 2094-BCxx-Mxx-S IAM drive module. Conversely, 2094-BMxx-S AM drive modules are supported on power rails with a 2094-BCxx-Mxx-M IAM power module with SERCOS interface. IMPORTANT Kinetix 6500 EtherNet/IP control modules (catalog numbers 2094-EN02D-M01-Sx) are not compatible with IAM/AM modules on the same Bulletin 2094 power rail with Kinetix 6000 or Kinetix 6200 SERCOS drives. Table 5 - IAM and AM Module/Network Compatibility IAM Module Control Module 2094-xCxx-Mxx-S 2094-xMxx-S Kinetix 6000 AM Module 2094-BMxx-M AM Power Modules N/A 2094-BCxx-Mxx-M (IAM power module) 2094-SE02F-M00-Sx 2094-EN02D-M01-Sx Kinetix 6200 Control Module Kinetix 6500 Control Module 2094-SE02F-M00-Sx SERCOS interface Fully compatible Fully compatible Not compatible 2094-EN02D-M01-Sx EtherNet/IP network Not compatible Not compatible Fully compatible For additional information on the 2094-BCxx-Mxx-M (IAM) and 2094-BMxx-M (AM) modules, refer to the Kinetix 6200 and Kinetix 6500 Multi-axis Servo Drives User Manual, publication 2094-UM002 2094-UM002. 20 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Start Agency Compliance Chapter 1 If this product is installed within the European Union and has the CE mark, the following regulations apply. ATTENTION: Meeting CE requires a grounded system, and the method of grounding the AC line filter and drive must match. Failure to do this renders the filter ineffective and may cause damage to the filter. For grounding examples, refer to Grounded Power Configurations on page 79. For more information on electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. CE Requirements (system without LIM module) To meet CE requirements when your Kinetix 6000 system does not include the LIM module, these requirements apply. · Install an AC line filter (catalog number 2090-XXLF-xxxx) as close to the IAM module as possible. · Use 2090 series motor power cables or use connector kits and terminate the cable shields to the chassis clamp provided. · Combined motor power cable length for all axes on the same DC bus must not exceed 240 m (787 ft) with 460V systems or 160 m (525 ft) with 230V systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft). · Use 2090 series motor feedback cables or use connector kits and properly terminate the feedback cable shield. Drive-to-motor feedback cables must not exceed 90 m (295.5 ft). · Install the Kinetix 6000 system inside an enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure. Separate signal and power cables. Refer to Appendix B on page 199 for interconnect diagrams, including input power wiring and drive/motor interconnect diagrams. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 21 Chapter 1 Start CE Requirements (system with LIM module) To meet CE requirements when your Kinetix 6000 system includes the LIM module, follow all the requirements as stated in CE Requirements (system without LIM module) and these additional requirements as they apply to the AC line filter. · Install the LIM module (catalog numbers 2094-AL09 2094-AL09 or 2094-BL02 2094-BL02) as close to the IAM module as possible. · Install the LIM module (catalog numbers 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx) with line filter (catalog number 2090-XXLF-xxxx) as close to the IAM module as possible. When the LIM module (catalog numbers 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx) supports two IAM modules, each IAM module requires an AC line filter installed as close to the IAM module as possible. 22 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Chapter 2 Planning the Kinetix 6000 Drive System Installation Introduction This chapter describes system installation guidelines used in preparation for mounting your Kinetix 6000 drive components. Topic Page Introduction 23 System Design Guidelines 24 Electrical Noise Reduction 31 ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 23 Chapter 2 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.rockwellautomation.com/en/e-tools. System Mounting Requirements · To comply with UL and CE requirements, the Kinetix 6000 drive system must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP2X such that they are not accessible to an operator or unskilled person. A NEMA 4X enclosure exceeds these requirements providing protection to IP66. · The panel you install inside the enclosure for mounting your system components must be on a flat, rigid, vertical surface that won't be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors. · Size the drive enclosure so as not to exceed the maximum ambient temperature rating. Consider heat dissipation specifications for all drive components. · Combined motor power cable length for all axes on the same DC bus must not exceed 240 m (787 ft) with 460V systems or 160 m (525 ft) with 230V systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft). IMPORTANT System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements. · Segregate input power wiring and motor power cables from control wiring and motor feedback cables. Use shielded cable for power wiring and provide a grounded 360° clamp termination. · Use high-frequency (HF) bonding techniques to connect the modules, enclosure, machine frame, and motor housing, and to provide a low-impedance return path for high-frequency (HF) energy and reduce electrical noise. Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001, to better understand the concept of electrical noise reduction. 24 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Transformer Selection The IAM module does not require an isolation transformer for three-phase input power. However, a transformer may be required to match the voltage requirements of the controller to the available service. To size a transformer for the main AC power inputs, refer to Circuit Breaker/Fuse Specifications on page 187 and Transformer Specifications for Control Power Input on page 188. IMPORTANT If using an autotransformer, make sure that the phase to neutral/ground voltages do not exceed the input voltage ratings of the drive. IMPORTANT Use a form factor of 1.5 for three-phase power (where form factor is used to compensate for transformer, drive module, and motor losses, and to account for utilization in the intermittent operating area of the torque speed curve). Example: Sizing a transformer to the voltage requirements of a 2094-BC01-M01-S 2094-BC01-M01-S Integrated Axis Module: 2094-BC01-M01-S 2094-BC01-M01-S = 6 kW continuous x 1.5 = 9.0 KVA transformer Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 25 Chapter 2 Planning the Kinetix 6000 Drive System Installation Circuit Breaker/Fuse Selection The Kinetix 6000 drives use internal solid-state motor short-circuit protection and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 200,000 A. Fuses or circuit breakers, with adequate withstand and interrupt ratings, as defined in NEC or applicable local codes, are permitted. The 2094-AL09 2094-AL09 and 2094-BL02 2094-BL02 LIM modules contain supplementary protection devices and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 5000 A. When these modules are used, protection on the line side of the LIM module is required. Fuses must be class J or CC only. The 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-Cx LIM modules contain branch circuit rated devices suitable for use on a circuit capable of delivering up to 65,000 A (460V) or 100,000 A (230V). Refer to the Line Interface Module Installation Instructions, publication 2094-IN005 2094-IN005, for power specifications and more information on using the LIM module. The Bulletin 140M and 140U products are another acceptable means of protection. As with fuses and circuit breakers, you must make sure that the selected components are properly coordinated and meet applicable codes including any requirements for branch circuit protection. When applying the 140M/140U 140M/140U product, evaluation of the short circuit available current is critical and must be kept below the short circuit current rating of the 140M/140U 140M/140U product. In most cases, class CC, J, L, and R fuses selected to match the drive input current rating will meet the NEC requirements or applicable local codes, and provide the full drive capabilities. Dual element, time delay (slow-acting) fuses should be used to avoid nuisance trips during the inrush current of power initialization. Refer to Circuit Breaker/Fuse Specifications on page 187 for recommended circuit breakers and fuses. Refer to Power Specifications on page 180 for input current and inrush current specifications for your IAM module. 26 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Enclosure Selection This example is provided to assist you in sizing an enclosure for your Bulletin 2094 drive system. The example system consists of these components: · 6-axis Bulletin 2094 servo drive system · Line Interface Module (LIM) · ControlLogix chassis and modules (controller) Size the Bulletin 2094 servo drive and LIM module and use the results to predict the amount of heat dissipated into the enclosure. You will also need heat dissipation data from other equipment inside the enclosure (such as the ControlLogix controller). Once the total amount of heat dissipation (in watts) is known, you can calculate the minimum enclosure size. Table 6 - Bulletin 2094 System Heat Dissipation Example Enclosure Component 2094-BC02-M02-x Integrated axis module (IAM), 400/460V 400/460V 2094-BM02-x Loading (1) Description Heat Dissipation (1) watts 15 kW (converter section) 20% 44 15 A (inverter section) 40% 72 Axis module (AM), 400/460V 400/460V, 15 A 60% 93 2094-BM02-x Axis module (AM), 400/460V 400/460V, 15 A 60% 93 2094-BM01-x Axis module (AM), 400/460V 400/460V 9 A 40% 73 2094-BM01-x Axis module (AM), 400/460V 400/460V, 9 A 40% 73 2094-BM01-x Axis module (AM), 400/460V 400/460V, 9 A 20% 57 2094-BL25S 2094-BL25S Line interface module (LIM), 400/460V 400/460V, 25 A; 24V DC 20 A 100% 43 2094-PRS6 2094-PRS6 Power rail, 460V, 6 axis N/A 0 2090-XB33-32 2090-XB33-32 Resistive brake module (RBM), 33 A, 32 N/A 30 Total Kinetix 6000 system wattage 578 (1) To determine heat dissipation specifications for the drive system components, refer to Power Dissipation Specifications on page 189. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 27 Chapter 2 Planning the Kinetix 6000 Drive System Installation Table 7 - ControlLogix System Heat Dissipation Example Enclosure Component Description Backplane Power Load (1) watts Heat Dissipation (1) watts 1756-M08SE 1756-M08SE 8-axis SERCOS interface module 3.2 0 1756-L5563 1756-L5563 L63 ControlLogix processor 4.5 0 1756-IB16D 1756-IB16D 16 -point input module 0.84 5.8 1756-OB16D 1756-OB16D 16 -point output module 4.64 3.3 1756-ENxTx EtherNet/IP communication module 4.0 0 17.18 (2) N/A Backplane total 1756-PB72 1756-PB72 24V DC ControlLogix power supply N/A 25 (2) 1756-A7 1756-A7 7-slot mounting chassis N/A N/A Total ControlLogix system wattage 34.1 (1) For ControlLogix module specifications, refer to the ControlLogix Selection Guide, publication 1756-SG001 1756-SG001. (2) Real power heat dissipation is determined by applying the backplane power load (17.18W) to the graph below. Figure 5 - ControlLogix Real Power 1756-P 1756-P B72 1756-P 1756-P B75 DC Backplane Power Load (watts) 75 60 45 30 15 0 0 20 40 60 80 100 Real Power (watts) For backplane power loading requirements of other ControlLogix power supplies, refer to the ControlLogix Selection Guide, publication 1756-SG001 1756-SG001. In this example, the amount of power dissipated inside the cabinet is the sum of the Bulletin 2094 system value (578 W) and the ControlLogix system value (34 W) for a total of 612 W. With no active method of heat dissipation (such as fans or air conditioning) either of these approximate equations can be used. Metric Standard English A= 0.38Q 1.8T - 1.1 A= 4.08Q T - 1.1 Where T is temperature difference between inside air and outside ambient (°C), Q is heat generated in enclosure (Watts), and A is enclosure surface area (m2). The exterior surface of all six sides of an enclosure is calculated as A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144 Where d (depth), w (width), and h (height) are in meters. 28 Where T is temperature difference between inside air and outside ambient (°F), Q is heat generated in enclosure (Watts), and A is enclosure surface area (ft²). The exterior surface of all six sides of an enclosure is calculated as Where d (depth), w (width), and h (height) are in inches. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Total system watts dissipated (Q) was calculated at 612 W. The maximum ambient rating of the Bulletin 2094 system is 50 °C (122 °F) and if the maximum environmental temperature is 30 °C (86 °F), then T=20 in the equation below. A= 0.38 (612) = 6.66 m 2 1.8 (20) - 1.1 In this example, the enclosure must have an exterior surface of 6.66 m2. If any portion of the enclosure is not able to transfer heat, it should not be included in the calculation. Because the minimum cabinet depth to house the 460V drive (selected for this example) is 302 mm (11.9 in.), then the cabinet needs to be approximately 2500 mm (high) x 950 mm (wide) x 302 mm (deep). 2 x (0.3 x 0.95) + 2 x (0.3 x 2.5) + 2 x (0.95 x 2.5) = 6.82 m2 Because this cabinet size is considerably larger than what is necessary to house the system components, it may be more efficient to provide a means of cooling in a smaller cabinet. Contact your cabinet manufacturer for options available to cool your cabinet. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 29 Chapter 2 Planning the Kinetix 6000 Drive System Installation Minimum Clearance Requirements This section provides information to assist you in sizing your cabinet and positioning your Bulletin 2094 system components. IMPORTANT Mount the module in an upright position. Do not mount the module on its side. Figure 6 - Minimum Clearance Requirements Clearance above for airflow and installation. Kinetix 6000 IAM Module (2094-BC01-Mxx-x is shown mounted on power rail) Clearance right of the Clearance left of the module is not required. (1) module is not required. (1) Power Rail (2094-PRSx is shown) Clearance below for airflow and installation. (1) The power rail (slim), catalog number 2094-PRSx, extends left and right of the first and last module 5.0 mm (0.20 in.). The power rail, catalog number 2094-PRx, extends approximately 25.4 mm (1.0 in.) left of the IAM module and right of the last module mounted on the rail. Table 8 - Minimum Clearance Dimensions Cat. No. Clearance Above, Min Clearance Below, Min Cabinet Depth Clearance, Min 2094-AC05-Mxx-x, 2094-AC09-M02-x, 2094-AMP5-x, 2094-AM01-x, 2094-AM02-x 50.8 mm (2.0 in.) 50.8 mm (2.0 in.) 198 mm (7.8 in.) 2094-BC01-Mxx-x, 2094-BC02-M02-x, 2094-BMP5-x, 2094-BM01-x, 2094-BM02-x 50.8 mm (2.0 in.) 50.8 mm (2.0 in.) 2094-BSP2 2094-BSP2 272 mm (10.7 in.) 272 mm (10.7 in.) 2094-AC16-M03-x, 2094-AC32-M05-x, 2094-AM03-x, 2094-AM05-x 305 mm (12.0 in.) 50.8 mm (2.0 in.) 198 mm (7.8 in.) 2094-BC04-M03-x, 2094-BC07-M05-x, 2094-BM03-x, 2094-BM05-x 305 mm (12.0 in.) 50.8 mm (2.0 in.) 272 mm (10.7 in.) IMPORTANT Although clearance left and right of the power rail is not necessary for ventilation, additional clearance is required when mounted adjacent to noise sensitive equipment or clean wireways. Refer to page 189 for power dissipation specifications. 30 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Electrical Noise Reduction Chapter 2 This section outlines best practices that minimize the possibility of noise-related failures as they apply specifically to Kinetix 6000 system installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. Bonding Modules Bonding is the practice of connecting metal chassis, assemblies, frames, shields, and enclosures to reduce the effects of electromagnetic interference (EMI). Unless specified, most paints are not conductive and act as insulators. To achieve a good bond between power rail and the subpanel, surfaces need to be paint-free or plated. Bonding metal surfaces creates a low-impedance return path for high-frequency energy. IMPORTANT To improve the bond between the power rail and subpanel, construct your subpanel out of zinc plated (paint-free) steel. Improper bonding of metal surfaces blocks the direct return path and allows high-frequency energy to travel elsewhere in the cabinet. Excessive high-frequency energy can effect the operation of other microprocessor controlled equipment. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 31 Chapter 2 Planning the Kinetix 6000 Drive System Installation These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets. Figure 7 - Recommended Bonding Practices for Painted Panels Stud-mounting the Subpanel to the Enclosure Back Wall Stud-mounting a Ground Bus or Chassis to the Subpanel Subpanel Back Wall of Enclosure Mounting Bracket or Ground Bus Subpanel Welded Stud Star Washer Nut Scrape Paint Flat Washer Welded Stud Nut Flat Washer Use a wire brush to remove paint from threads to maximize ground connection. Use plated panels or scrape paint on front of panel. If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole. Star Washer Bolt-mounting a Ground Bus or Chassis to the Back-panel Subpanel Bolt Tapped Hole Ground Bus or Mounting Bracket Nut Star Washer Scrape paint on both sides of panel and use star washers. Star Washer Flat Washer Nut Flat Washer Star Washer 32 If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Bonding Multiple Subpanels Bonding multiple subpanels creates a common low impedance exit path for the high frequency energy inside the cabinet. Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels. · Bond the top and bottom of each subpanel to the cabinet by using 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid. As a rule, the wider and shorter the braid is, the better the bond. · Scrape the paint from around each fastener to maximize metal-to-metal contact. Figure 8 - Multiple Subpanels and Cabinet Recommendations Wire Braid 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) Cabinet ground bus bonded to the subpanel. Paint removed from cabinet. Wire Braid 25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 33 Chapter 2 Planning the Kinetix 6000 Drive System Installation Establishing Noise Zones Observe these guidelines when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in the Bulletin 2094 system and mounted left of the IAM module with the AC (EMC) line filter mounted above the LIM module: · The clean zone (C) is to the right and beneath the Bulletin 2094 system (gray wireway). · The dirty zone (D) is to the left and above the Bulletin 2094 system, and above and below the LIM module (black wireway). · The very dirty zone (VD) is from the filter output to IAM module. Shielded cable is required on the EMC filter (load side) and the braided shield attached to the clamp provided. · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. Figure 9 - Noise Zones (LIM mounted left of IAM module) Dirty Wireway Clean Wireway AC Line Filter (required for CE) D VD Motor Power Cables D VAC Load D D D Very Dirty Filter/IAM Connections Segregated (not in wireway) VAC Line C VD D Fiber-optic Cable MAIN VAC No sensitive (2) equipment within 150 mm (6.0 in.). Kinetix 6000 System Line Interface Module I/O (1) and Feedback Cables D D Route 24V DC I/O shielded cable. C Route encoder/analog/registration shielded cables. (1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O cable in dirty wireway. (2) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. 34 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Observe these guidelines when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in the Bulletin 2094 system and mounted right of the IAM module with the AC (EMC) line filter mounted behind the IAM module: · The clean zone (C) is to the left and beneath the Bulletin 2094 system (gray wireway). · The dirty zone (D) is to the right and above the Bulletin 2094 system, and above and below the LIM module (black wireway). · The very dirty zone (VD) is from the filter output to IAM module. Shielded cable is required on the EMC filter (load side) and the braided shield attached to the clamp provided. · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. Figure 10 - Noise Zones (LIM with EMC filter behind IAM module) Dirty Wireway Clean Wireway Motor Power Cables Very Dirty Filter/IAM Connections Segregated (not in wireway) D D D D VAC Line VD Control VAC, AUX VAC Output, and 24V DC Brake C Fiber-optic Cable D I/O VD VAC Load D No sensitive (2) D AC (EMC) Line Filter equipment within 150 mm (6.0 in.). Kinetix 6000 System C MAIN VAC I/O (1) and Feedback Cables Line Interface Module C D Route encoder/analog/registration shielded cables. Route 24V DC I/O shielded cable. (1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O cable in dirty wireway. (2) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 35 Chapter 2 Planning the Kinetix 6000 Drive System Installation Observe these guidelines when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in the Bulletin 2094 system and mounted right of the drive with the AC (EMC) line filter mounted behind the LIM module: · The clean zone (C) is to the left and beneath the Bulletin 2094 system (gray wireway). · The dirty zone (D) is to the right and above the Bulletin 2094 system, and above and below the LIM module (black wireway). · The very dirty zone (VD) is from the filter output to drive. Shielded cable is required on the EMC filter (load side) and the braided shield attached to the clamp (when provided). · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. Figure 11 - Noise Zones (EMC filter behind LIM module) Dirty Wireway Clean Wireway Motor Power Cables D Control VAC, Auxiliary VAC, and 24V DC Brake D VAC Line VAC Load LIM PRS D PR PR VD PR/PRS Very Dirty Filter/IAM Connections Segregated (not in wireway) D LIM Fiber-optic Cable No sensitive (2) equipment within 150 mm (6.0 in.). VD I/O (1) and Feedback Cables C PRS PR PR LIM PR/PRS AC (EMC) Line Filter Kinetix 6000 System C D LIM I/O MAIN VAC LIM Line Interface Module (2094-ALxxS shown) D Route encoder/analog/registration shielded cables. 2094 Mounting (3) Brackets x2 Route 24V DC I/O shielded cable. (1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O cable in dirty wireway. (2) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. (3) Only the 2094-ALxxS and 2094-XL75S-Cx LIM modules are compatible with the 2094 mounting brackets. The 2094-BLxxS, 2094-AL09 2094-AL09, and 2094-BL02 2094-BL02 LIM modules are not compatible. 36 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Keep the DC common-bus cable (very dirty) segregated from all other cables (not in a wireway) when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in a DC common-bus configuration and the follower IAM module is mounted below the leader IAM module. Figure 12 - Noise Zones (DC common bus) Dirty Wireway D Clean Wireway VD AC Line Filter (required for CE) Motor Power Cables D Very Dirty Filter/IAM Connections Segregated (not in wireway) D D C VD VAC Line, AUX VAC Output, 24V Fiber-optic Cable VAC Load D D VAC Line No sensitive (2) equipment within 150 mm (6.0 in.). MAIN VAC Kinetix 6000 System (leader IAM) I/O (1) and Feedback Cables D Line Interface Module C D D D D VD C Very Dirty DC Bus Connections Segregated (not in wireway) Fiber-optic Cable No sensitive (2) equipment within 150 mm (6.0 in.). Kinetix 6000 System (follower IAM) I/O (1) and Feedback Cables C Route 24V DC I/O shielded cable. Route encoder/analog/registration shielded cables. (1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O cable in dirty wireway. (2) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 37 Chapter 2 Planning the Kinetix 6000 Drive System Installation Observe these guidelines when a 2094-AL09 2094-AL09 or 2094-BL02 2094-BL02 LIM module is used in the Bulletin 2094 system and mounted left of the IAM module: · The clean zone (C) is to the right and beneath the Bulletin 2094 system (gray wireway). · The dirty zone (D) is to the left and above the Bulletin 2094 system, and above and below the LIM module (black wireway). · The very dirty zone (VD) is limited to where the LIM module VAC output jumpers over to the IAM module. Shielded cable is required only if the very dirty cables enter a wireway. · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. This layout is preferred due to the reduced size of the very dirty zone. Figure 13 - Noise Zones (LIM mounted left of IAM module) Dirty Wireway Very Dirty Filter/IAM Connections (1) Segregated (not in wireway) D Clean Wireway Motor Power Cables C D D VD Fiber-optic Cable No sensitive (2) equipment within 150 mm (6.0 in.). Kinetix 6000 System D Line Interface Module C C D Route 24V DC I/O shielded cable. I/O (1) and Feedback Cables Route encoder/analog/registration shielded cables. (1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O cable in dirty wireway. (2) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. 38 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Observe these guidelines when the 2094-AL09 2094-AL09 or 2094-BL02 2094-BL02 LIM module is used in the Bulletin 2094 system and mounted above the IAM module: · The clean zone (C) is to the right and beneath the Bulletin 2094 system (gray wireway). · The dirty zone (D) is to the left and above the Bulletin 2094 system, and above and below the LIM module (black wireway). · The LIM VAC output is very dirty (VD). Use shielded cable with a braid clamp attached at both ends of the cable to reduce the rating to dirty (D). · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. Figure 14 - Noise Zones (LIM mounted above IAM module) Dirty Wireway Clean Wireway VD D Very dirty LIM/IAM (1) connections must be shielded with braid clamp at both ends. Line Interface Module D Motor Power Cables C D Fiber-optic Cable No sensitive (3) equipment within 150 mm (6.0 in.). Kinetix 6000 System C C D I/O (2) and Feedback Cables Route encoder/analog/registration shielded cables. Route 24V DC I/O shielded cable. (1) For examples of shield clamp attachment, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. (2) If drive system I/O cable contains (dirty) relay wires, route cable in dirty wireway. (3) When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 39 Chapter 2 Planning the Kinetix 6000 Drive System Installation Observe these guidelines when individual input power components are used in the Bulletin 2094 system and the Bulletin 2094 LIM module is not used: · The clean zone (C) is beneath the Bulletin 2094 system and includes the I/O wiring, feedback cable, and DC filter (gray wireway). · The dirty zone (D) is above the Bulletin 2094 system (black wireway) and includes the circuit breakers, transformer, 24V DC power supply, contactors, AC line filter, and motor power cables. · The very dirty zone (VD) is limited to where the AC line (EMC) filter VAC output jumpers over to the IAM module. Shielded cable is required only if the very dirty cables enter a wireway. · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. Figure 15 - Noise Zones (without LIM module) Dirty Wireway Very Dirty Filter/IAM Connections Segregated (not in wireway) D D (1) Clean Wireway Motor Power Cables D Fiber-optic Cable (2) C VD Contactors Circuit Breaker AC Line Filter (required for CE) 24V Motor Brake PS (4) XFMR Kinetix 6000 System DC Filter (3) (2) C I/O (1) and Feedback Cables C D Route 24V DC I/O shielded cable. Route encoder/analog/registration shielded cables. (1) If drive system I/O cable contains (dirty) relay wires, route cable in dirty wireway. (2) When space to the right of the IAM does not permit 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 GMC-RM001. (3) This is a clean 24V DC available for any device that may require it. The 24V enters the clean wireway and exits to the right. (4) This is a dirty 24V DC available for motor brakes and contactors. The 24V enters the dirty wireway and exits to the left. 40 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Observe these guidelines when installing your Logix platform SERCOS interface module: · The clean zone (C) is beneath the less noisy modules (I/O, analog, encoder, registration, an so forth. (gray wireway). · The dirty zone (D) is above and below the power supply and noisy modules (black wireway). · The SERCOS fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone. Figure 16 - Noise Zones (ControlLogix chassis) Clean Wireway Dirty Wireway D (1) Route dirty wireways directly above the ControlLogix rack (shielded by the chassis). AC Line Filter Spare Slots D Line Filter/Power Supply Connections Segregated (not in wireway) Dirty I/O (24V DC I/O, AC I/O) C Clean I/O (Analog, Encoder Registration) Cable Categories for Kinetix 6000 Systems These tables indicate the zoning requirements of cables connecting to the Kinetix 6000 drive components. Table 9 - IAM Module (converter side) Zone Wire/Cable Connector CTRL 1 and 2 CPD DC-/DC+ (unshielded cable) L1, L2, L3 (shielded cable) Dirty Clean Ferrite Sleeve Shielded Cable X X IPD L1, L2, L3 (unshielded cable) X X X CONT EN- and CONT EN+ (M1 contactor) CED DPI Very Dirty Method X DPI Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 X X 41 Chapter 2 Planning the Kinetix 6000 Drive System Installation Table 10 - AM Module or Axis Module (inverter side) Zone Wire/Cable Connector U, V, W (motor power) MP Very Dirty Dirty Method Clean Ferrite Sleeve X MBRK-, MBRK+ (motor brake) X X MBRK-, MBRK+ (motor brake) 1326AB 1326AB motors with resolver feedback Shielded Cable X DBRK-, DBRK+ (resistive brake) BC X X COM, PWR (24V DC), filtered (1) X COM, PWR (24V DC), unfiltered (2) X COM, PWR (24V DC), safety enable, and feedback signals for safe-off feature SO Motor feedback MF X X Auxiliary feedback AF X X X X Registration and analog outputs Others Fiber-optic X IOD Rx and Tx X No Restrictions (1) This is a clean 24V DC available for any device that may require it. (2) This is a dirty 24V DC available for motor brakes and contactors. Table 11 - Line Interface Module Zone Wire/Cable Connector VAC line (main input) IPL X Aux power input APL Method X VAC load (shielded option) VAC load (unshielded option) OPL Very Dirty Dirty Clean Ferrite Sleeve X Shielded Cable X X Control power output CPL X MBRK PWR, MBRK COM P1L/PSL X Status I/O IOL X Aux power output P2L X Table 12 - External Shunt Module Zone Wire/Cable COL, DC+ (shielded option) COL, DC+ (unshielded option) Connector RC Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable X X X X Thermal switch TS X Fan (if present) 42 Method N/A X Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 Table 13 - Resistive Brake Module Zone Wire/Cable Connections Resistive brake module coil power TB3-6 and TB3-7 X Resistive brake module I/O TB1-1.TB1-5 and TB3-8 X Resistive brake module drive and motor power TB1 and TB2 X 230V power TB4 Method X Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable X Noise Reduction Guidelines for Drive Accessories Refer to this section when mounting an AC (EMC) line filter or external shunt module for guidelines designed to reduce system failures caused by excessive electrical noise. AC Line Filters Observe these guidelines when mounting your AC (EMC) line filter (refer to the figure on page 40 for an example): · Mount the AC line filter on the same panel as the Kinetix 6000 drive and as close to the power rail as possible. · Good HF bonding to the panel is critical. For painted panels, refer to the examples on page 32. · Segregate input and output wiring as far as possible. IMPORTANT CE test certification applies only to AC line filter and single power rail. Sharing a line filter with multiple power rails may perform satisfactorily, but the user takes legal responsibility. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 43 Chapter 2 Planning the Kinetix 6000 Drive System Installation External Shunt Modules Observe these guidelines when mounting your external shunt module outside the enclosure: · Mount circuit components and wiring in the very dirty zone or in an external shielded enclosure. Run shunt power and fan wiring inside metal conduit to minimize the effects of EMI and RFI. · Mount resistors (other than metal-clad) in a shielded and ventilated enclosure outside the cabinet. · Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible. · Route thermal switch and fan wires separate from shunt power. Figure 17 - External Shunt Module Outside the Enclosure Customer-supplied Metal Enclosure 150 mm (6.0 in.) clearance (min) on all four sides of the shunt module. Metal Conduit (where required by local code) 1394 Digital Servo Controller 300W Shunt Module ALLEN-BRADLEY R BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO. FOR USE WITH 1394-SJT22-X 1394-SJT22-X SYSTEM MODULE Shunt thermal Switch and Fan Wires (when present) Dirty Wireway Clean Wireway Shunt Power Wiring Methods: Twisted pair in conduit (1st choice). Shielded twisted pair (2nd choice). Twisted pair, two twists per foot (min) (3rd choice). (1) D Very Dirty Connections Segregated (not in wireway) D Motor Power Cables D D VD VD 2094-BSP2 2094-BSP2 Shunt Module No sensitive equipment within 150 mm (6.0 in.). Kinetix 6000 System D C C Line Interface Module D I/O and Feedback Cables Route 24V DC I/O shielded cable. 44 Enclosure Route encoder/analog/registration shielded cables. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Planning the Kinetix 6000 Drive System Installation Chapter 2 When mounting your shunt module inside the enclosure, follow these additional guidelines: · Mount metal-clad modules anywhere in the dirty zone, but as close to the Bulletin 2094 drive system as possible. · Route shunt power wires with motor power cables. · Keep unshielded wiring as short as possible. Keep shunt wiring as flat to the cabinet as possible. · Separate shunt power cables from other sensitive, low voltage signal cables. Figure 18 - External Shunt Module Inside the Enclosure Clean Wireway Dirty Wireway Enclosure 150 mm (6.0 in.) clearance (min) on all four sides of the shunt module. 1394 Digital Servo Controller 300W Shunt Module ALLEN-BRADLEY R BULLETIN 1394 300W SHUNT MODULE CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO. FOR USE WITH 1394-SJT22-X 1394-SJT22-X SYSTEM MODULE Shunt thermal Switch and Fan Wires (when present) Very Dirty Connections Segregated (not in wireway) D VD Motor Power Cables D D VD D Shunt Power Wiring Methods: Twisted pair in conduit (1st choice). Shielded twisted pair (2nd choice). Twisted pair, two twists per foot (min) (3rd choice). 2094-BSP2 2094-BSP2 Shunt Module No sensitive equipment within 150 mm (6.0 in.). Kinetix 6000 System D Line Interface Module D C C I/O and Feedback Cables Route 24V DC I/O shielded cable. Route encoder/analog/registration shielded cables. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 45 Chapter 2 Planning the Kinetix 6000 Drive System Installation Resistive Brake Modules Observe these guidelines when mounting your RBM module: · Mount circuit components and wiring in the dirty zone or in an external shielded enclosure. If mounting the RBM module in a separate ventilated shielded enclosure, run wiring inside metal conduit to minimize the effects of EMI and RFI. · Keep unshielded wiring as short as possible. Keep wiring as flat to the cabinet as possible. · Route RBM module power and I/O cables separate from other sensitive low voltage signal cables. Figure 19 - Noise Zones (RBM mounted above AM module) Clean Wireway Dirty Wireway D D RBM I/O Very Dirty LIM/IAM Connections Segregated (not in wireway) LIM VAC Input Power Motor Power Cables D C D VD Fiber-optic Cable No sensitive equipment within 150 mm (6.0 in.). Kinetix 6000 System D Line Interface Module C D LIM and IAM/AM (dirty) I/O IAM/AM Feedback and (clean) I/O Motor Brake and Thermal Switch The thermal switch and brake are mounted inside the motor, but how you connect to the axis module depends on the motor series. Refer to Wire the Motor/Resistive Brake (BC) Connector on page 106 for wiring guidelines. Refer to Axis Module/Rotary Motor Wiring Examples beginning on page 212 for the interconnect diagram of your drive/motor combination. 46 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Chapter 3 Mounting the Kinetix 6000 Drive System Introduction This chapter provides the system installation procedures for mounting your Kinetix 6000 drive components on the Bulletin 2094 power rail. Topic Page Introduction 47 Determine Mounting Order 48 Mount Modules on the Power Rail 49 This procedure assumes you have prepared your panel, mounted your Bulletin 2094 power rail, and understand how to bond your system. For installation instructions regarding equipment and accessories not included here, refer to the instructions that came with those products. SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting and wiring of the Bulletin 2094 power rail and drive modules prior to applying power. Once power is applied, connector terminals may have voltage present even when not in use. ATTENTION: Plan the installation of your system so that you can perform all cutting, drilling, tapping, and welding with the system removed from the enclosure. Because the system is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components. Using the 2094 Mounting Brackets You can use Bulletin 2094 mounting brackets to mount the power rail or LIM module over the AC line filter. Refer to the 2094 Mounting Brackets Installation Instructions, publication 2094-IN008 2094-IN008, when using mounting brackets with your Kinetix 6000 drive system. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 47 Chapter 3 Mounting the Kinetix 6000 Drive System Installing the 2094 Power Rail The Bulletin 2094 power rail comes in lengths to support one IAM module and up to seven additional AM modules, or up to six additional AM modules and one shunt module. The connector pins for each slot are covered by a protective boot. The boot is designed to protect the pins from damage and make sure that no foreign objects lodge between the pins during installation. Refer to the Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003 2094-IN003, when installing your power rail. ATTENTION: To avoid damage to the power rail during installation, do not remove the protective boots until the module for each slot is ready for mounting. Determine Mounting Order Mount IAM, AM, shunt, and slot-filler modules in the order (left to right) as shown. Mount axis modules according to power utilization (highest to lowest) from left to right starting with the highest power utilization. If power utilization is unknown, position axis modules (highest to lowest) from left to right based on amp rating. Figure 20 - Module Mounting Order Example Highest Power Utilization or Amp Rating Integrated Axis Module 2094-AC09-M02-x 48 Axis Module 2094-AM02-x Axis Module 2094-AM02-x Lowest Power Utilization or Amp Rating Axis Module 2094-AM02-x Axis Module 2094-AM01-x Axis Module 2094-AM01-x Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Shunt Module 2094-BSP2 2094-BSP2 Slot-filler Module 2094-PRF 2094-PRF Mounting the Kinetix 6000 Drive System IMPORTANT Chapter 3 The IAM module must be positioned in the leftmost slot of the power rail. Position your AM modules, shunt module, and slot-filler modules to the right of the IAM module. The shunt module must be installed to the right of the last AM module. Only slot-filler modules may be installed to the right of the shunt module. Do not mount the shunt module on power rails with a follower IAM module. Common-bus follower IAM modules will disable the internal, rail mounted, and external shunt modules. SHOCK HAZARD: To avoid personal injury due to electrical shock, place a 2094-PRF 2094-PRF slot-filler module in all empty slots on the power rail. Any power rail connector without a module installed will disable the Bulletin 2094 system; however, control power will still be present. Mount Modules on the Power Rail Follow these steps to mount the IAM, AM, shunt, and slot-filler modules. TIP All modules mount to the power rail by using the same technique; however, only the IAM module is shown. 1. Remove the protective boots from the power rail connectors. IMPORTANT The IAM module must be positioned in the leftmost slot of the power rail. Position your axis modules, shunt module, and slot-filler modules to the right of the IAM module. 2. Determine the next available slot and module for mounting. 3. Remove the label (applied to back and side of module) covering the pins that mate with the power rail. ATTENTION: To avoid damage to the pins located on the back of each IAM, AM, shunt, and slot-filler module and to make sure that module pins mate properly with the power rail, hang modules as shown in steps 4.7. The power rail must be mounted vertically on the panel before hanging modules on the power rail. Do not mount modules if the power rail is horizontal. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 49 Chapter 3 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 modules. Kinetix 6000 IAM, AM, Shunt, or Slot-filler Module (IAM module is shown) Power Rail 5. Pivot module downward and align the guide pins on the power rail with the guide pin holes in the back of the module. Pivot module downward and align with guide pins. Guide Pin Holes Guide Pins Power rail (side view) in upright vertical position. Kinetix 6000 IAM, AM, Shunt, or Slot-filler Module, Rear View (IAM module is shown) TIP 50 Kinetix 6000 IAM, AM, Shunt, or Slot-filler Module, Side View (IAM module is shown) The IAM module can have two or three power rail connectors and guide pins, the AM module can have one or two, all other modules have one. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Mounting the Kinetix 6000 Drive System Chapter 3 6. Gently push the module against the power rail connectors and into the final mounting position. Bracket secured in slot. Power Rail Kinetix 6000 IAM, AM, Shunt, or Slot-filler Module (IAM module is shown) 7. Use 2.26 N·m (20 lb·in) torque to tighten the mounting screws. Bottom front view of single-wide AM, shunt, or slot-filler module (AM module is shown). Bottom front view of double-wide IAM or AM module (AM module is shown). Mounting Screws IMPORTANT There are two mounting screws when mounting 2094-AC32-M05-x, 2094-BC04-M03-x, and 2094-BC07-M05-x (double-wide) IAM modules, and 2094-BM03-x and 2094-BM05-x (double-wide) AM modules. 8. Repeat steps 1.7 for each AM, shunt, or slot-filler module in your Bulletin 2094 drive system. Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 51 Chapter 3 Mounting the Kinetix 6000 Drive System Notes: 52 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Chapter 4 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 53 Power Module and Control Module Features 58 Control Signal Specifications 63 Power and Relay Specifications 67 Feedback Specifications 73 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 53 Chapter 4 Kinetix 6000 Connector Data IAM/AM Module Features Use these illustrations to identify the features and indicators for the IAM/AM modules. Although the physical size of the 460V modules is larger than the 230V modules, the location of the features and indicators is identical. Figure 21 - Integrated Axis Module Features and Indicators Kinetix 6000 IAM Module, Top View (2094-AC05-M01-S 2094-AC05-M01-S module is shown) DC- 4 5 6 L3 L2 W DC+ CONT ENCONT EN+ MBRK MBRK + COM PWR DBRK DBRK + 14 Kinetix 6000 IAM Module, Front View (2094-AC05-M01-S 2094-AC05-M01-S module is shown) 15 6 1 2 3 4 5 6 L1 V U 1 2 3 4 CTRL 1 1 2 3 4 5 6 7 8 9 1 2 2 CTRL 2 1 2 3 3 1 2 4 5 16 17 18 7 19 1 RX TX DPI BAUD RATE 8 13 9 10 11 12 20 Item Description Item Description 1 Safe-off (SO) connector 11 SERCOS receive (Rx) connector 2 Contactor enable (CED) connector 12 Mounting screw 3 DC bus/AC input power (IPD) connector 13 I/O (IOD) connector 4 Control power (CPD) connector 14 SERCOS node address switch 5 Motor cable shield clamp 15 Seven-segment fault status indicator 6 Motor power (MP) connector 16 Drive status indicator 7 Motor/resistive brake (BC) connector 17 COMM status indicator 8 SERCOS communication rate and optical power switches 18 Bus status indicator 9 SERCOS transmit (Tx) connector 19 Motor feedback (MF) connector 10 DPI connector 20 Auxiliary feedback (AF) connector 54 Rockwell Automation Publication 2094-UM001D-EN-P 2094-UM001D-EN-P - May 2010 Kinetix 6000 Connector Data Chapter 4 Figure 22 - Axis Module Features and Indicators Kinetix 6000 AM Module, Top View (2094-AM01-S 2094-AM01-S module is shown) Kinetix 6000 AM Module, Front View (2094-AM01-S 2094-AM01-S module is shown) MBRK - 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 W V U 1 2 3 4 10 2 MBRK + COM PWR DBRK DBRK + 11 12 13 4 14 RX TX BAUD RATE 5 9 6 7 8 15 Item Description Item Description Item Description 1 Safe-off (SO) connector 6 SERCOS transmi