Rockwell Automation 2093-xxxx User Manual
Kinetix 2000 Multi-axis
Servo Drive
Catalog Numbers
2093-AC05-MP1, 2093-AC05-MP2,
2093-AC05-MP5
2093-AM01, 2093-AM02
2093-AMP1, 2093-AMP2, 2093-AMP5
2093-PRS1, 2093-PRS2, 2093-PRS3,
2093-PRS4, 2093-PRS5, 2093-PRS7,
2093-PRS8S
2093-ASP06
2093-PRF
User Manual
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (publication SGI-1.1
available from your local Rockwell Automation sales office or online at
http://literature.rockwellautomation.com
) 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
IMPORTANT
ATTENTION
WARNING
BURN HAZ-
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.
Identifies information that is critical for successful application and
understanding of the product.
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
Labels may be on or inside the equipment, for example, a drive or motor,
to alert people that dangerous voltage may be present.
Labels may be on or inside the equipment, for example, a drive or motor,
to alert people that surfaces may reach dangerous temperatures.
Allen-Bradley, CompactLogix, ControlFlash, ControlLogix, DriveExplorer, Kinetix, Logix5000, RSLogix, RSLogix 5000, SoftLogix, SCANport,
Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are the property of their respective companies.
Start
Planning the Kinetix 2000 Drive
System Installation
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
About the Kinetix 2000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 12
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Agency Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CE Requirements (System without LIM). . . . . . . . . . . . . . . . . . . . 17
CE Requirements (System with LIM) . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transformer Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Circuit Breaker/Fuse Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Enclosure Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimizing Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bonding Multiple Subpanels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Establishing Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cable Categories for Kinetix 2000 Systems . . . . . . . . . . . . . . . . . . 34
Noise Reduction Guidelines for Drive Accessories . . . . . . . . . . . 36
Chapter 3
Mounting the Kinetix 2000 Drive
System
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installing the 2093 Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Determining Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2093-PRS8S Module Configuration . . . . . . . . . . . . . . . . . . . . . . . . 39
Mount the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Mounting the Line Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Segregating Power and Logic Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 4
Kinetix 2000 Connector Data
3 Publication 2093-UM001A-EN-P — March 2007
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Locating IAM/AM Connectors and Indicators . . . . . . . . . . . . . . . . . 43
I/O Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Motor Feedback Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . 48
IAM Input Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
IAM and AM Motor Power and Brake Connector Pinouts . . . . . 50
IAM/AM Signal Specifications Explained. . . . . . . . . . . . . . . . . . . . . . 51
4
Connecting the Kinetix 2000 Drive
System
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SERCOS Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Motor Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Feedback Specifications Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Motor and Auxiliary Feedback Specifications . . . . . . . . . . . . . . . . 57
Motor Encoder Feedback Specifications . . . . . . . . . . . . . . . . . . . . 58
Feedback Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Locating Shunt Module Connectors and Indicators. . . . . . . . . . . . . . . 60
Chapter 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Routing Power and Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Determining Your Type of Input Power . . . . . . . . . . . . . . . . . . . . . . . 63
Grounded Three-phase Power Configurations . . . . . . . . . . . . . . . 63
Ungrounded Three-phase Power Configurations . . . . . . . . . . . . . 65
Grounded Single-phase Power Configurations . . . . . . . . . . . . . . . 66
DC Common Bus Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Common Bus Fusing Requirements . . . . . . . . . . . . . . . . . . . . . . . . 68
Setting the Ground Jumper in Ungrounded Power Configurations . . 69
Set Ground Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Grounding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Grounding Your System to the Subpanel. . . . . . . . . . . . . . . . . . . . 71
Grounding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Wiring the LIM Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Wiring the Auxiliary Input Power (APL) Connector . . . . . . . . . . . 77
Wiring the VAC LINE (IPL) Connector . . . . . . . . . . . . . . . . . . . . 77
Wiring the VAC LOAD (OPL) Connector . . . . . . . . . . . . . . . . . . 78
Wiring the Control Power Output (CPL) Connector . . . . . . . . . . 79
Wiring the Auxiliary Power Output (P2L) Connector . . . . . . . . . . 79
Wiring the Brake Power Output (24V dc) Connector . . . . . . . . . . 80
Wiring the IAM/AM Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Wiring the Control Power (CPD) Connector. . . . . . . . . . . . . . . . . 81
Wiring the Input Power (IPD) Connector . . . . . . . . . . . . . . . . . . . 82
Wiring the Contactor Enable (CED) Connector . . . . . . . . . . . . . . 84
Wiring the Motor Power (MP) Connector . . . . . . . . . . . . . . . . . . . 85
Wiring the Motor Brake (BC) Connector . . . . . . . . . . . . . . . . . . . . 89
Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . 92
Flying-lead Feedback Cable Pin-outs . . . . . . . . . . . . . . . . . . . . . . . 93
Wiring Feedback and I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connecting Premolded Motor Feedback Cables . . . . . . . . . . . . . . 95
Wiring Low-profile Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . 95
Publication 2093-UM001A-EN-P — March 2007
5
Configure and Startup the
Kinetix 2000 Drive System
Wiring 15-pin Panel-mounted Breakout Kit . . . . . . . . . . . . . . . . . 97
Wiring 44-pin Panel-mounted Breakout Kit . . . . . . . . . . . . . . . . . 97
Shunt Module Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Connecting Your SERCOS Fiber-optic Cables . . . . . . . . . . . . . . . . . . 99
SERCOS Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 6
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
System Configuration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 103
Configure the IAM/AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Configure the Logix SERCOS Interface Module . . . . . . . . . . . . . . . 109
Configure the Logix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Configure the SERCOS Interface Module. . . . . . . . . . . . . . . . . . 110
Configure the Kinetix 2000 Modules. . . . . . . . . . . . . . . . . . . . . . 113
Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Configure Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Download the Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Apply Power to the
Kinetix 2000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Test the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Tune the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Troubleshooting the Kinetix 2000
Drive System
Removing and Replacing the
Kinetix 2000 Drive Modules
Chapter 7
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Interpreting Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
IAM/AM Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
SM Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Troubleshooting General System Problems. . . . . . . . . . . . . . . . . . . . 143
Logix/Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Chapter 8
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Remove Modules from the Power Rail . . . . . . . . . . . . . . . . . . . . . . . 150
Replace Modules on the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . 151
Remove the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Replace the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Publication 2093-UM001A-EN-P — March 2007
6
Specifications and Dimensions
Appendix A
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Converter Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Inverter Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Auxiliary Control Power Specifications . . . . . . . . . . . . . . . . . . . . 156
Shunt Module Power Specifications . . . . . . . . . . . . . . . . . . . . . . . 157
Circuit Breaker/Fuse Specifications . . . . . . . . . . . . . . . . . . . . . . . 157
Contactor Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Transformer Specifications for Control Power Input . . . . . . . . . 159
Power Dissipation Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Maximum Feedback Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . 161
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Weight Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Line Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Interconnect Diagrams
Upgrading Firmware
Appendix B
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Power Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
DC Common Bus Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . 174
Shunt Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Axis Module/Motor Wiring Examples. . . . . . . . . . . . . . . . . . . . . 178
Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Appendix C
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Selecting Software Tools to Upgrade the Kinetix 2000 Firmware. . . 188
Using Drive Explorer to Flash the Kinetix 2000 Drive. . . . . . . . 188
Using Drive Executive to Flash the Kinetix 2000 Drive . . . . . . . 193
Using Hyperterminal to FLASH the Kinetix 2000 Drive . . . . . . . . . 202
Flashing Kinetix 2000 Firmware with Hyperterminal . . . . . . . . . 204
Publication 2093-UM001A-EN-P — March 2007
7
DC Common Bus Applications
Appendix D
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Calculating Total Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Calculating Additional Bus Capacitance. . . . . . . . . . . . . . . . . . . . . . . 210
Kinetix 2000 Capacitance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Common Bus Capacitance Example . . . . . . . . . . . . . . . . . . . . . . . . . 212
Setting the Additional Bus Capacitance Parameter . . . . . . . . . . . . . . 213
Remove SERCOS Communication . . . . . . . . . . . . . . . . . . . . . . . 213
Set the Additional Bus Capacitance Parameter . . . . . . . . . . . . . . 213
Save the Add Bus Cap Parameter to Non-volatile Memory . . . . 215
Reconnect SERCOS Communication . . . . . . . . . . . . . . . . . . . . . 216
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
New Product Satisfaction Return. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Publication 2093-UM001A-EN-P — March 2007
8
Publication 2093-UM001A-EN-P — March 2007
Read this preface to familiarize yourself with the rest of the manual.
Preface
About This Publication
Who Should Use This
Manual
Conventions Used in This
Manual
This manual provides detailed installation instructions for mounting, wiring,
and troubleshooting your Kinetix 2000 drive, and system integration for your
drive/motor combination with a Logix controller.
This manual is intended for engineers or technicians directly involved in the
installation and wiring of a Kinetix 2000 drive, and programmers directly
involved in the operation, field maintenance, and integration of a Kinetix 2000
drive with a SERCOS interface.
If you do not have a basic understanding of the Kinetix 2000 drive, contact
your local Rockwell Automation sales representative before using this product,
for information on available training courses.
These conventions are used throughout this manual:
• Bulleted lists such as this one provide information, not procedural steps
• Numbered lists provide sequential steps or hierarchical information
• Acronyms for the Kinetix 2000 drive components, shown in the table
below, are used throughout this manual.
Kinetix 2000 Component Catalog Numbers Acronym
Integrated Axis Module 2093-AC05-MPx IAM
Axis Module (double width) 2093-AM0x
Axis Module (single-width) 2093-AMPx
Shunt Module 2093-ASP06 SM
Power Rail 2093-PRSxx PR
Power Rail Slot Filler 2093-PRF SF
Line Interface Module
2094-AL09, 2094-AL15S,
2094-AL25S, 2094-AL50S,
2094-AL75S, 2094-AL75S-C2
AM
LIM
9 Publication 2093-UM001A-EN-P — March 2007
10
Additional Resources
The following documents contain additional information concerning related
Allen-Bradley products.
Resource Description
ControlFLASH Firmware Upgrade Kit User Manual, publication
1756-6.5.6
3, 8 or 16-axis SERCOS interface Module Installation Instructions,
publication 1756-IN572
Logix5000 Controllers Motion Instructions Reference Manual,
publication 1756-RM007
ControlLogix Motion Module Programming Manual, publication
1756-RM086
ControlLogix Controllers User Manual, publication 1756-UM001
CompactLogix SERCOS Interface Module Installation Instructions,
publication 1768-IN005
16-axis PCI SERCOS interface Card Installation Instructions, publication
1784-IN041
3, 8, or 16-axis PCI SERCOS Interface Card Installation Instructions,
publication 1784-IN572
SoftLogix Motion Card Setup and Configuration Manual, publication
1784-UM003
Fiber-optic Cable Installation and Handling Instructions, publication
2090-IN010
Kinetix 2000 Installation Instructions, publication 2093-IN001 (IAM and
AM) 2093-IN002 (Shunt), 2093-IN003 (Power Rail), and 2093-IN004 (Slot
Filler).
Line Interface Module Installation Instructions, publication 2094-IN005
Rockwell Automation Industrial Automation Glossary, publication AG-7.1 A glossary of industrial automation terms and abbreviations
System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001
EMC Noise Management DVD, publication GMC-SP004
Kinetix Motion Control Selection Guide, publication GMC-SG001
Rockwell Automation Configuration and Selection Tools website
http://www.ab.com/e-tools
Motion Analyzer, version 4.2 or later
http://www.ab.com/motion/software/motion_analyzer.html
Rockwell Automation Product Certification website
Motion Modules in Logix5000 Control Systems User Manual, publication
LOGIX-UM002
National Electrical Code, published by National Fire Protection
Association of Boston, MA.
For ControlFLASH information not specific to any drive family
ControlLogix SERCOS interface module installation instructions
The instructions needed to program a motion application
More detailed information on the use of ControlLogix motion features and
application examples
Information on installing, configuring, programming, and
operating a ControlLogix system
Information on configuring and troubleshooting a CompactLogix motion
module
SoftLogix SERCOS interface PCI card installation instructions
ControlLogix SERCOS interface module installation instructions
Information on configuring and troubleshooting your SoftLogix PCI card
Information on proper handling, installing, testing, and troubleshooting
fiber-optic cables
Information on installing the individual modules that comprise a Kinetix 2000
servo drive system
Information on the installation and troubleshooting of your Bulletin 2094 Line
Interface Module (LIM)
Information, examples, and techniques designed to minimize system failures
caused by electrical noise
Specifications, motor/servo-drive system combinations, and accessories for
Kinetix motion control products
Online product selection and system configuration tools, including AutoCAD
(DXF) drawings
Drive and motor sizing with application analysis software
For declarations of conformity (DoC) currently available from Rockwell
Automation
Information on configuring and troubleshooting your ControlLogix and
CompactLogix SERCOS interface modules
An article on wire sizes and types for grounding electrical equipment
Publication 2093-UM001A-EN-P — March 2007
You can view or download publications at
http://literature.rockwellautomation.com
. To order paper copies of technical
documentation, contact your local Rockwell Automation distributor or sales
representative.
Start
Chapter
1
Introduction
Use this chapter to become familiar with the Kinetix 2000 drive components.
This chapter also reviews design and installation requirements for
Kinetix 2000 drive systems.
Topic Page
About the Kinetix 2000 Drive System 12
Catalog Number Explanation 16
Agency Compliance 17
11 Publication 2093-UM001A-EN-P — March 2007
12 Start
About the Kinetix 2000
Drive System
Kinetix 2000
Component
Integrated Axis
Module
Axis Module
Shunt Module 2093-ASP06
Power Rail 2093-PRSxx
Power Rail Slot
Filler
Logix Controller
Platform
RSLogix 5000
Software
Servo Motors
Integrated Linear
Actuators
Cables
Line Filters, ac 2090-XXLF-xxxx
Line Interface
Module
Catalog Numbers Description
2093-AC05-MPx
2093-AMxx
2093-AMPx
2093-PRF
1756-L60M03SE,
1756-MxxSE, and
1768-M04SE modules,
and the 1784-PM16SE
PCI card
9324-RLD300ENE
MP-Series, TL-Series,
and Y-Series
MP-Series Compatible linear actuators include the MPAI-Axxx (Integrated Actuator) 230V actuators.
Motor Power, Feedback,
and Brake cables
Fiber-optic cables
2094-AL09,
2094-AL15S,
2094-AL25S,
2094-AL50S,
2094-AL75S,
2094-AL75S-C2
The Kinetix 2000 multi-axis servo drive is designed to provide a Kinetix
Integrated Motion solution for applications with output power requirements
between 3
Kinetix 2000 Drive System Overview
Integrated Axis Module (IAM) mounts on a Kinetix 2000 power rail, and is a 230V ac power converter
and inverter. It is installed on a Kinetix 2000 power rail.
Axis Module (AM), is a shared 230V dc bus power inverter, that mounts on a Kinetix 2000 power rail. The
AM must be used with an IAM.
Shunt Module (SM), This module mounts on the Kinetix 2000power rail and provides additional shunting
capability in regenerative applications.
Power Rail (PR) 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,
AM, SM, and SF modules mount to the power rail.
Slot Filler (SF) is used when one or more slots on the Kinetix 2000 power rail are empty after all other
power rail components are installed. One slot filler is required for each empty slot.
SERCOS interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix
platform and Kinetix 2000 drive system. The communication link uses the IEC 61491 SErial Real-time
COmmunication System (SERCOS) protocol over a fiber-optic cable.
RSLogix 5000 software provides support for programming, commissioning, and maintaining the Logix
family of controllers.
Compatible servo motors include the MP-Series (Low Inertia, Food Grade, and Stainless Steel) 230V
motors; TL-Series motors; and Y-Series motors.
Motor power, feedback, and brake cables include integral molded, bayonet style, quick connect/
quick-release connectors at the motor. Power and brake cables have flying leads on the drive end and
straight connectors that connect to servo motors. Standard feedback cables have angled connectors
(45º) on the drive end and straight connectors that connect to servo motors. Optional feedback cables
have a straight connector on the motor end and flying leads that wire to a low-profile connector kit on
the drive end.
SERCOS fiber-optic cables are available in enclosure only, PVC, nylon, and glass with connectors at both
ends.
Bulletin 2090-XXLF-xxxx single-phase and three-phase ac line filters are required to meet CE and
available for use in 230V systems.
Line Interface Module (LIM), contains the circuit breakers, ac line filter, power supplies, and contactor
required for Kinetix 2000 operation. This module does not mount to the power rail.
Alternatively, individual components may be purchased in place of a LIM.
...45 kW (4...49 A).
Publication 2093-UM001A-EN-P — March 2007
Start 13
Typical Kinetix 2000 system installations include three-phase ac
configurations, with and without the line interface module (LIM), and dc
common bus configurations.
TM
SERCOS interface
OK
CP
Tx (rear)
Rx (front)
170...264V ac
Single-phase
Control Power
170...264V ac
Single-phase
or Three-phase
Input Power
Line
Interface
Module
(optional
component)
Line Filter built into this LIM (2094-AL09)
To Input Sensors
and Control String
WARNING
Typical Kinetix 2000 System Installation (with LIM)
ControlLogix Controller Programming Network
1756-M08SE SERCOS Interface Module
ControlLogix Chassis
SERCOS fiber-optic ring
Integrated
Module
Power
Rail
I/O Connections
Motor Feedback
Motor Power
To avoid personal injury due to electrical shock, place a slot
filler (catalog number 2093-PRF) in all empty slots on the power
rail.
Any power rail connector without a module installed will
disable the Kinetix 2000 three-phase power, however control
power is still present.
Workstation with RSLogix 5000 Software
Kinetix 2000 Multi-axis Servo Drive System
Axis
1 2
1 2 3
Shunt Module
and
Slot Filler Module
(Required when slot
is unoccupied by an
IAM, AM, or Shunt.)
Bonded Cabinet
Ground Bus
Axis Modules (4x)
MPL-, MPAI-, TL-, and Y-Series Motors
(MP-Series Low Inertia Motors Shown)
Publication 2093-UM001A-EN-P — March 2007
14 Start
Typical Kinetix 2000 System Installation (without LIM)
170...264V ac
Single-phase
or Three-phase
Input Power
Bonded Cabinet
Ground Bus
Line
Disconnect
Device
Input
Fusing
Magnetic
Contactor
ControlLogix Controller Programming Network
1756-M08SE SERCOS Interface Module
TM
SERCOS interface
OK
CP
ControlLogix Chassis
Tx (rear)
Rx (front)
SERCOS fiber-optic ring
170...264V ac
Single-phase
Control Power
To Input Sensors
and Control String
Motor Feedback
Motor Power
Integrated
Axis
Module
Power
Rail
I/O Connections
Workstation with RSLogix 5000 Software
Kinetix 2000 Multi-axis Servo Drive System
1 2
1 2 3
Shunt Module
and
Slot Filler Module
(Required when slot
is unoccupied by an
IAM, AM, or Shunt.)
Bonded Cabinet
Ground Bus
Axis Modules (4x)
MPL-, MPAI-, TL-, and Y-Series Motors
(MP-Series Low Inertia Motors Shown)
Publication 2093-UM001A-EN-P — March 2007
Typical DC Common Bus System Installation
Logix Controller Programming Network
Start 15
170...264V ac
Single-phase
or Three-phase
Input Power
Line Interface Module
(optional component)
2094-AL
170...264V ac
Single-phase
Control Power
xx
S
Common
Fusing
Bus
Line Filter
2090-XXLF-
170...264V ac
Single-phase
Control Power
Integrated
Module
Common Bus
Power
Rail
xxxx
Axis
(IAM)
Logix Chassis
(ControlLogix is shown)
Integrated
Axis
Module
(IAM)
Power
Rail
Kinetix 2000 Multi-axis Servo Drive System
SERCOS Fiber-optic Ring 2090-SC
SERCOS
Fiber-optic Ring
2090-SC
xxx-x
1 2
1 2 3
Logix SERCOS Interface Module
SERCOS interface
OK
CP
Tx (rear)
Rx (front)
xxx-x
1 2
1 2 3
Shunt Module (optional component)
Slot Filler Module
(Required when slot
is unoccupied by an
IAM, AM, or Shunt.)
Bonded Cabinet
Ground Bus
Axis Modules (4x)
Workstation with
RSLogix 5000 Software
Shunt Module
and
Slot Filler Module
(Required when slot
is unoccupied by an
IAM, AM, or Shunt.)
Bonded Cabinet
Ground Bus
Axis Modules (4x)
In the example above, a leader IAM is connected to a follower IAM via the dc
common bus. When planning your panel layout, you must calculate the total
bus capacitance of your dc common bus system to correctly size the leader
IAM to pre-charge the entire system. In RSLogix5000 software you identify
the common bus follower (disabling its shunt capabilities), and in doing so
require the leader IAM to control the entire common dc bus.
Refer to Appendix D, beginning on page 209, for more information.
IMPORTANT
If total bus capacitance of your system exceeds the leader IAM
pre-charge rating and input power is applied, the IAM seven-segment
Fault Status LED indicator will display error code E90 (pre-charge
timeout fault). To correct this condition, you must replace the leader
IAM with a larger module or decrease the total bus capacitance by
removing axis modules.
Publication 2093-UM001A-EN-P — March 2007
16 Start
Catalog Number
Explanation
Kinetix 2000 drive catalog numbers and descriptions are listed in the table
below.
Kinetix 2000 Drive Catalog Numbers
Integrated Axis Modules (230V) Catalog Number
Kinetix 2000, IAM, 230V, 3 kW
Kinetix 2000, IAM, 230V, 3 kW
Kinetix 2000, IAM, 230V, 3 kW
Axis Modules (230V)
Kinetix 2000, AM, 230V, 1 A Inverter 2093-AMP1
Kinetix 2000, AM, 230V, 2 A Inverter 2093-AMP2
Kinetix 2000, AM, 230V, 3 A Inverter 2093-AMP5
Kinetix 2000, AM, 230V, 6 A Inverter 2093-AM01
Kinetix 2000, AM, 230V, 9 A Inverter 2093-AM02
Power Rails
Kinetix 2000, Single-Axis Power Rail 2093-PRS1
Kinetix 2000, Two-Axis Power Rail 2093-PRS2
Kinetix 2000, Three-Axis Power Rail 2093-PRS3
Kinetix 2000, Four-Axis Power Rail 2093-PRS4
Kinetix 2000, Five-Axis Power Rail 2093-PRS5
Kinetix 2000, Seven-Axis Power Rail 2093-PRS7
Kinetix 2000, Eight-Axis Power Rail with Shunt or Slot Filler 2093-PRS8S
Shunt Module
Kinetix 2000, SM, 230V, 50 W 2093-ASP06
Slot Filler
Kinetix 2000, SF, Power Rail Slot Filler 2093-PRF
(1)
Derated to 2 kW for single-phase operation.
(1)
Converter, 1 A Inverter
(1)
Converter, 2 A Inverter
(1)
Converter, 3 A Inverter
2093-AC05-MP1
2093-AC05-MP2
2093-AC05-MP5
Publication 2093-UM001A-EN-P — March 2007
Start 17
Agency Compliance
If this product is installed within the European Union or EEC regions 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 Determining Your Type of Input
Power on page 63.
For more information on electrical noise reduction, refer to the System Design
for Control of Electrical Noise Reference Manual, publication GMC-RM001.
CE Requirements (System without LIM)
To meet CE requirements when your Kinetix 2000 system does not include
the line interface module (LIM), the following requirements apply.
• Install an ac line filter (2090-XXLF-xxxx) as close to the integrated axis
module (IAM) as possible.
• Use 2090-series motor power cables or use connector kits.
• Combined motor power cable length for all axes on the same dc bus
must not exceed 160 m (525 ft) with 230V systems. Drive-to-motor
power cables must not exceed 30 m (98.5 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 30 m (98.5 ft).
• Install the Kinetix 2000 system inside an enclosure. Run input power
wiring in conduit (grounded to the enclosure) outside of the enclosure.
Separate signal and power cables.
Wiring instructions are available in Chapter 5 of this publication. Product
catalog numbers are listed in the Kinetix Motion Control Selection Guide,
publication GMC-SG001.
Publication 2093-UM001A-EN-P — March 2007
18 Start
CE Requirements (System with LIM)
To meet CE requirements when your Kinetix 2000 system includes the line
interface module (LIM), follow all the requirements as stated in CE
Requirements (System without LIM), and these additional requirements as
they apply to the ac line filter.
• Install the LIM (2094-AL09) as close to the integrated axis module
(IAM) as possible.
• Install the LIM (2094-ALxxS, -or -XL75S-Cx) with the line filter
(2090-XXLF-xxxx) as close to the IAM as possible.
When the LIM (2094-ALxxS, or -XL75S-Cx) supports two IAMs, each
IAM requires an ac line filter installed as close to the IAM as possible.
Publication 2093-UM001A-EN-P — March 2007
Chapter
Planning the Kinetix 2000 Drive System
Installation
2
Introduction
System Design Guidelines
This chapter describes system installation guidelines used in preparation for
mounting your Kinetix 2000 drive components.
Topic Page
System Design Guidelines 19
Minimizing Electrical Noise 26
ATTENTION
Use the information in this section when designing your enclosure and
planning to mount your system components on the panel.
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.
System Mounting Requirements
The following is general information for selecting an enclosure and mounting
your system components within the panel.
• In order to comply with UL and CE requirements, the Kinetix 2000
system must be enclosed in a grounded conductive enclosure offering
protection as defined in standard EN 60529 (IEC 529) to IP55 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.
19 Publication 2093-UM001A-EN-P — March 2007
20 Planning the Kinetix 2000 Drive System Installation
• Size the drive enclosure so as not to exceed the maximum ambient
temperature rating. Consider heat dissipation specifications for all drive
components and other devices that radiate heat into the cabinet.
• Segregate input power wiring and motor power cables from control
wiring and motor feedback cables as they leave the drive. Maintain this
separation throughout the wire run.
• Use Rockwell Automation/Allen-Bradley shielded cable for power
wiring and provide a grounded 360° clamp termination to the enclosure
wall.
• 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, to better understand the concept of
electrical noise reduction.
IMPORTANT
To improve the bond between the power rail and subpanel,
construct your subpanel out of zinc plated (paint-free) steel.
Transformer Selection
The integrated axis module (IAM) does not require an isolation transformer
for three-phase input power. However, a transformer may be required to
match the voltage requirements of the controller to the available service.
To size a transformer for the main ac power inputs, refer to the Circuit
Breaker/Fuse Specifications on page 157 and Transformer Specifications for
Control Power Input on page 159. Multiple power rails in a single cabinet
require additional transformers or additional transformer capacity.
IMPORTANT
IMPORTANT
If using an autotransformer, make sure that the phase to neutral/
ground voltages do not exceed the input voltage ratings of the drive.
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).
Publication 2093-UM001A-EN-P — March 2007
Example: Sizing a transformer to the voltage requirements of a
2093-AC05-MP5 Integrated Axis Module:
2093-AC05-MP5 = 3 kW continuous x 1.5 = 4.5 KVA transformer
Planning the Kinetix 2000 Drive System Installation 21
Circuit Breaker/Fuse Selection
The Kinetix 2000 system utilizes internal short circuit output protection and is
suitable for use on a circuit capable of delivering up to 100,000 Amperes, when
protected by class CC, J, L, and R fuses. Circuit breakers with adequate
widthstand and interrupt ratings, as defined in NEC 2002, article 110.9 and
110.10, are also permitted.
The Bulletin 140M product may be another acceptable means of protection
with the Kinetix 2000 system. As with fuses and circuit breakers, you must
make sure that the selected components are properly coordinated and meet
applicable codes. When applying the 140M product, evaluation of the short
circuit available current is critical and must be kept below the short circuit
rating of the 140M product. As long as you do this review, and the conditions
for use are met, the 140M product is appropriate for use with the Kinetix 2000
system.
The line interface module (LIM) contains different circuit protection based on
type:
• 2094-AL09 contains supplementary protection device, 1492-CB (UL
508), and therefore class CC or J fuses with 5kA SCCR must be used on
the line side of the 2094-AL09 LIM.
• 2094-AL15S, 2094-AL25S, 2094-AL50S, 2094-AL75S, and 2094-XL75S
contain Bulletin 140U (UL 489) motor branch circuit protection.
Overcurrent protection must be adequately coordinated per NEC 2002, article
240.
In most cases, fuses selected to match the drive input current rating will meet
the NEC requirements 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 157 for recommended
circuit breakers and fuses.
Refer to Power Specifications on page 154 for input current and inrush current
specifications for your IAM.
Enclosure Selection
The following example is provided to assist you in sizing an enclosure for your
Kinetix 2000 system. The example system consists of the following
components:
• Six-axis Kinetix 2000 servo drive system
• Line Interface Module (LIM)
• ControlLogix chassis and modules (controller)
Size the Kinetix 2000 servo drive and LIM and use the results to predict the
amount of heat dissipated into the enclosure. You will also need heat
Publication 2093-UM001A-EN-P — March 2007
22 Planning the Kinetix 2000 Drive System Installation
dissipation data from other equipment inside the enclosure (such as
ControlLogix controller). Once the total amount of heat dissipation (in Watts)
is known, the minimum enclosure size can be calculated.
Kinetix 2000 System Heat Dissipation Example
Enclosure Component Description
2093-AC09-M02
2093-AM02 Axis module (AM), 230V, 9 A 60% 67.3
2093-AM02 Axis module (AM), 230V, 9 A 60% 67.3
2093-AM01 Axis module (AM),230V, 6 A 40% 46.7
2093-AM01 Axis module (AM), 230V, 6 A 40% 46.7
2093-AM01 Axis module (AM), 230V, 6 A 20% 46.7
2093-AL09 Line interface module (LIM), 230V, 6 kW, 6 A; 24V dc 3 A 100% 72.0
2093-PR6 Power rail, 230V, 6 axis N/A 0.0
Total Kinetix 2000 system Wattage
(1)
To determine heat dissipation specifications for the Kinetix 2000 components, refer to Power Dissipation Specifications on page 160.
Integrated axis module (IAM),
230V, three-phase
Loading
(1)
Heat Dissipation
Watts
3 kW (converter section) 20% 7.0
1 A (inverter section) 40% 33.6
387.3
(1)
ControlLogix System Heat Dissipation Example
Enclosure
Component
Description
1756-M08SE 8-axis SERCOS interface module 3.2 0
1756-L55M12 5555 ControlLogix processor 4.5 0
1756-IB16D 16 -point input module 0.84 5.8
1756-OB16D 16 -point output module 4.64 3.3
1756-ENBT Ethernet communications module 4.0 0
Backplane total
1756-PB72 24V dc ControlLogix power supply N/A
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.
(2)
Real power heat dissipation is determined by applying the backplane power load (17.18 W) to the graph below.
Backplane Power
(1)
Watts
Load
(2)
17.18
Heat Dissipation
Watts
N/A
25
ControlLogix Real Power
1756-P B72
1756-P B75
Backplane dc
Power Load
(Watts)
75
60
45
30
15
0
0 20 40 60 8 0 100
Real Power (Watts)
(1)
(2)
Publication 2093-UM001A-EN-P — March 2007
Planning the Kinetix 2000 Drive System Installation 23
For backplane power loading requirements of other ControlLogix power
supplies, refer to the ControlLogix Selection Guide, publication 1756-SG001.
In this example, the amount of power dissipated inside the cabinet is the sum
of the Kinetix 2000 system value (387 W) and the ControlLogix system value
(34 W) for a total of 421 W.
With no active method of heat dissipation (such as fans or air conditioning)
either of the following approximate equations can be used.
Metric Standard English
0.38Q
------------------------
A
=
1.8T 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 (m
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.
2
). The exterior surface
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.
4.08Q
----------------
A
=
T 1.1–
The maximum ambient rating of the Kinetix 2000 system is 50 °C (122 °F)
and if the maximum environmental temperature is 30 °C (86 °F) then Q=606
and T=20 in the equation below.
0.38 421()
--------------------------------
A
1.8 20()1.1–
≈=
In this example, the enclosure must have an exterior surface of 4.58 meters
4.58m
2
2
. If
any portion of the enclosure is not able to transfer heat, it should not be
included in the calculation.
Since the minimum cabinet depth to house the 230V drive (selected for this
example) is 200 mm (7.9 in.), then the cabinet needs to be approximately
2000 mm (78.7 in.) high x 1000 mm (39.4 in.) wide x 200 mm (7.9 in.) deep.
2 x (0.2 x 1.0) + 2 x (0.2 x 1.0) + 2 x (1.0 x 2.0) = 4.8 m2
7.9 x 39.4) + 2 x (7.9 x 39.4) + 2 x (39.4 x 78.7) = 48 ft.
2 x (
2
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.
Publication 2093-UM001A-EN-P — March 2007
24 Planning the Kinetix 2000 Drive System Installation
Minimum Clearance Requirements
This section provides information to assist you in sizing your cabinet and
positioning your Kinetix 2000 system components.
IMPORTANT
Mount the module in an upright position. Do not mount the module on
its side.
Minimum Clearance Requirements
Clearance above
for airflow and installation.
Integrated Axis Module (IAM),
catalog number 2093-AC05-MP1,
is shown mounted on power rail
as the first module.
Clearance left of the
module is not required.
(1)
The power rail, catalog number 2093-PRSxx, does not extend left of the first module or right of the last module.
(1)
Clearance below
for airflow and installation.
Clearance right of the
module is not required.
(1)
Minimum Clearance Dimensions
Cat. No. Clearance Above, Min Clearance Below, Min
2093-AC05-MP1,
2093-AC05-MP2,
2093-AC05-MP5.
2093-AMP1,
2093-AMP2,
50.8 mm (2.0 in.) 50.8 mm (2.0 in.)
2093-AMP5,
2093-AM01,
2093-AM02
2093-ASP06 305 mm (12.0 in.) 50.8 mm (2.0 in.) 200 mm (7.9 in.)
2093-PRF None None None
(1)
Additional clearance required to accommodate cable bend restrictions.
Cabinet Depth Clearance, Min
200 mm (7.9 in.)
235 mm (9.25 in.)
(1)
If 15-pin connector kit, catalog number
2090-K2CK-D15M, is attached.
44-pin connector kit options include:
• 2090-U3BK-D44xx connector kit
(containing a 2090-U3BK-D44 terminal
block and 2090-U3BK-D44xx cable)
• 2090-U3BK-D44 terminal block and
custom-built cable.
• 2090-U3BK-D44 terminal block and flying
lead cable.
Publication 2093-UM001A-EN-P — March 2007
Planning the Kinetix 2000 Drive System Installation 25
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 160 for power dissipation specifications.
Publication 2093-UM001A-EN-P — March 2007
26 Planning the Kinetix 2000 Drive System Installation
Minimizing Electrical
Noise
This section outlines best practices which minimize the possibility of
noise-related failures as they apply specifically to Kinetix 2000 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.
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 blocks the direct return path and results in high-frequency
energy traveling elsewhere in the cabinet. Excessive high-frequency energy can
effect the operation of other microprocessor controlled equipment.
The illustrations that follow show details of recommended bonding practices
for painted panels, enclosures, and mounting brackets.
Publication 2093-UM001A-EN-P — March 2007
Planning the Kinetix 2000 Drive System Installation 27
Recommended Bonding Practices for Painted Panels
Stud-mounting the Subpanel
to the Enclosure Back Wall
Back Wall of
Enclosure
Subpanel Welded Stud
Star Washer
Nut
Use a wire brush to remove paint from
threads to maximize ground
connection.
Use plated panels or scrape paint on
front of panel.
Welded Stud
Mounting Bracket or
Flat Washer
Nut
Stud-mounting a Ground Bus
or Chassis to the Subpanel
Ground Bus
Flat Washer
If the mounting bracket is coated
with a non-conductive material
(anodized or painted), scrape the
Star Washer
material around the mounting hole.
Subpanel
Scrape Paint
Bolt-mounting a Ground Bus or Chassis to the Back-panel
Ground Bus or
Mounting Bracket
Flat Washer
Nut
Subpanel
Tapped Hole
Nut
Scrape paint on both sides of
panel and use star washers.
Star Washer
Flat Washer
Bolt
Star Washer
If the mounting bracket is coated
Star Washer
with a non-conductive material
(anodized or painted), scrape the
material around the mounting hole.
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.
Publication 2093-UM001A-EN-P — March 2007
28 Planning the Kinetix 2000 Drive System Installation
Multiple Subpanels and Cabinet Recommendations
Bond the top and bottom of each subpanel to the cabinet using
25.4 mm (1.0 in.) by 6.35 mm (0.25 in.) wire braid.
Cabinet ground bus
bonded to the subpanel.
Scrape the paint around each fastener to
maximize metal to metal contact.
Establishing Noise Zones
Observe the following guidelines when a LIM (2094-AL09) is used in the
Kinetix 2000 system and mounted left of the IAM:
This layout is preferred due to the reduced size of the very dirty zone.
• The clean zone (C) is to the right and beneath the Kinetix 2000 system
(grey wireway).
• The dirty zone (D) is to the left and above the Kinetix 2000 system, and
above and below the LIM (black wireway).
• The very dirty zone (VD) is limited to where the LIM VAC output
jumpers over to the IAM. Shielded cable is required only if the very dirty
cables enter a wireway.
• The SERCOS fiber-optic cables are immune to electrical noise.
Publication 2093-UM001A-EN-P — March 2007
Planning the Kinetix 2000 Drive System Installation 29
Establishing Noise Zones (LIM mounted left of IAM)
Dirty Wireway
D
D
2094-AL09 Line Interface Module
Line Filter built into this LIM
(1)
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM 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 Chapter 4 of the System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001.
Very Dirty LIM/IAM Connections
Segregated (not in wireway)
VD
DD
Route 24V dc
I/O Shielded
C
C
Route Encoder/Analog/Registration
Shielded Cables
Clean Wireway
Fiber-optic Cable
No Sensitive
Equipment
within 150 mm
Kinetix 2000
System
(1)
I/O and
Feedback Cables
(2)
Publication 2093-UM001A-EN-P — March 2007
30 Planning the Kinetix 2000 Drive System Installation
Observe the following guidelines when a LIM (2094-ALxxS, or
2094-XL75S-Cx) is used in the Kinetix 2000 system and mounted left of the
IAM with the ac (EMC) line filter mounted above the LIM:
• The clean zone (C) is to the left and below the Kinetix 2000 system
(grey wireway).
• The dirty zone (D) is to the right and above the Kinetix 2000 system,
and above and below the LIM (black wireway).
• The very dirty zone (VD) is from the filter output to IAM. 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.
Establishing Noise Zones (LIM mounted right of IAM)
Very Dirty Filter/IAM Connections
Clean Wireway Dirty Wireway
Segregated (Not in Wireway)
No Sensitive
Equipment
Within 150 mm
I/O and Feedback Cables
C
Route Encoder/Analog/Registration
Shielded Cables
(1)
(2)
VD D
V ac Line
Line Filter
Fiber-optic Cable
(2)
VD
(1)
D
If IAM/AM I/O cable contains (dirty) relay wires, route cable with LIM I/O cable in dirty wireway.
When space does not permit the 150 mm (6.0 in.) segregation, use a grounded steel shield instead. For
examples, refer to Chapter 4 of the System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001.
C
V ac LOAD
D
MAIN VAC
Kinetix 2000
Drives
Line Interface Module
Route Motor Power and
24V dc I/O Shielded Cables
D
D
D
Publication 2093-UM001A-EN-P — March 2007
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