Rockwell Automation 2094-EN02D-M01-Sx User Manual

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User Manual

Kinetix 6200 and Kinetix 6500 Modular Multi-axis Servo Drives

Catalog Numbers 2094-BCxx-Mxx-M, 2094-BMxx-M 2094-SE02F-M00-Sx, 2094-EN02D-M01-Sx, 2094-BSP2, 2094-PRF, 2094-SEPM-B24-S

Important User Information

IMPORTANT

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 your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/ 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.

available from

) describes some

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.

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, CompactLogix, ControlFLASH, ControlLogix, Guardmaster, HPK-Series, Integrated Architecture, Kinetix, LDC-Series, LDL-Series, MP-Series, PanelView, POINT I/O, PowerFlex, RSLinx, RSLogix, SoftLogix, RDD -Series, Rockwell Automation, Rockwell Software, Stratix, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual contains new and updated information.

Summary of Changes

New and Updated Information

Much information regarding the Kinetix® 6000M integrated drive-motor (IDM) system has been added to this manual, however, the focus in this manual is on how the IDM system affects the overall operation of the Kinetix 6200 drive system.

For mounting, wiring, configuring, and troubleshooting information specific to the Kinetix 6000M integrated drive-motor systems, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

This revision also includes the following new and updated information:

• Bulletin 2090-K6CK-D44S0 connector kit and 2090-CS0DSDS-AAxx cable for cascading safe torque-off signals

• Motor connector and cable changes for the Bulletin MPL-A/B15xxx and MPL-A/B2xxx low-inertia motors and MPAR-A/B1xxx and MPAR-A/B2xxx electric cylinders with SpeedTec DIN (M7) connectors

• MPAI-A/B2xxxx (frame 64 and 144) heavy-duty electric cylinders

Section Topic Page

Preface Added acronyms for the Kinetix 6000M integrated drive-motor (IDM) system. 11

Added the IPIM module to About the Kinetix 6200 and Kinetix 6500 Drive Systems. 14

Chapter 1

Chapter 2

Chapter 3

Chapter 5

Chapter 6

Chapter 8

Added the Kinetix 6000M integrated drive-motor (ID M) to typical system installatio n diagrams and catalog number explanation.

Added the IPIM module to Minimum Clearance Requirements. 35

Added the IPIM module to Es tablishing Noise Zones. 45

Added the IPIM module to Determine Mounting Order. 56

Revised motor power, brake, and feedback cable compatibility tables to include the MPL-A/B15xxx-xx7xAA and MPL-A/B2xxx-xx7xAA low-inertia motors and MPAR-A/B1xxx and MPAR-A/B2xxx electric cylinders with SpeedTec (M7) connectors.

Added 2090-K6CK-D44S0 with 2090-CS0DSDS-AAxx cable for cascading safe torqueoff signals from drive-to-drive.

Added IPIM Module Connections with summary of installation connections and links to other diagrams and publications with additional information.

Added Kinetix 6000M Integrated Drive-Motor Sercos Connections 134

Added Ethernet Cable Connections 135

Updated the introduction with an overview of IDM system configuration. 139

Updated the introduction with an overview of the IDM system troubleshooting 196

14…18

111, power 116, brake 119, feedback

119…127

129

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 3

Summary of Changes

Section Topic Page

Updated existing circular DIN (SpeedTec) interconnect diagram with Bulletin

Appendix A

Appendix B

Appendix C

MPL-A/B15xxx-xx7xAA and MPL-A/B2xxx-xx7xAA low-inertia motors with SpeedTec (M7) connectors.

Updated the MP-Series™ (Bulletin MPAI) electric cylinders interconnect diagram with frame 64 and 144 cable catalog numbers.

Updated the MP-Series (Bulletin MPAR) electric cylinders interconnect diagram with cable catalog number changes for SpeedTec (M7) connector

Added Kinetix 6000M Integrated Drive-Motor Wiring Example. 251

Added Bulletin MDF catalog numbers to Controlling a Brake Example 252

Added an overview for IDM system firmware upgrades. 257

Updated the procedure and tables with IPIM module values. 267

244

248

4 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start

Preface

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

About the Kinetix 6200 and Kinetix 6500 Drive Systems. . . . . . . . . . . . 14

Typical Hardware Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Typical Communication Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Kinetix Drive Component Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Kinetix 6000M Integrated Drive-Motor System Compatibility . . . . . . 24

Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

CE Requirements (system without LIM module) . . . . . . . . . . . . . . . 25

CE Requirements (system with LIM module). . . . . . . . . . . . . . . . . . . 25

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Mounting the Kinetix 6200 and Kinetix 6500 Drive System

Chapter 2

System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Circuit Breaker/Fuse Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Electrical Noise Reduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Establishing Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Cable Categories for Kinetix 6200 and Kinetix 6500 Systems . . . . 47

Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 50

Chapter 3

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Using the 2094 Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Installing the 2094 Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Determine Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Mount Modules on the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Mount the Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Kinetix 6200 and Kinetix 6500 Connector Data

Chapter 4

2094 Power Module and Control Module Features . . . . . . . . . . . . . . . . . 64

I/O, Safety, and Auxiliary Feedback Connector Pinout . . . . . . . . . . 67

Motor Feedback Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Ethernet Communication Connector Pinout . . . . . . . . . . . . . . . . . . . 69

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 5

Table of Contents

IAM Input Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

IAM and AM Motor Power and Brake Connector Pinout. . . . . . . . 70

Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Ethernet Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . 73

Sercos Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Power and Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Motor/Resistive Brake Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Input Power Cycle Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Peak Current Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Motor Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Auxiliary Position Feedback Specifications. . . . . . . . . . . . . . . . . . . . . . 88

Safe Speed Monitoring Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Safe Torque-off Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Connecting the Kinetix 6200 and Kinetix 6500 Drive System

Chapter 5

Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 93

Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Ungrounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

DC Common Bus Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Common Bus Fusing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Setting the Ground Jumper in Ungrounded Power Configurations . . . 97

Set the Ground Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Grounding the Modular Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Ground the Power Rail to the System Subpanel . . . . . . . . . . . . . . . . 100

Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Power Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Wiring the IAM/AM Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . 105

Wire the Control Power (CPD) Connector . . . . . . . . . . . . . . . . . . . 105

Wire the Input Power (IPD) Connector. . . . . . . . . . . . . . . . . . . . . . . 106

Wire the Contactor Enable (CED) Connector. . . . . . . . . . . . . . . . . 108

Wire the Motor Power (MP) Connector . . . . . . . . . . . . . . . . . . . . . . 109

Wire the Motor/Resistive Brake (BC) Connector . . . . . . . . . . . . . . 115

Apply the Motor Cable Shield Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Flying-lead Feedback Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Wiring the Feedback and I/O Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 123

Connect Premolded Motor Feedback Cables. . . . . . . . . . . . . . . . . . . 123

Connect Panel-mounted Breakout Board Kits . . . . . . . . . . . . . . . . . 124

6 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Configure and Start the Kinetix 6200 Drive System

Table of Contents

Wire Low-profile Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

IPIM Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

RBM Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Sercos Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Kinetix 6000M Integrated Drive-Motor Sercos Connections . . . . . . . 134

Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Chapter 6

Configure the Kinetix 6000M Integrated Drive-Motor System . . . . . 139

Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Configure the Logix Sercos interface Module . . . . . . . . . . . . . . . . . . . . . . 146

Configure the Logix Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Configure the Logix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Configure the Kinetix 6200 Drive Modules. . . . . . . . . . . . . . . . . . . . 150

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Configure Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Apply Power to the Kinetix 6200 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Configure and Start the Kinetix 6500 Drive System

Troubleshooting the Kinetix 6200 and Kinetix 6500 Drive System

Chapter 7

Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Configure the Logix EtherNet/IP Module . . . . . . . . . . . . . . . . . . . . . . . . 171

Configure the Logix Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Configure the Logix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Configure the Kinetix 6500 Drive Modules. . . . . . . . . . . . . . . . . . . . 175

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Configure Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Apply Power to the Kinetix 6500 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Chapter 8

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Kinetix 6000M IDM System Error Codes . . . . . . . . . . . . . . . . . . . . . 196

Four-character Display Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Control Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Shunt Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

General System Anomalies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 7

Table of Contents

Removing and Replacing the Kinetix 6200 and Kinetix 6500 Drive Modules

Interconnect Diagrams

Logix Controller and Drive Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Kinetix 6500 Drive Exception Behavior . . . . . . . . . . . . . . . . . . . . . . . 214

Kinetix 6200 Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Drive Exception/Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Chapter 9

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Remove Kinetix 6200 and Kinetix 6500 Drive Modules . . . . . . . . . . . . 224

Remove the Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Remove the Drive Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Replace Kinetix 6200 and Kinetix 6500 Drive Modules. . . . . . . . . . . . . 227

Replace the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Replace the Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Remove the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Replace the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Appendix A

Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Power Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

DC Common Bus Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Shunt Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Axis Module/Rotary Motor Wiring Examples. . . . . . . . . . . . . . . . . . 242

Axis Module/Linear Motor/Actuator Wiring Examples . . . . . . . . 247

Kinetix 6000M Integrated Drive-Motor Wiring Example . . . . . . . 251

Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Appendix B

Upgrading the Drive Firmware

Upgrade Kinetix 6000M System Firmware . . . . . . . . . . . . . . . . . . . . . . . . 257

Upgrade Drive Firmware with ControlFLASH Software . . . . . . . . . . . 258

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Configure Logix Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Upgrade Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Appendix C

DC Common Bus Applications

8 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Calculate Total Bus Capacitance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Calculate Additional Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Bulletin 2094 Drive Capacitance Values. . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Common Bus Capacitance Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Appendix D

Table of Contents

Changing the Default IDN Parameter Values

RBM Module Interconnect Diagrams

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Change IDN Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Read the Present IDN Parameter Value . . . . . . . . . . . . . . . . . . . . . . . 272

Calculate/Select the New IDN Value . . . . . . . . . . . . . . . . . . . . . . . . . 274

Write the New IDN Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . 275

Appendix E

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

RBM Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Index

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 9

Table of Contents

Notes:

10 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Preface

About This Publication

Who Should Use This Manual

This manual provides detailed installation instructions for mounting, wiring, and troubleshooting Kinetix 6200 and Kinetix 6500 (Bulletin 2094) drives; and system integration for your drive and motor/actuator combination with a Logix controller.

For information on wiring, configuring, and troubleshooting the safe-speed monitoring functions, refer to the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Safety Reference Manual, publication 2094-RM001

For information on wiring, configuring, and troubleshooting the safe torque-off functions, refer to the Kinetix 6200 and Kinetix 6500 Safe Torque-off Safety Reference Manual, publication 2094-RM002

This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 6200 and Kinetix 6500 drives; and programmers directly involved in the operation, field maintenance, and integration of these drives with a sercos interface or EtherNet/IP communication module.

If you do not have a basic understanding of the Kinetix 6200 and Kinetix 6500 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 6200 and Kinetix 6500 drive modules are shown

in the table below and are used throughout this manual.

Kinetix 6200 and Kinetix 6500 Drive Modules

Integrated Axis Module 2094-BCxx-Mxx-MIAM

Axis Module 2094-BMxx-M AM

Line Interface Module 2094-BLxx and 2094-BLxxS-xx LIM

Resistive Brake Module 2090-XBxx-xx RBM

Kinetix 6000M Drive Modules Cat. No. Acronym

Integrated Drive-Motor MDF-SBxxxxx IDM

IDM Power Interface Module 2094-SEPM-B24-S IPIM

Cat. No. Acronym

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 11

Preface

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003

Kinetix 6000 Shunt Module Installation Instructions, publication 2094-IN004

Slot-filler Module Installation Instructions, publication 2094-IN006

Line Interface Module Installation Instructions, publication 2094-IN005

2094 Mounting Bracket Installation Instructions, publication 2094-IN008

Resistive Brake Module Installation Instructions, publication 2090-IN009

Fiber-optic Cable Installation and Handling Instructions, publication 2090-IN010

External Shunt Modules Installation Instructions, publication 209 0-IN004

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

EMC Noise Management DVD, publication GMC-SP004

Kinetix 6000M Integrated Drive-Motor User Manual, publication 2094-UM003

Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Ser vo Drives Safety Reference Manual, publication 2094-RM001

Kinetix 6200 and Kinetix 6500 Safe Torque-off Servo Drives Safet y Reference Manual, publication 2094-RM002

Kinetix 6000 and Kinetix 6200/6500 Drive Systems, publication GMC-RM003

Kinetix Motion Control Selection Guide, publication GMC-SG001

Kinetix Rotary Motion Specifications, publication GMC-TD001

Kinetix Linear Motion Specifications, publication GMC-TD002

Kinetix Servo Drives Specifications, publication GMC-TD003

Kinetix Motion Accessories Specifications, publication GMC-TD004

Rockwell Automation Configuration and Selection Tools website http://ww w.rockwellautomation.com/en/e-tools

Rockwell Automation Product Certification, website http://ww w.rockwellautomation.com/products/certification

Sercos and Analog Motion Configuration User Manual, publication MOTION-UM001

Motion Coordinate System User Manual, publication MOTION-UM002

Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual, publication MOTION-UM003

SoftLogix Motion Card Setup and Configuration Manual, publication 1784-UM003

ControlFL ASH Firmware Upg rade Kit User Ma nual, public ation 1756-QS105

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

Information on the installation of your Bulletin 2094 power rail.

Information on the installation of your Bulletin 2094 shunt module.

Information on the installation of Bulletin 2094 slot-filler module.

Information on the installation and troubleshooting of Bulletin 2094 line interface modules (LIM).

Information on the installation of Bulletin 2094 mounting brackets.

Information on the installation and wiring of Bulletin 2090 Resistive Brake Modules.

Information on proper handling, installing, testing, and troubleshooting fiber-optic cables.

Information on mounting and wiring the Bulletin 1394 shunt modules with Bulletin 2 094 servo drive systems.

Information, examples, and techniques designed to minimize system failures caused by electrical noise.

Information on installing, configuring, startup, troubleshooting, and applications for your Kinetix 6000M integrated drive-motor (IDM) system.

Information on wiring, configuring, and troubleshooting the safe-speed features of your Kinetix 6200 and Kinetix 6500 drives.

Information on wiring, configuring, and troubleshooting the safe torque-off features of your Kinetix 6200 and Kinetix 6500 drives.

System design guide to select the required (drive specific) drive module, power accessory, connector kit, motor cable, and interface cable catalog numbers for your drive and motor/ actuator motion control system.

Overview of Kinetix servo drives, motors, actuators, and motion accessories designed to help make initial decisions for the motion control products best suited for your system requirements.

Product specifications for MP-Series (Bulletin MPL, MPM, MPF, MPS), Kinetix 6000M (Bulletin MDF), TL-Series™, RDD-Serie s™, and HPK-Series™ rotary motors.

Product specifications for Bulletin MPAS and MPMA linear stages, Bulletin MPAR, MPAI, and TLAR electric cylinders, and LDC-Series™ and LDL-Series™ linear motors.

Product specifications for Kinetix Integrated Motion over the EtherNet/IP network, Integrated Motion over sercos interface, EtherNet/IP networking, and component servo drive families.

Product specifications for Bulletin 2090 motor and inter face cables, low-profile connector kits, drive power components, and other servo drive accessory items.

Motion Analyzer application analysis software for drive/motor sizing and online product selection and system configuration tools, including AutoCAD (DXF) files.

For declarations of conformity (DoC) currently available from Rockwell Automation.

Information on configuring and troubleshooting your ControlLogix®, CompactLogix™, and SoftLogix™ sercos interface modules.

Information to create a mot ion coordinate system with sercos or analog motion modules.

Information on configuring and troubleshooting your ControlLogix and CompactLogix EtherNet/IP network modules.

Information on configuring and troubleshooting SoftLogix PCI cards.

For ControlFLASH™ information not specific to any drive family.

A glossary of industrial automation terms and abbreviations.

You can view or download publications at

http://www.rockwellautomation.com/literature

technical documentation, contact your local Allen-Bradley® distributor or Rockwell Automation sales representative.

12 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

. To order paper copies of

Chapter 1

Start

Use this chapter to become familiar with the design and installation requirements for Kinetix 6200 and Kinetix 6500 drive systems.

Top ic Pa ge

About the Kinetix 6200 and Kinetix 6500 Drive Systems 14

Typical Ha rdware Configurations 15

Typical Communication Configurations 19

Catalog Number Explanation 23

Kinetix Drive Component Compatibility 24

Kinetix 6000M Integrated Drive-Motor System Compatibility 24

Agenc y Compliance 25

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 13

Chapter 1 Start

About the Kinetix 6200 and Kinetix 6500 Drive Systems

The Kinetix 6200 and Kinetix 6500 modular multi-axis servo drives are designed to provide a Kinetix Integrated Motion solution for your drive/motor/actuator applications.

Table 1 - Kinetix 6200 and Kinetix 6500 Drive System Overview

System Component

Integrated Axis Module

Axis Module 2094-BMxx-M

Control Module

Shunt Module 2094-BSP2 The Bulletin 2094 shunt module mounts to the power rail and provides additional shunting in regenerative applications.

Kinetix 6000M IDM System

Power Rai l

Power Rai l Slot-filler Module

Logix Controller Platform

RSLogix™ 5000 Software

Rotary Servo Motors

Linear Motors LDC-Series Compatible motors include LDC-Series iron core (400V-class) linear motors.

Linear Actuators MP-Series

Cables

AC Line Filters 2090-XXLF-xxxx

Line Interface Modules

External Shunt Modules

Resistive Brake Module

Cat. No. Description

2094-BCxx-Mxx-M

2094-SE02F-M00-Sx Interchangeable modular components for wiring I/O, safety, and feedback options using sercos interface.

2094-EN02D-M01-Sx Interchangeable modular components for wiring I/O, safety, and feedback options using EtherNet/IP networking.

2094-SEPM-B24-S Bulletin MDF

2094-PRSx 2094-PRx

2094-PRF

1756-MxxSE modules 1768-M04SE module 1784-PM16SE PCI card

1756-ENxTx modules CompactLogix 5370 controllers

9324-RLD300ENE RSLogix 5000 software provides support for programming, commissioning, and maintaining the Logix family of controllers.

MP-Series, RDD-Series 1326AB

2090-Series motor/actuator cables

Kinetix 6000M integrated drive-motor cables

Communication

2094-xLxx 2094-xLxxS 2094-XL75S-Cx

1394-SRxxxx

2090-XBxx-xx

Integrated Axis (power) Modules (IAM) with safe speed monitoring are available with 400V-class AC input power and contains an inverter and converter section. The IAM power module requires one control module.

Axis (power) Modules (AM) are a shared DC-bus inverter rated for 400V-class input power. The AM power modules each require one control module and must be used with an IAM power module.

The Kinetix 6000M integrated drive-motor (IDM) system consists of the IDM power interface module (IPIM) and up to 16 (Bulletin MDF) IDM units. The IPIM module mounts on the Bulletin 2094 power rail and provides power and communication to the IDM units. The IPIM module also monitors power output and provides overload protection.

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.

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.

The sercos interface module/PCI card serves as a link between the ControlLogix/CompactLogix/SoftLogix platform and the Kinetix 6200 drive system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (sercos) protocol over a fiber-optic cable.

The EtherNet/IP network module serves as a link between the ControlLogix platform and Kinetix 6500 drive system. Linear, device-level ring (DLR), and star topology is supported. The Kinetix 6000M IPIM module connects to the EtherNet/IP network for monitoring, diagnostics, and firmware upgrades.

Compatible rotary motors include the MP-Series (Bulletin MPL, MPM, MPF, and MPS), RDD-Series (Bulletin RDB), and 1326AB (M2L/S2L) 400V-class motors.

Compatible actuators include MP-Series (400V-class) Bulletin MPAS single-axis and Bul letin MPMA multi-axis integrated linear stages, and MP-Series (400V-class) Bulletin MPAR and MPAI electric cylinders.

Bulletin 2090 motor/actuator 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 s to low-profile connector kits on the drive end and straight connectors on the motor end.

Bulletin 2090 integrated drive-motor (IDM) hybrid and network cables connect between the 2094 IPIM module and the Kinetix 6000M IDM units. Bulletin 889D and 879D cables connect between digital input connectors and sensors.

Bulletin 2090 sercos fiber-optic cables are available as enclosure only, PVC, nylon, and glass with connectors at both ends.

Ethernet cables are available in standard lengths for Kinetix 6500, Kinetix 6200, and Kinetix 6000M IPIM modules. Shielded cable is recommended.

Bulletin 2090-XXLF-xxxx three-phase AC line filters are required to meet CE and available for use in all Kinetix 6200 and Kinetix 6500 (400V-class) drive systems.

Line interface modules (LIM) include the circuit breakers, AC line filter (catalog number 2094-BL02 only), power supplies, and safety contactor required for Kinetix 6200 and Kinetix 6500 operation. The LIM module does not mount to the power rail. You can purchase individual components separately in place of the LIM module.

You can use Bulletin 1394 external passive shunt modules when the IAM/AM power module internal shunt and power rail mounted 2094-BSP2 shunt module capability is exceeded.

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.

ervo motors. Feedback cables have flying leads that wire

14 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start Chapter 1

Kinetix 6200 or Kinetix 6500 Multi-axis Servo Drive System

2094-BLxxS Line Interface Module (optional component)

2094-BMxx-M AM Power Modules (5) with Bulletin 2094 Control Modules (5)

Three-phase Input Power

2094-BCxx-Mxx-M

IAM Power Module

with

Bulletin 2094

Control Module

2094-BSP2 Shunt Module (optional component)

2090-XXLF-xxxx

AC Line Fi lter

(required for CE)

2094-PRSx

Power Rail

2094-PRF Slot Filler Module (required to fill any unused slots)

I/O Connections

To Input Sensors

and Control String

115/230V Control Power

2090-K6CK-Dxxxx

Low Profile Connector Kits for I/O, Safety,

Motor Feedback, and Aux Feedback

MP-Series Integrated Linear Stages (MPAS-B9xxx ballscrew shown)

MP-Series Rotary Motors

(MPL-Bxxxx motors shown)

Bulletin 2090

Motor Feedback Cables

Bulletin 2090

Motor Power Cables

MP-Series Electric Cylinders

(MPAR-Bxxxx electric cylinder shown)

LDC-Series Linear Motors

(LDC-Cxxxxxxx linear motor shown)

RDD-Series Direct Drive Motors (RDB-Bxxxx motor shown)

MP-Series Heavy Duty Electric Cylinders (MPAI-Bxxxx electric cylinders shown)

Typical Hardware Configurations

MAIN VAC

Typical Kinetix 6200 and Kinetix 6500 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 slot-filler module in all empty slots on the power rail. Any power rail connector without a module installed will disable the threephase power; however, control power is still present.

Figure 1 - Typical Kinetix 6200 or Kinetix 6500 System Installation (with LIM)

m b.co .a w w w E IN USA D A M

55 C-M07 . LD XXXX X XXXX

. NO

NO.

CAT SERIAL

S A SERIE

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 15

CAT. NO. LDC-M075500 SERIAL NO. XXXX X XXXX

SERIES A

www.ab.com

MADE IN USA

Kinetix 6200 or Kinetix 6500 Multi-axis Servo Drive System

Three-p hase Input Power

Single-phase

Control Power

I/O Connections

To Input Sensors

and Control String

2090-K6CK-Dxxxx

Low Profile Connector Kits for I/O, Safety,

Motor Feedback, and Aux Feedback

MP-Series Rotary Motors

(MPL-Bxxxx motors shown)

Bulletin 2090

Motor Feedback Cables

Bulletin 2090

Motor Power Cables

Line

Disconnect

Device

Magnetic

Contac tor

Input

Fusing

2094-BMxx-M AM Power Modules (5) with Bulletin 2094 Control Modules (5)

2094-BCxx-Mxx-M

IAM Power Module

with

Bulletin 2094

Control Module

2094-BSP2 Shunt Module (optional component)

2090-XXLF-xxxx

AC Line Filter

(required for CE)

2094-PRSx

Power Rail

2094-PRF Slot Filler Module (required to fill any unused slots)

MP-Series Integrated Linear Stages (MPAS-B9xxx ballscrew shown)

LDC-Series Linear Motors

(LDC-Cxxxxxxx linear motor shown)

RDD-Series Direct Drive Motor (RDB-Bxxxx motor shown)

MP-Series Electric Cylinders

(MPAR-Bxxxx electric cylinder shown)

MP-Series Heavy Duty Electric Cylinders (MPAI-Bxxxx electric cylinders shown)

2090-XXLF-xxxx

AC Line Filter

(required for CE)

Chapter 1 Start

Figure 2 - Typical Kinetix 6200 or Kinetix 6500 System Installation (without LIM)

16 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start Chapter 1

Three-phase Input Power

Kinetix 6200 Modular

Servo Drive System

2094-BSP2 Shunt Module (optional component)

2094-SEPM-B24-S IPIM Module

2094-PRSx

Power Rail

2094-PRF Slot Filler Module (required to fill any unused slots)

To Input Sensors

and Control String

2090-K6CK-Dxxxx

Low Profile Connector Kits for I/O, Safety,

Motor Feedback, and Aux Feedback

Compatible Rotary Motors,

Linear Motors, and Linear Actuators

(MPL-Bxxxx motor shown)

Bulletin 2090

Motor Feedback Cables

Bulletin 2090

Motor Power Cables

Bulletin 2090 Hybrid Cables

Bulletin 2090 Network Cables

MDF-SBxxxxx-Qx8xA-S Drive-Motor Unit

This configuration illustrates the Kinetix 6000M integrated drive-motor (IDM) system with IDM power interface module (IPIM) installed on the Bulletin 2094 power rail. The IPIM module is included in the drive-to-drive fiber-optic cable installation along with the axis modules.

Figure 3 - Typical Kinetix 6000M Integrated Drive-Motor System Installation

For more information on Kinetix 6000M integrated drive-motor system installation, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 17

Chapter 1 Start

Three-phase Input Power

115/230V Control Power

DC Common Bus

Kinetix 6200 or Kinetix 6500 Multi-axis Servo Drive System

2094-BLxxS Line Interface Module (optional component)

2094-BMxx-M AM Power Modules (5) with Bulletin 2094 Control Modules (5)

2094-BCxx-Mxx-M

IAM Power Module

with

Bulletin 2094

Control Module

2094-BSP2 Shunt Module (optional component)

2090-XXLF-xxxx

AC Line Filter

(required for CE)

2094-PRSx

Power Rail

2094-PRF Slot Filler Module (required to fill any unused slots)

2094-BMxx-M AM Power Modules (5) with Bulletin 2094 Control Modules (5)

2094-BCxx-Mxx-M

IAM Power Module

with

Bulletin 2094

Control Module

2094-PRSx

Power Rail

2094-PRF Slot Filler Module (required to fill any unused slots)

2094-SEPM-B24-S IPIM Module

IMPORTANT

Figure 4 - Typical DC Common Bus System Installation

In the example above, the leader IAM module is connected to the follower IAM module via the DC common-bus. The follower system also includes the Kinetix 6000M integrated drive-motor (IDM) power interface module (IPIM) that supports up to 16 IDM units.

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

page 267,

for more information.

If total bus capacitance of your system exceeds the leader IAM power module pre-charge rating, the IAM module four-character display scrolls a power cycle

C, beginning on

user limit condition. If input power is applied, the display scrolls a power cycle fault limit condition.

To correct this condition, you must replace the leader IAM power module with a larger module or decrease the total bus capacitance by removing the IPIM module or AM power modules.

18 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start Chapter 1

SERCOS interface

Tx (rear)

Rx (front)

62006200

SAFE SPEED

62006200

SAFE SPEED

0.2 m

(7.1 in.)

0.1 m

(5.1 in.)

62006200

SAFE SPEED

62006200

SAFE SPEED

62006200

SAFE SPEED

62006200

SAFE SPEED

62006200

SAFE SPEED

62006200

SAFE SPEED

0.3 m

(12.0 in.)

0.2 m

(7.1 in.)

TX RX

62006200

SAFE SPEED

62006200

SAFE SPEED

62006200

SAFE SPEED

Logix Sercos interface Module

Logix Platform

(Control Logix is shown)

RSLogix 5000

Software

2090-SCxxx-x

Sercos Fiber-optic Cable

Logix Controller Programming Network

2094-BMxx-M AM Power Modules (5) with 2094-SE02F-M00-Sx Control Modules (5)

2094-BCxx-Mxx-M

IAM Power Module

with

2094-SE02F-M00-Sx

Control Module

Ethernet (RJ45) connections are

required only for programming

the 2094-SE02F-M00-S1

safety configuration.

1585J-M8TBJM-x

Ethernet Cable

0.2 m (7.1 in.)

Kinetix 6200 Drive-to-Drive Sercos Cables

Kinetix 6200 Single-wide

2094-BCxx-Mxx-M

IAM Power Module

with

2094-SE02F-M00-Sx

Control Module

Kinetix 6200 Double-wide

2094-BCxx-Mxx-M

IAM Power Module

2094-SE02F-M00-Sx

Control Module

2094-BMxx-M Single-wide AM Power Module with

2094-SE02F-M00-Sx Control Module

2094-BMxx-M Double-wide AM Power Module with

2094-SE02F-M00-Sx Control Module

Kinetix 6200 (top view)

Sercos Connectors

2094-PRSx

Power Rail

2094-BMxx-M Single-wide AM Power Module

with 2094-SE02F-M00-Sx Control Module

2094-SEPM-B24-S IPIM Module

2094-BMxx-S Single-wide AM Modules

Kinetix 6000 and Kinetix 6000M (top view) Sercos Connectors

Typical Communication Configurations

In this example, drive-to-drive sercos cables and catalog numbers are shown when Kinetix 6000, Kinetix 6000M, 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. For more information on Ethernet cables, refer to the Industrial Ethernet Media Brochure, publication 1585-BR001

Figure 5 - Typical Kinetix 6000 and Kinetix 6200 Communication (sercos)

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 19

Chapter 1 Start

TIP

Logix Platform (Contro lLogix is shown)

RSLogix 5000

Software

Kinetix 6500 Modular Multi-axis Servo Drive System

1585J-M8CBJM-x

Ethernet (shielded) Cable

1756-ENxT EtherNet/IP Module

1734-AENT POINT I/O™

EtherNet/IP Adapter

ControlLogix Controller Programming Network

Panel View™ Pl us Display Terminal

1783-ETAP

Modules

PowerFlex® 755

Drive Modules

2094-BMxx-M Axis Modules (5) with

2094-EN02D-M01-Sx Control Modules (5)

2094-BCxx-Mxx-M

Integrated

Axis Module

with

2094-EN02D-M01-Sx

Control Module

1585J-M8CBJM-OM3

0.3 m (1.0 ft) Ethernet cable

for drive-to-drive connections.

The Kinetix 6500 control modules can use any Ethernet topology including star, linear, and device-level ring (DLR). DLR is an ODVA standard and provides fault tolerant connectivity.

1756-EN2F modules are available for applications that require fiber-optic cable for noise immunity.

In this example, all devices are connected in linear topology. The Kinetix 6500 control module includes dual-port connectivity. Devices without dual ports should include the 1783-ETAP module or be connected at the end of the line.

• Up to 64 devices in linear configurations.

• No redundancy. If any device becomes disconnected, all the devices

downstream loose communication.

Figure 6 - Kinetix 6500 Linear Communication Installation (EtherNet/IP network)

20 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start Chapter 1

ControlLogix Platform

RSLogix 5000

Software

Kinetix 6500 Modular Multi-axis Servo Drive System

1585J-M8CBJM-x

Ethernet (shielded) Cable

1756-ENxTR EtherNet/IP Module

1734-AENT POINT I/O

EtherNet/IP Adapter

ControlLogix Controller Programming Network

1783-ETAP

Module

PowerFlex 755

Drive Module

2094-BMxx-M Axis Modules (5) with

2094-EN02D-M01-Sx Control Modules (5)

2094-BCxx-Mxx-M

Integrated

Axis Module

with

2094-EN02D-M01-Sx

Control Module

1585J-M8CBJM-OM3

0.3 m (1.0 ft) Ethernet cable

for drive-to-drive connections.

In this example, the devices are connected by using device-level ring (DLR) topology. DLR topology is fault redundant. For example, if a device in the ring is disconnected, the rest of the devices in the ring continue to maintain communication.

• Up to 64 devices in the DLR configurations.

• All Devices in a DLR ring should have dual-port connectivity or be

connected in the ring by using a 1783-ETAP module.

Figure 7 - Kinetix 6500 Ring Communication Installation (EtherNet/IP network)

755

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 21

Chapter 1 Start

ControlLogix Platform

RSLogix 5000

Software

Kinetix 6500 Modular Multi-axis Servo Drive System

2094-BMxx-M Axis Modules (5) with

2094-EN02D-M01-Sx Control Modules (5)

2094-BCxx-Mxx-M

Integrated

Axis Module

with

2094-EN02D-M01-Sx

Control Module

1585J-M8CBJM-x

Ethernet (shielded) Cable

1756-ENxT EtherNet/IP Module

1734-AENT POINT I/O EtherNet/IP Adapter

ControlLogix Controller Programming Network

Panel View Plus Display Terminal

PowerFlex 755

Drive Module

1783-EMS

Stratix™ Switch

PowerFlex 755

Drive Module

1585J-M8CBJM-OM3

0.3 m (1.0 ft) Ethernet cable

for drive-to-drive connections.

In this example, the devices are connected by using star topology. Each device is connected directly to the switch, making this topology fault tolerant. The 2094 power rail modules and other devices operate independently. The loss of one device does not impact the operation of the other devices.

Figure 8 - Kinetix 6500 Star Communication Installation (EtherNet/IP network)

755755

22 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start Chapter 1

Catalog Number Explanation

Kinetix 6200 and Kinetix 6500 (Bulletin 2094) modular drive catalog numbers and descriptions are listed in the tables below. All power modules are compatible with the Kinetix 6200 and Kinetix 6500 control modules.

Table 2 - Kinetix 6200 and Kinetix 6500 Drive Catalog Numbers

Integrated Axis Modules (460V) Cat. No.

IAM power module, 400V-class, 6 kW converter, 4 A (0-pk) inverter 2094-BC01-MP5-M

IAM power module, 400V-class, 6 kW converter, 9 A (0-pk) inverter 2094-BC01-M01-M

IAM power module, 400V-class, 15 kW converter, 15 A (0-pk) inverter 2094-BC02-M02-M

IAM power module, 400V-class, 28 kW converter, 30 A (0-pk) inverter 2094-BC04-M03-M

IAM power module, 400V-class, 45 kW converter, 49 A (0-pk) inverter 2094-BC07-M05-M

Axis Modules (460V)

AM power module, 400V-class, 4 A (0-pk) 2094-BMP5-M

AM power module, 400V-class, 9 A (0-pk) 2094-BM01-M

AM power module, 400V-class, 15 A (0-pk) 2094-BM02-M

AM power module, 400V-class, 30 A (0-pk) 2094-BM03-M

AM power module, 400V-class, 49 A (0-pk) 2094-BM05-M

Kinetix 6200 Control Modules

Control module, sercos interface, safe torque-off 2094-SE02F-M00-S0

Control module, sercos interface, safe speed monitoring 2094-SE02F-M00-S1

Kinetix 6500 Control Modules

Control module, EtherNet/IP network, safe torque-off 2094-EN02D-M01-S0

Control module, EtherNet/IP network, safe speed monitoring 2094-EN02D-M01-S1

Table 3 - Kinetix 6000 Drive Component Catalog Numbers

Drive Components Cat. No.

Integrated power interface (IPIM) module, 400V-class, 15 kW, 24 A (rms) 2094-SEPM-B24-S

Kinetix 6000 shunt module, 200/400V-class, 200 W 2094-BSP2

Kinetix 6000 slot-filler module, 200/400V-class 2094-PRF

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 23

Chapter 1 Start

IMPORTANT

Kinetix Drive Component Compatibility

IAM Module Control Module

2094-xCxx-Mxx-S N/A

2094-SE02F-M00-Sx

2094-BCxx-Mxx-M (IAM power module)

sercos interface

2094-EN02D-M01-Sx EtherNet/IP network

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 shunt module, 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.

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 4 - IAM and AM Module/Network Compatibility

2094-BMxx-M

2094-xMxx-S Kinetix 6000 AM Module

Fully compatible Fully compatible Not compatible

Not compatible Not compatible Fully compatible

2094-SE02F-M00-Sx Kinetix 6200 Control Module

AM Power Modules

2094-EN02D-M01-Sx Kinetix 6500 Control Module

Kinetix 6000M Integrated Drive-Motor System Compatibility

For additional information on the 2094-BCxx-Mxx-S IAM and 2094-BMxx-S AM modules, refer to the Kinetix 6000 Multi-axis Servo Drives User Manual, publication 2094-UM001

Bulletin 2094 power rails with Kinetix 6000 (series B) or Kinetix 6200 drives are compatible with Kinetix 6000M integrated drive-motor (IDM) systems. The IDM power interface module (IPIM) mounts to the power rail and connects to as many as 16 IDM units.

Table 5 - IPIM Module Compatibility

IAM Module Control Module

2094-BCxx-Mxx-S (series B) N/A

2094-BCxx-Mxx-M (IAM power module)

2094-SE02F-M00-Sx sercos interface

2094-EN02D-M01-Sx EtherNet/IP network Not compatible

2094-SEPM-B24-S IDM Power Interface Module (IPIM)

Fully c ompatible

For more information on Kinetix 6000M integrated drive-motor system installation, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

24 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Start Chapter 1

Agency Compliance

If this product is installed within the European Union and has the CE mark, the following regulations apply.

ATT EN TI ON : 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 93

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 module)

To meet CE requirements when your Kinetix 6200 and Kinetix 6500 system does not include the LIM module, these requirements apply.

• Install 2090-XXLF-xxxx AC line filters for three-phase input power and single-phase control power 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 lengths for all Kinetix 6200 and Kinetix 6500 axes and hybrid cable lengths for all IDM units on the same DC bus must not exceed 240 m (787 ft) with 400V-class systems. Driveto-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 6200 and Kinetix 6500 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 A on page 231 power wiring and drive/motor interconnect diagrams.

for interconnect diagrams, including input

CE Requirements (system with LIM module)

To meet CE requirements when your Kinetix 6200 and Kinetix 6500 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-BL02) as close to the IAM module as possible.

• Install the LIM module (catalog numbers 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-BLxxS or 2094-XL75SCx) supports two IAM modules, each IAM module requires an AC line filter installed as close to the IAM module as possible.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 25

Chapter 1 Start

Notes:

26 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Chapter 2

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

This chapter describes system installation guidelines used in preparation for mounting your Kinetix 6200 and Kinetix 6500 drive components.

Top ic Pa ge

System Design Guidelines 28

Electrical Noise Reduction 36

ATT EN TI ON : 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-UM002E-EN-P - May 2012 27

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

IMPORTANT

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 6200 and Kinetix 6500 drive systems 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 lengths for all axes and hybrid cable lengths for all IDM units on the same DC bus must not exceed 240 m (787 ft) with 400V-class systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft).

System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements.

• Combined length of Ethernet cables on Kinetix 6500 systems connecting drive-to-drive, drive-to-controller, or drive-to-switch must not exceed 100 m (328 ft).

• 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 lowimpedance 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 reduction.

, to better understand the concept of electrical noise

28 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

IMPORTANT

Transformer Selection

The IAM power module does not require an isolation transformer for threephase 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 Kinetix 6200/ 6500 power specifications in the Kinetix Servo Drives Technical Data, publication GMC-TD003

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).

For example, to size a transformer to the voltage requirements of a 2094-BC01-M01-M integrated axis module: 2094-BC01-M01-M = 6 kW continuous x 1.5 = 9.0 KVA transformer

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 29

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Circuit Breaker/Fuse Options

The 2094-BCxx-Mxx-M and 2094-BMxx-M drive modules and the Kinetix 6000M integrated drive-motor system (2094-SEPM-B24-S IPIM module and MDF-SBxxxxx IDM units) use internal solid-state motor shortcircuit 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-BL02 LIM module contains supplementary protection devices and, when protected by suitable branch circuit protection, is rated for use on a circuit capable of delivering up to 5000 A. When this module is used, protection on the line side of the LIM module is required. Fuses must be class J or CC only.

The 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 (400V-class).

Refer to the Line Interface Module Installation Instructions, publication

2094-IN005

module.

, for power specifications and more information on using the LIM

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 product, evaluation of the short circuit available current is critical and must be kept below the short circuit current rating of the 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.

30 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

IMPORTANT

Circuit Breaker and Fuse Specifications

While circuit breakers offer some convenience, there are limitations for their use. Circuit breakers do not handle high current inrush as well as fuses.

Make sure the selected components are properly coordinated and meet acceptable codes including any requirements for branch circuit protection. Evaluation of the short-circuit available current is critical and must be kept below the short-circuit current rating of the circuit breaker.

The following fuse examples and Allen-Bradley circuit breakers are recommended for use with 2094-BCxx-Mxx-M IAM power modules when the Line Interface Module (LIM) is not used.

LIM Module (catalog number 2094-BLxxS) provides branch circuit protection to the IAM power module. Follow all applicable NEC and local codes.

V AC Input Power Control Input Power DC Common Bus Fuse

IAM Module Cat. No.

2094-BC01-MP5-M

2094-BC01-M01-M

2094-BC02-M02-M KTK-R-30 (30 A) 1492-SP3D400 140M-F8E-C45 FWJ-40A A70QS40-4

2094-BC04-M03-M LPJ-45SP (45 A)

2094-BC07-M05-M LPJ-80SP (80 A) 140U-H6C3-C90 FWJ-125A A70QS125-4

Bussmann Fuse

KTK-R-20 (20 A) 1492-SP3D300 140M-F8E-C32

Allen-Bradley Circuit Breaker

Disconnect

N/A

Magnetic Contactor

140U-H6C3-C50 FWJ-70A A70QS70-4

Bussmann Fuse

FNQ-R-10 (10 A) or FNQ-R-7.5 (7.5 A)

Allen-Bradley

(1)

Circuit Breaker

1492-SP2D060 or 1492-SP1D150

(2)

Bussmann Fuse

FWJ-20A14F DCT20-2

Ferraz Shawmut Fuse

(1) Use FNQ-R-7.5 fuse for higher single-cycle inrush current capability. This is recommended when the continuous control power current exceeds 3.0 A. (2) Use 1492-SP1D150 circuit breaker for higher single-cycle inrush current capability. This is recommended when the continuous control power current exceeds 3.0 A.

Refer to the Kinetix Servo Drives Technical Data, publication GMC-TD003 additional power specifications for your IAM power module.

, for

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 31

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

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 Description Loading

2094-BC02-M02-M

2094-BM02-M Axis module (AM), 400/460V, 15 A 60% 93

2094-BM01-M Axis module (AM), 400/460V, 9 A 40% 73

2094-BM01-M Axis module (AM), 400/460V, 9 A 20% 57

2094-BL25S Line interface module (LIM), 400/460V, 25 A; 24V DC 20 A 100% 43

2094-PRS6 Power rail, 460V, 6 axis N/A 0 2090-XB33-32 Resistive brake module (RBM), 33 A, 32 Ω N/A 30

Total Kinetix 6200 and Kinetix 6500 system wattage 578

Integrated axis module (IAM), 400/460V

(1)

15 kW (converter section) 20% 44

15 A (inverter section) 40% 72

Heat Dissipation watts

(1)

(1) To determine heat dissipation specifications for your drive system components, refer to Tabl e 8 on page 34.

32 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

75 60 45 30 15 0

0 2 0 4 0 6 0 8 0 100

Backplane

Power Load

(watts)

Real Power (watts)

1756-P B72 1756-P B75 DC

A =

4.08Q

T - 1.1

A =

0.38 (612)

1.8 (20) - 1.1

= 6.66 m

Table 7 - ControlLogix System Heat Dissipation Example

Enclosure Component Description

Backplane Power Load

watts

1756-M08SE 8-axis sercos interface module 3.2 0

1756-L5563 L63 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-ENxTx EtherNet/IP communication module 4.0 0

Backplane total 17.18

(2)

1756-PB72 24V DC ControlLogix power supply N/A 25

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 (17.18W) to the graph below.

(1)

Figure 9 - ControlLogix Real Power

Heat Dissipation

watts

N/A

(2)

(1)

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 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

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

). The exterior

surface of all six sides of an enclosure is calculated as

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

A = 2dw + 2dh + 2wh A = (2dw + 2dh + 2wh) / 144

Where d (depth), w (width), and h (height) are in meters. Where d (depth), w (width), and h (height) are in inches.

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.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 33

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

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 m

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.

Table 8 - Power Dissipation Specifications

Usage as % of Rated Power Output

Bulletin 2094 Drive Modules

IAM (converter) power module

2094-BC01-MP5-M

2094-BC01-M01-M 33

2094-BC02-M02-M 3644546475

2094-BC04-M03-M 50 67 87 110 135

2094-BC07-M05-SM 71 101 137 179 226

IAM (inverter) module or AM power module

2094-BC01-MP5-S or 2094-BMP5-M 46 54 61 69 77

2094-BC01-M01-S or 2094-BM01-M 57 73 90 108 126

2094-BC02-M02-S or 2094-BM02-M 53 72 93 116 142

2094-BC04-M03-S or 2094-BM03-M 94 130 169 211 255

2094-BC07-M05-S or 2094-BM05-M 121 183 252 326 407

Shunt module - 2094-BSP2 68 121 174 227 280

IPIM module - 2094-SEPM-B24-S

(1)

20% 40% 60% 80% 100%

(2)

18 21 25 29

(2)

To calculate power dissipation for IPIM modules on your 2094 power rail, refer to the Kinetix 6000M Integrated Drive-Motor User Manual, publication 2094-UM003

(watts)

(1) Power dissipation for the Bulletin 2094 control modules, catalog numbers 2094-SE02F-M00-Sx and 2094-EN02D-M01-Sx, is included in the IAM and AM power module specific ations. (2) Internal shunt power is not included in the calculations and must be added based on utilization.

34 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

IMPORTANT

Clearance right of the module is not required.

(1)

Clearance above

for airflow and installation.

Clearance left of the

module is not required.

(1)

Kinetix 6200 or

Kinetix 6500 Drive System

Mounted on 2094 Power Rail

80 mm (3.10 in.) clearance below drive for airflow and installation.

Drive Cat. No. F

2094-BC01-Mxx-M 2094-BC02-M02-M

285 mm (11.2) in.

2094-BMP5-M, 2094-BM01-M, 2094-BM02-M

2094-SEPM-B24-S 2094-BSP2

287 mm (11.3) in.

2094-BC04-M03-M 2094-BM03-M

375 mm (14.7) in.

2094-BC07-M05-M 2094-BM05-M

Refer to Power Dissipation Specifications on page 34, and

Kinetix Servo Drives Technical Data, publication GMC-TD003

for Kinetix 6000 drive dimensions.

Minimum Clearance Requirements

This section provides information to assist you in sizing your cabinet and positioning your Bulletin 2094 system components.

Mount the module in an upright position. Do not mount the module on its side.

Figure 10

illustrates minimum clearance requirements for proper airflow and

installation:

• Additional clearance is required for the cables and wires connected to the top and front of the drive.

• Additional clearance left and right of the power rail is required when the drive is mounted adjacent to noise sensitive equipment or clean wireways.

Figure 10 - Minimum Clearance Requirements

Drive Cat. No. Cabinet Depth, min

2094-BC01-Mxx-M, 2094-BC02-M02-M, 2094-BMP5-M, 2094-BM01-M, 2094-BM02-M

2094-BSP2 272 mm (10.7 in.) 2094-SEPM-B24-S 263 mm (10.3 in.)

(1) Minimum cabinet depth is based on the use of 2090-K6CK-xxxx low-profile connector kits. Other means of making feedback connections may require additional clearance.

(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 Bulletin

2094-PRx power rail extends approximately 25.4 mm (1.0 in.) left of the IAM module and right of the last module mounted on the rail.

Table 9 - Minimum Cabinet Depth

(1)

302 mm (11.9 in.)

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 35

Drive Cat. No. Cabinet Depth, min

2094-BC04-M03-M, 2094-BC07-M05-M, 2094-BM03-M, 2094-BM05-M

302 mm (11.9 in.)

(1)

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

IMPORTANT

Electrical Noise Reduction

This section outlines best practices that minimize the possibility of noise-related failures as they apply specifically to Kinetix 6200 and Kinetix 6500 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 highfrequency energ y.

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 highfrequency energy can effect the operation of other microprocessor controlled equipment.

36 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

Stud-mounting the Subpanel

to the Enclosure Back Wall

Stud-mounting a Ground Bus

or Chassis to the Subpanel

Subpanel Wel ded S tud

Scrape Paint

Flat Washer

If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole.

Star Washer

Nut

Flat Washer

Mounting Bracket or

Ground Bus

Use a wire brush to remove paint from threads to maximize ground connection.

Back Wall of Enclosure

Weld ed St ud

Subpanel

Star Washer

Use plated panels or scrape paint on front of panel.

Subpanel

Nut

Star Washer

Flat Washer

Star Washer

Star Washer Scrape paint on both sides of panel and use star washers.

Tapped Hole

Bolt

Flat Washer

Ground Bus or

Mounting Bracket

If the mounting bracket is coated with a non-conductive material (anodized or painted), scrape the material around the mounting hole.

Bolt-mounting a Ground Bus or Chassis to the Back-panel

These illustrations show details of recommended bonding practices for painted panels, enclosures, and mounting brackets.

Figure 11 - Recommended Bonding Practices for Painted Panels

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 37

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Wire B raid

25.4 mm (1.0 in.) by

6.35 mm (0.25 in.)

Paint removed

from cabinet.

Cabinet ground bus

bonded to the subpanel.

Wire B raid

25.4 mm (1.0 in.) by

6.35 mm (0.25 in.)

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 12 - Multiple Subpanels and Cabinet Recommendations

38 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

Line Interface Module

Kinetix 6200 or Kinetix 6500 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Fiber-optic Cable

VAC L oad

VAC L ine

AC Line Filter

(required for CE)

I/O

(1)

, Feedback, and

Ethernet Cables

Route 24V DC switched signals in shielded cable.

Route encoder, analog, registration, and

communication signals in shielded cables.

I/O

(1)

and Safety Cables

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Establishing Noise Zones

Observe these guidelines when the 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. Ethernet cables are noise sensitive and belong in the clean zone.

Figure 13 - Noise Zones (LIM mounted left of IAM module)

(1) If drive system I/O cable contains (dirty) relay wires, route cable with LIM module I/O c able 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

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 39

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

I/O

(1)

, Feedback, and

Ethernet Cables

Line Interface Module

Clean Wireway

Dirty Wireway

Motor Power Cables

VAC Loa d

VAC L ine

AC (EM C) Line Filter

Control VAC,

AUX VAC O utput,

and 24V DC Brake

I/O

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Route 24V DC switched signals

in shielded cable.

Route encoder, analog, registration, and communication signals in shielded cables.

I/O

(1)

and Safety Cables

Fiber-optic Cable

Kinetix 6200 or

Kinetix 6500 System

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Observe these guidelines when the 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. Ethernet cables are noise sensitive and belong in the clean zone.

Figure 14 - Noise Zones (LIM with EMC filter behind IAM module)

40 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

LIM

PRS

LIM

Line Interface Module

Clean Wireway

Dirty Wireway

Motor Power Cables

2094 Mounting

(3)

Brackets x2

VAC L oad

VAC L ine

AC (EMC) Line Filter

Control VAC, Auxiliary VAC, and 24V DC Brake

LIM I/O

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

No sensitive

(2)

equipment within

150 mm (6.0 in.).

I/O

(1)

, Feedback, and

Ethernet Cables

Route 24V DC switched signals

in shielded cable.

Route encoder, analog, registration, and communication signals in shielded cables.

I/O

(1)

and Safety Cables

Fiber-optic Cable

Kinetix 6200 or

Kinetix 6500 System

Observe these guidelines when the 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. Ethernet cables are noise sensitive and belong in the clean zone.

Figure 15 - Noise Zones (EMC filter behind LIM module)

System Design for Control of Electrical Noise Reference Manual, publication 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, and 2094-BL02 LIM modules are not compatible.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 41

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Line Interface Module

Kinetix 6200 or Kinetix 6500 System

Dirty Wireway

Clean Wireway

Motor Power Cables

VAC L ine, AUX VA C Out put, 24V

VAC L ine

AC Lin e Filter

(required for CE)

VAC Loa d

Kinetix 6200 or Kinetix 6500 System

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Very Dirty DC Bus Connections

Segregated (not in wireway)

Fiber-optic Cab le

I/O

(1)

, Feedback, and

Ethernet Cables

Route 24V DC switched signals in shielded cable.

Route encoder, analog, registration, and

communication signals in shielded cables.

I/O

(1)

and Safety Cables

I/O

(1)

, Feedback, and

Ethernet Cables

Fiber-optic Cable

No sensitive

(2)

equipment within

150 mm (6.0 in.).

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Keep the DC common-bus cable (very dirty) segregated from all other cables (not in a wireway) when the 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 16 - Noise Zones (DC common bus)

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

42 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

(1)

Line Interface Module

Kinetix 6200 or Kinetix 6500 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

I/O

(1)

, Feedback, and

Ethernet Cables

Route 24V DC switched signals in shielded cable.

Route encoder, analog, registration, and

communication signals in shielded cables.

I/O

(1)

and Safety Cables

Fiber-optic Cable

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Observe these guidelines when the 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. Ethernet cables are noise sensitive and belong in the clean zone.

This layout is preferred due to the reduced size of the very dirty zone.

Figure 17 - Noise Zones (LIM mounted left of IAM module)

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 43

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Line Interface Module

Kinetix 6200 or Kinetix 6500 System

Dirt y Wireway Clean Wireway

Motor Power Cables

No sensitive

(3)

equipment within

150 mm (6.0 in.).

I/O

(2)

, Feedback, and

Ethernet Cables

Route 24V DC switched signals in shielded cable.

Route encoder, analog, registration, and

communication signals in shielded cables.

I/O

(2)

and Safety Cables

Fiber-optic Cable

Very dirty LIM/IAM

(1)

connections must be shielded with braid clamp at both ends.

Observe these guidelines when the 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. Ethernet cables are noise sensitive and belong in the clean zone.

Figure 18 - Noise Zones (LIM mounted above IAM module)

(1) For examples of shield clamp attachment, refer to the System Design for Control of Electrical Noise Reference Manual, publication

GMC-RM001

(2) If drive system I/O cable contains (dirty) relay wires, route cable in dir ty 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

44 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

(1)

Kinetix 6200 or Kinetix 6500 System

Dirty Wireway

Clean Wireway

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Route 24V DC switched signals in shielded cable.

Route encoder, analog, registration, and

communication signals in shielded cables.

I/O

(1)

and Safety Cables

No sensitive

(2)

equipment within

150 mm (6.0 in.).

2094-BL02 or 2094-BLxxS

Line Interface Module

I/O

(1)

, Feedback, and

Network Cables

Motor and Hybrid Cables

Fiber-optic Cables and

IPIM Digital Input Wires

Observe these guidelines when your system includes the 2094-SEPM-B24-S IPIM module. In this example, a 2094-BL02 LIM module is used in the Bulletin 2094 system and mounted left of the IAM module:

• Establish clean (C) and dirty zones (D) similar to other Bulletin 2094 drive systems.

• The sercos fiber-optic cables are immune to electrical noise, but due to their delicate nature, route them in the clean zone.

• IPIM digital input wires are noise sensitive and belong with the fiber-optic cables in the clean zone.

• Ethernet cables are noise sensitive and belong in the clean zone, however, they are connected only when programming the IPIM module.

• IDM network cables, although noise sensitive by nature, are shielded and may be routed with the hybrid cables outside of the enclosure.

• The Bulletin 2090 hybrid cable is dirty and belongs in the dirty zone.

This layout is preferred due to the reduced size of the very dirty zone.

Figure 19 - Noise Zones (Bulletin 2094 power rail with IPIM module)

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 45

System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

(1)

(4)

(3)

Dirty Wireway

Clean Wireway

Motor Power Cables

24V Motor

Brake PS

Circuit

Breaker

XFMR

Line Filter

(required

for CE)

Filter

Contac tors

Kinetix 6200 or

Kinetix 6500 System

(2)

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

I/O

(1)

, Feedback, and

Ethernet Cables

Route 24V DC switched signals in shielded cable.

Route encoder, analog, registration, and

communication signals in shielded cables.

I/O

(1)

and

Safety Cables

Fiber-optic Cable

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. Ethernet cables are noise sensitive and belong in the clean zone.

Figure 20 - Noise Zones (without LIM module)

(1) If drive system I/O cable contains (dirty) relay wires, route cable in dir ty 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

(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.

examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

46 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

(1)

AC Lin e

Filter

Spare Slots

Dirty Wireway

Clean Wireway

Route dirty wireways directly above the ControlLogix controller chassis

(shielded by the chassis).

Line Filter/Power Supply

Connections Segregated

(not in wireway)

Dirty I/O

(24V DC I/O, AC I/O)

Clean I/O

(Analo g, Encoder

Registration)

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. Ethernet cables are noise sensitive and belong in the clean zone.

Figure 21 - Noise Zones (ControlLogix chassis)

Cable Categories for Kinetix 6200 and Kinetix 6500 Systems

These tables indicate the zoning requirements of cables connecting to the Kinetix 6200 and Kinetix 6500 drive components.

Table 10 - IAM Power Module (converter side)

Zone Method

Wire/Cable Connector

CTRL 1 and 2 CPD X

DC-/DC+ (unshielded cable)

L1, L2, L3 (shielded cable) X X

L1, L2, L3 (unshielded cable) X

CONT EN- and CONT EN+ (M1 contactor) CED X

IPD

Very Dirty

Dirty Clean

Ferrite Sleeve

Shielded Cable

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 47

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Table 11 - AM Power Module or Axis Module (inverter side)

Wire/Cable Connector

U, V, W ( motor power) MP X X

MBRK-, MBRK+ (motor brake)

MBRK-, MBRK+ (motor brake) 1326AB motors with resolver feedback

DBRK-, DBRK+ (resistive brake) X

COM, PWR (24V DC), filtered

COM, PWR (24V DC), unfiltered

(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.

(1)

(2)

Table 12 - Control Module

Wire/Cable Connector

Motor feedback MF X X

Auxiliary feedback

Registration and I/O X X

Safety X

Fiber-optic (sercos) Rx and Tx No restric tions

Ethernet PORT1, PORT2 X X

IOD

Zone Method

Very Dirty

Dirty Clean

Ferrite Sleeve

Zone Method

Very Dirty

Dirty Clean

Ferrite Sleeve

Shielded Cable

Table 13 - Line Interface Module (LIM)

Wire/Cable Connector

VAC line (main input) IPL X

Aux power input APL X

VAC load (shielded option)

VAC load (unshielded option) X

OPL

Control power output CPL X

MBRK PWR, MBRK COM P1L/PSL X

Status I/O IOL X

Aux power output P2L X

Very Dirty

Zone Method

Dirty Clean

Ferrite Sleeve

Shielded Cable

48 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

Table 14 - Shunt Module

Zone Method

Wire/Cable Connector

COL, DC+ (shielded option)

COL, DC+ (unshielded option) X

Very Dirty

Dirty Clean

Ferrite Sleeve

Thermal switch TS X X

Fan (if present) N/A X

Table 15 - IDM Power Interface Module (IPIM)

Shielded Cable

Wire/Cable

Hybrid DC bus power, control power, inter-module communication, and safe-off

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

(1)

Zone Method

Enable input X X

Fiber-optic No rest rictions

Ethernet network X X

IDM network

(1) There is no option for making your own hybrid power or IDM network cables.

(1)

Table 16 - Resistive Brake Module (RBM)

Wire/Cable Connections

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

Resistive brake module coil power TB3-6 and TB3-7 X

Resistive brake module I/O

TB1-1…TB1-5 and TB3-8

Resistive brake module drive and motor power TB1 and TB2 X X

230V power TB4 X

Zone Method

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 49

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

IMPORTANT

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 46

• Mount the AC line filter on the same panel as the Kinetix 6200 and Kinetix 6500 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 37

• Segregate input and output wiring as far as possible.

for an example):

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.

50 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

1394 Digital Servo Controller

300W Shunt Module

BULLETIN 1394 300W SHUNT MODULE

ALLEN-BRADLEY

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

Line Interface Module

Kinetix 6200 or Kinetix 6500 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Very Dirty Connections Segregated

(not in wireway)

Customer-supplied

Metal Enclosure

150 mm (6.0 in.) clearance (min) on all four sides of the shunt module.

Enclosure

2094-BSP2 Shunt Module

Metal Conduit (where required by local code)

Shunt thermal Switch and Fan Wires (when present)

No sensitive

equipment within

150 mm (6.0 in.).

Clean I/O, Feedback, and

Ethernet Cables

Dirty I/O and

Safety Cables

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice).

Shielded twisted pair (2nd choice).

Twisted pair, two twists per foot (min) (3rd choice).

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 22 - External Shunt Module Outside the Enclosure

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 51

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

1394 Digital Servo Controller

300W Shunt Module

BULLETIN 1394 300W SHUNT MODULE

ALLEN-BRADLEY

FOR USE WITH 1394-SJT22-X SYSTEM MODULE

CAT. PART SER. INPUT DC INPUT AC FOR FUSE REPLACEMENT USE: BUSSMAN CAT. NO.

Line Interface Module

Kinetix 6200 or

Kinetix 6500 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Enclosure

2094-BSP2 Shunt Module

150 mm (6.0 in.)

clearance (min) on all four

sides of the shunt module.

Shunt thermal Switch and Fan Wires (when present)

Very Dirty Connections Segregated

(not in 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).

No sensitive equipment within 150 mm (6.0 in.).

Dirty I/O and

Safety Cables

Clean I/O, Feedback, and

Ethernet Cables

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 23 - External Shunt Module Inside the Enclosure

52 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation Chapter 2

Line Interface Module

Kinetix 6200 or Kinetix 6500 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Very Dirty LIM/IAM Connections

Segregated (not in wireway)

RBM I/O

LIM VAC Input Power

No sensitive

equipment within

150 mm (6.0 in.).

Fiber-o ptic Cable

Dirty I/O and Safety Cables

Clean I/O, Feedback, and

Ethernet Cables

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 24 - Noise Zones (RBM mounted above AM power module)

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 115 wiring guidelines. Refer to Axis Module/Rotary Motor Wiring Examples beginning on page 242

for the interconnect diagram of your drive/motor

combination.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 53

for

Chapter 2 Planning the Kinetix 6200 and Kinetix 6500 Drive System Installation

Notes:

54 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Chapter 3

Mounting the Kinetix 6200 and Kinetix 6500 Drive System

This chapter provides the system installation procedures for mounting your Kinetix 6200 and Kinetix 6500 drive components on the Bulletin 2094 power rail.

Top ic Pa ge

Before You Begin 55

Determine Mounting Order 56

Mount Modules on the Power Rail 57

Mount the Control Modules 60

Before You Begin

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.

Before you begin, consider your Bulletin 2094 power rail installation and using 2094 mounting brackets.

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 Kinetix 6200 and Kinetix 6500 drive system.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 55

, when using mounting brackets with your

Chapter 3 Mounting the Kinetix 6200 and Kinetix 6500 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/IPIM modules, or up to six additional AM/IPIM modules and one shunt module. The connector pins for each slot are covered by a protective cover. The cover 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 when installing your power rail.

The Kinetix 6000M integrated drive-motor (IDM) system is supported by Bulletin 2094 (400V-class) power rail configurations. You can mount up to four IDM power interface (IPIM) modules on the Bulletin 2094 power rail. Refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication

2094-UM003

ATT EN TI ON : To avoid damage to the power rail during installation, do not remove the protective covers until the module for each slot is ready for mounting.

, for more information.

Determine Mounting Order

Mount IAM, AM/IPIM, shunt, and slot-filler modules in the order (left to right) as shown in Figure 25

. Mount axis modules and the IPIM module according to power utilization (highest to lowest) from left to right starting with the highest power utilization.

Power utilization is the average power (kW) consumed by a servo axis. If Motion Analyzer software was used to size the axis, the calculated axis power required can be used for the power utilization value. If Motion Analyzer software was not used, you can use the continuous power value (kW) for each module to determine mounting order.

Table 17 - Kinetix 6200/6500 (400V-class) Axis Modules

Attribute 2094-BMP5-M 2094-BM01-M 2094-BM02-M 2094-BM03-M 2094-BM05-M

Continuous Power Output, nom

Table 18 - Kinetix 6000M (400V-class) IDM Power Interface Module

Attribute 2094-SEPM-B24-S

Continuous Power Output, nom 15.0 kW

1.8 kW 3.9 kW 6.6 kW 13.5 kW 22.0 kW

56 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Mounting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 3

Highest Power Utilization

Lowest Power Utilization

Integrated Axis Module

2094-BC02-M02-M

IPIM Module

2094-SEPM-B24-S

Axis Module

2094-BM01-M

Axis Module

2094-BM01-M

Axis Module

2094-BMP5-M

Axis Module

2094-BMP5-M

Shunt Module

2094-BSP2

Slot-filler Module

2094-PRF

IMPORTANT

TIP

IMPORTANT

Figure 25 - Module Mounting Order Example

Mount Modules on the Power Rail

The IAM module must be positioned in the leftmost slot of the power rail. Position your AM/IPIM 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/IPIM 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 2094PRF 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.

Follow these steps to mount the IAM, AM, IPIM, shunt, and slot-filler modules.

All modules mount to the power rail by using the same technique; however, only the IAM module is used in the examples.

1. Remove the protective covers from the power rail connectors.

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.

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Chapter 3 Mounting the Kinetix 6200 and Kinetix 6500 Drive System

Power Rail

IAM or AM Power Module, IPIM, Shunt, or Slot-filler Module (IAM power module is shown)

Slots for additional axis modules,

shunt module, or slot-filler modules.

Power Rail Sl ot

Mounting Bracket

Guide Pin Holes

Power rail (side view)

in upright vertical position.

Guide Pins

Pivot module downward and align with guide pins.

IAM or AM Power Module, IPIM,

Shunt, or Slot-filler Module, Side View

(IAM power module is shown)

IAM or AM Power Module, IPIM,

Shunt, or Slot-filler Module, Rear View

(AM power module is shown)

2. Determine the next available slot and module for mounting.

3. Hang the mounting bracket from the slot on the power rail.

ATT EN TI ON : To avoid damage to the pins located on the back of each IAM, AM, IPIM, shunt, and slot-filler module and to make sure that module pins mate properly with the power rail, hang modules as shown in step 3

through step 6.

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.

4. Pivot module downward and align the guide pins on the power rail with the guide pin holes in the back of the module.

58 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Mounting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 3

TIP

Power Rail

Bracket secured in slot.

IAM or AM Power Module, IPIM, Shunt, or Slot-filler Module (IAM power module is shown)

Bottom front view of the

double-wide IAM or AM power module.

(AM power module is shown).

Mounting Screws

Bottom front view of the single-wide AM, IPIM, shunt, or slot-filler module (AM power module is shown).

IMPORTANT

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.

5. Gently push the module against the power rail connectors and into the final mounting position.

6. Use 2.26 N•m (20 lb•in) torque to tighten the mounting screws.

There are two mounting screws when mounting 2094-BC04-M03-M, and 2094-BC07-M05-M (double-wide) IAM modules, and 2094-BM03-M and 2094-BM05-M (double-wide) AM modules.

Repeat step 1

through step 6 for each AM, IPIM, shunt, or slot-filler module in

your Bulletin 2094 drive system

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 59

Chapter 3 Mounting the Kinetix 6200 and Kinetix 6500 Drive System

IMPORTANT

IAM or AM Power Module, (IAM power module is shown)

Captive

Screw

2094-SE02F-M00-Sx

or 2094-EN02D-M01-Sx

Control Module

Threaded Ho le in Tongue

Mounting Hooks

Mounting Studs (other mounting stud is hidden from view)

Guide Pins

Signal Conne ctors

Power-applied Indicator

Mount the Control Modules

The IAM and AM power modules are equipped with two mounting hooks and a threaded hole. The control module has two mounting studs, guide pins, and a captive screw for mating the control module with a power module.

For convenience and ease of use, mount the IAM and AM power modules on the power rail before mounting the control modules.

When the power modules are placed on a flat surface, with the power-rail connectors facing down, the mounting screw that extends from the front of the drive and fastens to the power rail, pushes back and interferes with the control module installation.

Follow these steps to mount control modules to either IAM (inverter) power modules or AM power modules. In this procedure an IAM power module is shown.

1. Remove all input power from the IAM power module.

Verify that the Power-applied indicator is off. When the indicator is on, voltage is present on the IAM and AM power module signal connectors.

ATTENTION: To avoid damage to equipment, do not mount your Bulletin 2094 control module to the power module when the Powerapplied indicator is on. Remove all input power from the IAM power module before mounting the control module.

2. Position the control module in front of the power module.

60 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Mounting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 3

Mounting Stud (right side)

Left-side mounting stud and hook are hidden from view.

Mounting Hook (right side)

IAM or AM Power Module (IAM power module is shown)

2094-SE02F-M00-Sx

or 2094-EN02D-M01-Sx

Control Module

Left-side mounting stud and hook are hidden from view.

Mounting Stud and Hook Engaged (right side)

Guide Pins Straddling Tongue

Guide Pin Alignment on

Either Side of Tongue

IAM or AM Power Module (IAM power module is shown)

2094-SE02F-M00-Sx

or 2094-EN02D-M01-Sx

Control Module

Captive Screw

(apply 1.1 N•m (10.0 lb•in) torque)

IAM or AM Power Module (IAM power module is shown)

2094-SE02F-M00-Sx

or 2094-EN02D-M01-Sx

Control Module

3. Guide the control module mounting studs so they engage with the power module hooks.

4. Pivot the control module toward the power module to engage the signal connectors and guide pins.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 61

5. Tighten the captive screw.

6. Repeat step 2

through step 5 to mount a control module onto each IAM

and AM power module installed on your Bulletin 2094 power rail.

Chapter 3 Mounting the Kinetix 6200 and Kinetix 6500 Drive System

Notes:

62 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Chapter 4

Kinetix 6200 and Kinetix 6500 Connector Data

This chapter provides power, feedback, and I/O connector locations and signal descriptions for your Kinetix 6200 and Kinetix 6500 drive modules.

Top ic Pa ge

2094 Power Module and Control Module Features 64

Control Signal Specifications 71

Power and Relay Specifications 75

Feedback Specifications 80

Safe Speed Monitoring Safety Features 89

For the Kinetix 6000M integrated drive-motor (IDM) unit and IDM power interface module (IPIM) connector locations and signal descriptions, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication

2094-UM003

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 63

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Kinetix 6200 or Kinetix 6500 IAM Power Module, Top View (2094-BC01-MP5-M is shown)

Kinetix 6200 or Kinetix 6500

IAM Power Module, Front View

(2094-BC01-MP5-M is shown)

Item Description

1 Control power (CPD) connector

2 DC bus/AC input power (IPD) connector

3 Contactor enable (CED) connector

4 Motor cable shield clamp

5 Motor power (MP) connector

6 Motor/resistive brake (BC) connec tor

7 Node address switch

8 Power-applied indicator

9Mounting screw

Kinetix 6200 or Kinetix 6500 AM Power Module, Top View (2094-BMP5-M is shown)

Kinetix 6200 or Kinetix 6500

AM Power Module, Front View

(2094-BMP5-M is shown)

Item Description

1 Motor cable shield clamp

2 Motor power (MP) connector

3 Motor/resistive brake (BC) connector

4 Power-applied indicator

5Mounting screw

2094 Power Module and Control Module Features

1 2

CTRL 2 CTRL 1

1 2 3 4 5 6

DCDC+

L3 L2 L1

1 2

CONT ENCONT EN+

MBRK -

MBRK +

DBRK -

DBRK +

PWR

COM

1 2 3 4

1 2 3 4 5 6

Use these illustrations to identify the features and indicators for the IAM/AM power modules and control modules. Sercos interface and Ethernet network connectors for the Kinetix 6000M IPIM module are also shown. For the remainder of the IPIM module features and indicators, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

Figure 26 - IAM Power Module Features and Indicators

7 8

Figure 27 - AM Power Module Features and Indicators

64 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

1 2 3 4

MBRK -

MBRK +

COM

PWR

DBRK -

DBRK +

1 2 3 4 5 6

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

620062 00

SAFE SPEED

10 11

4 5

Kinetix 6200

Control Module, Top View

(2094-SE02F-M00-S1 is shown)

Kinetix 6200

Control Module, Front View

(2094-SE02F-M00-S1 is shown)

Item Description

1 Guide pins (2x)

2Captive screw

Sercos communication rate and optical power switches

4 Sercos transmit (Tx) Connector

(1)

(1) For the remainder of the IPIM module features and indicators, refer

to the Kinetix 600 0M Integrated Drive-Motor User Manu al, publication 2094-UM003

5 Sercos receive (Rx) Connector

(1)

Item Description

6 Four-character status display

7PORT 1 status indicator

8Drive status indicator

9 Comm status indicator

10 DC bus status indicator

Safety lock status indicator (2094-SE02F-M00-S1 modules only)

12 I/O, safety, and aux feedback (IOD) connector

13 Power module mounting screw access hole

14 Motor feedback (MF) connector

Item Description

15 Ethernet (PORT1) connector

(1)

(1) The Kinetix 6000M IPIM module has two Ethernet ports. They

provide the same function on the IPIM module as the Ethernet port on the Kinetix 6200 control module. Refer to the Kinetix 6000M Integrated Drive-Motor User Manual, publication 2094-UM003

, for

more information.

Kinetix 6200

Control Module, Bottom View

(2094-SE02F-M00-S1 is shown)

2094-SEPM-B24-S

IPIM Module, Top View

2094-SEPM-B24-S IPIM Module, Bottom View

Figure 28 - Control Module Features and Indicators (sercos)

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 65

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Item Description

1 Guide pins (2x)

2Captive screw

Item Description

3 Four-character status display

4PORT 1 status indicator

5PORT 2 status indicator

6 Module status indicator

7Network status indicator

8 DC bus status indicator

Safety lock status indicator (2094-EN02D-M01-S1 modules only)

10 I/O, safety, and aux feedback (IOD) connector

11 Power module mounting screw access hole

12 Motor feedback (MF) connector

Item Description

13 Ethernet (PORT1) connector

14 Ethernet (PORT2) connector

Kinetix 6500

Control Module, Top View

(2094-EN02D-M01-S1 is shown)

Kinetix 6500

Control Module, Front View

(2094-EN02D-M01-S1 is shown)

Kinetix 6500

Control Module, Bottom View

(2094-EN02D-M01-S1 is shown)

Figure 29 - Control Module Features and Indicators (Ethernet)

Designator Description Connector Module

IOD User I/O (drive), safety, and auxiliary feedback 44-pin high-density D-shell (female) Control

MF Motor feedback 15-pin high-density D-shell (female) Control

CPD Control input power (drive) 2-position plug/header IAM

IPD VAC input power (drive) and DC bus 6-position plug/header IAM

CED Contactor enable 2-position plug/header IAM

MP Motor power 4-position plug/header IAM/AM

BC Motor/Resistive brake 6-position plug/header IAM/AM

Tx and Rx Sercos transmit and receive Sercos fiber-optic (2) Control

PORT1 and PORT2

Table 19 - Kinetix 6200 and Kinetix 6500 Power Module and Control Module Connectors

EtherNet/IP network RJ-45 Ethernet (2) Control

66 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

I/O, Safety, and Auxiliary Feedback Connector Pinout

IOD Pin

(1)

Description Signal IOD Pin

Sine differential input + A differential input +

Sine differential input A differential input -

Cosine differential input + B differential input +

Cosine differential input B differential input -

Data differential input + Index differential input +

Data differential input Index differential input -

AUX_SIN + AUX_A+

AUX_SIN AUX_A-

AUX_COS + AUX_B+

AUX_COS AUX_B-

AUX_DATA+ AUX_I+

AUX_DATAAUX_I-

(1)

Description Signal

(S52) Safe limited speed input 0 SLS_IN_CH0

Safe stop input 2 SS_IN_CH2

(S62) Safe limited speed input 1 SLS_IN_CH1

Safe stop input 3 SS_IN_CH3

25 Reset reference RESET_REF

26 (S34) Reset input RESET_IN

27 (S11) Pulse test output 0 TEST_OUT_0

28 (S21) Pulse test output 1 TEST_OUT_1

7 Clock output + AUX_CLK+ 29 (68) Safe limited speed output 0 SLS_OUT_CH0

8Clock output - AUX_CLK- 30 (78)Safe limited speed output 1 SLS_OUT_CH1

9 Encoder 5V power output EPWR5V 31 (S32) Door monitor input 0 DM_IN_CH0

10 Encoder common ECOM 32 (S42) Door monitor input 1 DM_IN_CH1

11 Encoder 9V power output EPWR9V 33 (X32) Lock monitor input 0 LM_IN_CH0

12 Reserved – 34 (X42) Lock monitor input 1 LM_IN_CH1

13 Reserved – 35 (51) Door control channel output- DC_OUT_CH0

14 24V power out 24VPWR

15 24V common 24VCOM

(2)

36 (52) Door control channel output+ DC_OUT_CH1

37 (S72) Enabling switch monitor input 0 ESM_IN_CH0

16 Reserved – 38 (S82) Enabling switch monitor input 1 ESM_IN_CH1

17 (A1) Safety 24V power input SPWR 39 24V power out 24VPWR

18 (A2) Safety 24V common SCOM 40 24V common 24VCOM

19 (S12) Safe stop input 0 SS_IN_CH0 41 Digital input 1 (drive enable) INPUT1

20 (S22) Safe stop input 1 SS_IN_CH1 42 Digital input 2 (home) INPUT2

21 (34) Safe stop output 0 SS_OUT_CH0 43 Digital input 3 (registration 1) INPUT3

22 (44) Safe stop output 1 SS_OUT_CH1 44 Digital input 4 (registration 2) INPUT4

(3)

(4)

(2)

(1) Designators in parenthesis refer to the Guardmaster® MSR57P safety relay and PowerFlex 750-Series safety option terminals. (2) This signal applies to only the 2094-SE02F-M00-S0 and 2094-EN02D-M01-S0 control modules. Use this supply to power the Safety 24V (SPWR/SCOM) input. Do not connect this 24V supply

to any external safety de vice. (3) Use signals 24VPWR and 24VCOM (IOD-39 and IOD-40) as a 24V D C source to operate the digital inputs (50 mA maximum per input). (4) Default assignments are in parenthesis. Use sercos IDN Write instruction to change default assignments. Refer to Digital Inputs

on page 71 for more information.

Refer to the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Safety Reference Manual, publication 2094-RM001

, for more information on safe-

speed monitoring safety functions.

Refer to the Kinetix 6200 and Kinetix 6500 Safe Torque-off Safety Reference Manual, publication 2094-RM002

, for more information on safe torque-off

safety functions.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 67

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

44-pin Control Module

I/O, Safety, and Auxiliary Feedback

Conne ctor

IMPORTANT

Pin 11

Pin 6

Pin 15

Pin 1

Pin 10

Pin 5

15-pin Control Module

Motor Feedback Connector

Figure 30 - Pin Orientation for 44-pin I/O, Safety, and Feedback (IOD) Connector

Pin 30

Pin 44

Pin 15

Pin 31 Pin 16

Pin 1

Motor Feedback Connector Pinout

MF Pin Description Signal MF Pin Description Signal

6 Encoder common MTR_ECOM 14 Encoder 5V power output MTR_EPWR5V

7 Encoder 9V power output MTR_EPWR9V 15 Clock output - MTR_CLK-

8 Hall commutation S3 input MTR_S3

(1) Not applicable unless motor has integrated thermal protection.

Sine differential input + A differential input +

Sine differential input A differential input -

Cosine differential input + B differential input +

Cosine differential input B differential input -

Data differential input/output + Index differential input +

MTR_S IN+ MTR_A M+

MTR_S INMTR_A M-

MTR_C OS+ MTR_B M+

MTR_C OSMTR_B M-

MTR_D ATA+ MTR_IM+

9 Clock output + MTR_CLK+

11 Motor thermostat (normally closed)

12 Hall commutation S1 input MTR_S1

13 Hall commutation S2 input MTR_S2

Data differential input/output Index differential input -

(1)

MTR_D ATAMTR_IM-

MTR_T S

Combined motor-power cable length for all axes on the same DC bus must not exceed 240 m (787 ft) with 460V systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft).

System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements.

Figure 31 - Pin Orientation for 15-pin Motor Feedback (MF) Connector

68 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

8-pin Control Module

Ethernet Connector

Ethernet Communication Connector Pinout

Pin Description Signal

1 Transmit+ TD+

2 Transmit- TD-

3 Receive+ RD+

4 Reserved —

5 Reserved —

6 Receive- RD-

7 Reserved —

8 Reserved —

Figure 32 - Pin Orientation for 8-pin Ethernet PORT1 and PORT2 Connectors

IAM Input Connector Pinout

Table 20 - Control Power Connector

CPD Pin Description Signal

2CTRL 1

Control power VAC input

Table 21 - DC Bus and Input Power Connector

IPD Pin Description Signal

1 An integral, unregulated power supply, consisting

2DC+

3 Chassis ground.

5L2

6L1

of AC line input, three-phase bridge rectifier, and filter capacitors.

Three-phase input power.

Table 22 - Contactor Enable Connector

CED Pin Description Signal

2 CONT EN+

Relay-driven dry contact used in the safety string for a three-phase power contactor.

CTRL 2

DC-

CONT EN-

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 69

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

IMPORTANT

IAM and AM Motor Power and Brake Connector Pinout

Table 23 - Motor Power Connector

MP Pin Description Signal

4 Chassis ground

Three-phase motor power

Combined motor-power cable length for all axes on the same DC bus must not exceed 240 m (787 ft) with 460V systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft).

System performance was tested at these cable length specifications. These limitations also apply when meeting CE requirements.

Table 24 - Motor Brake/Resistive Brake Connector

BC Pin Description Signal

5MBRK+

4 Motor brake common COM

1DBRK+

Motor brake connections

+24V brake input power (from LIM module or customer supplied)

RBM module connections (from RBM module and safety string)

MBRK-

PWR

DBRK-

70 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

IMPORTANT

Control Signal Specifications

This section provides a description of the Kinetix 6200 and Kinetix 6500 drive I/O (IOD), communication, contactor enable (CED), brake (BC), and control power (CPD) connectors.

Digital Inputs

Four assignable inputs are available for the machine interface on the control module. Each IAM and AM module supplies 24V DC @ 200 mA for the purpose of registration, home, enable, over-travel positive, and over-travel negative inputs. These are sinking inputs that require a sourcing device. A 24V DC power and common connection is provided for the digital inputs.

To improve registration input EMC performance, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

Over-travel limit input devices must be normally closed.

The four digital inputs (IOD-41…IOD-44) have default assignments, however, you can reassign them according to the needs of your specific application.

Table 25 - Digital Input Default IDN Assignments

IOD Pin Input IDN Type Default

41 1 P-0-052

42 2 P-0-053 Home

43 3 P-0-054 Registration 1

44 4 P-0-055 Registration 2

INT

Enable

You can change the digital input default settings on Kinetix 6200 control modules by using a sercos IDN Write instruction. For example, digital input 4 (IOD-44) is configured by IDN P-0-055. By default the value is 4 (Registration

2). You can use the sercos IDN Write instruction to change IDN P-0-055 value to 7, and then digital input 4 is configured as Regeneration OK. Digital input IDN values are in the table on page 72

. Refer to Appendix D on page 271 for

more information on changing default IDN values.

You can change the digital input default settings on Kinetix 6500 control modules by using RSLogix 5000 software. Refer to Configure the Drive Modules on page 167

for more information on changing default values.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 71

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Table 26 - Understanding Digital Input Functions

Function Description Default Behavior

If the controller configuration specifies checking of the enable input, an active

Enable

state enables the power electronics to control the motor and an inactive state prevents motion.

The drive generates an exception if the input is inactive when the controller commands motion and has authorized checking. The drive behavior in this

The function is always inactive. If the controller instructs the drive to monitor the Enable input, the drive issues a vendor-specific initialization fault (Enable Input Assignment).

situation is programmable.

Home

been seen. Typically, a transition of this signal is used to establish a reference position for the machine axis.

Registration 1 An inactive-to-active transition (also known as a positive transition) or ac tive-

An active state indicates to a homing sequence that the referencing sensor has

Registration 2 4

to-inactive transition (also known as a negative transition) is used to latch position values for use in registration moves.

The function is always inactive. If the controller instructs the drive to perform a home procedure, the drive issues a vendor-specific exception (Sensor Assignment).

The function is always inactive. If the controller instructs the drive to perform a registration procedure, the drive issues a vendorspecific exception (Sensor Assignment).

If the controller configuration specifies checking of the hardware over-travel

Posi tive Over-travel

inputs, an inactive state indicates that a position limit has been exceeded in the positive direction.

The drive generates an exception if the input is inactive when the controller

The function is always inactive. If the controller instructs the drive to monitor the hardware over-travel inputs, the drive issues a vendor-specific initialization fault (Over-travel Input Assignment).

authorizes checking. The drive behavior in this situation is programmable.

If the controller configuration specifies checking of the hardware overtravel

Negative Over-travel

inputs, an inactive state indicates that a position limit has been exceeded in the negative direction.

The drive generates an exception if the input is inactive when the controller

authorizes checking. The drive behavior in this situation is programmable.

The function is always active. If the controller instructs the drive

Regeneration OKAn inactive state indicates that an ex ternal regenerative power supply has a

fault and a regenerative power supply exception is generated by the drive.

that a regenerative power supply with a fault output is present, the drive issues a vendor-specific initialization fault (Regeneration OK Input Assignment).

IDN Value

Table 27 - Digital Input Specifications

Attribute Value

Type Active high, single-ended, current sinking

Assignable functions

Default function assignments (sercos)

(1)

Input current (with 24V applied) 11 mA, typical

On-state input voltage 21.6…26.4V @ 200 mA total

Off-state input voltage -1.0…3.0V

Pulse reject filtering (Home and Registration functions only) 1.0 μs, nom

Pulse reject filtering (all other input functions) 1.0 ms, nom

Propagation delay (Home and Registration functions only) 10 μs

Registration repeatability 500 ns

Windowed registration invalid-to-valid event delay 125 μs, min

Home-to-marker event delay 10 μs, min

Input reaction time (Disable) 25 ms, max

Input reaction time (Enable, Positive Over-travel, and Regeneration OK inputs) 20 ms, max

(1) The default settings are overwritten by RSLogix 5000 software configuration settings during phase-up or through sercos IDN Write instruction. Refer to Appendix D on page 271 for

information on changing default settings.

Enable, Home, Positive Over-travel, Negative Over-travel, Registration 1, Registration 2, and Regeneration OK

Input 1 = Enable Input 3 = Registration 1 Input 2 = Home Input 4 = Registration 2

72 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

INPUT

INPUTx

24VCOM

24VPWR

IOD-39

IOD-41, IOD-42, IOD-43, or IOD-44

IOD-40

Kinetix 6200 or Kinetix 6500 Control Module

24V DC

Figure 33 - Digital Input Circuitry

Ethernet Communication Specifications

The PORT1 and PORT2 (RJ-45) Ethernet connectors are provided for communication with the Logix controller (Kinetix 6500 control modules) and for programming the safety configuration (Kinetix 6200 and Kinetix 6500 control modules).

Attribute Value

Communication 100BASE-TX, full duplex

Cyclic update period 500 μs, min

Embedded switch features

Auto MDI/MDIX crossover detection/ correction

Port-to-port time synchronization variation

Cabling CAT5e shielded, 100 m (328 ft) max

Three-port, cut-through, time correction on IEEE-1588 packets, limited filtering, quality of service with four priority levels

Yes

100 ns, max

Sercos Communication Specifications

The Rx and Tx sercos connectors are provided on the Kinetix 6200 control module for communication with the Logix controller.

Attribute Value

Data rates 4 and 8 Mbps, selectable via DIP switch

Light intensity Low power or high power, selectable via DIP switch

Cyclic update period 500 μs, min

Node addresses 001…099

(2)

(1)

(1) The Kinetix 6000M IDM system supports only 8 Mbps and is hardwired for this setting. (2) Node address assignments begin with the IAM module. Node addresses for additional axes on the same power rail are assigned by

incrementing from left to right (starting with the IAM module address). Each IDM unit has it’s own node address switches and can be set to any valid address. However, node addresses for the IAM and AM modules on the power rail and for IDM units must be unique.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 73

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

IMPORTANT

Normally

Open Relay

Bulletin 2094

IAM Power Module

Contactor Enable Relay

Contactor enable is a relay-driven contact used in the protective control string to protect the drive electronics during certain fault conditions. It is capable of handling 120V AC or 24V DC at 1 A or less. Contactor enable is a function of the converter and is not available in the axis modules. An active state indicates the drive is operational and does not have a fault.

ATT EN TI ON : Wiring the contactor enable relay is required. To avoid personal injury or damage to the drive, wire the contactor enable relay into your safety control string so that:

• three-phase power is removed from the drive in the event of shutdown fault conditions.

• drive operation is prevented when the power rail is not fully populated.

• control power is applied to the drive prior to three-phase power.

Refer to IAM Module (without LIM module) on page 236

All power rail slots must have a module installed or the contactor enable relay will not close.

for a wiring example.

Figure 34 - Contactor Enable Relay Circuit

CONT EN+

CONT EN-

Table 28 - Contactor Enable Relay Output Specifications

Attribute Value Min Max

On-state current

On-state resistance

Off-state voltage

Current flow when the relay is closed – 1 A

Contact resistance when the relay is closed – 1 Ω

Voltage across the contacts when the relay is open – 120V AC or 24V DC

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Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

PWR

(BC-3)

MBRK-

(BC-6)

MBRK+

(BC-5)

DBRK(BC-2)

DBRK+

(BC-1)

COM

(BC-4)

Bulletin 2094

IAM/AM Power

Module

Power and Relay Specifications

This section provides a description of the Bulletin 2094 power module brake relay (BC), input power (IPD), motor power (MP), and control power (CPD) connectors.

Motor/Resistive Brake Relay

Two connections are required for the (customer-supplied) motor/resistive brake input power (BC-3 and BC-4) and two connections each for the motor and resistive brake output, as shown in the figure below. Connections are rated for +24V and current as shown in the table below.

An active signal releases the motor brake (BC-5 and BC-6). The brake signal is the same as the contactor enable signal, with the addition of the turn-on and turn-off delays specified by the brake active delay and brake inactive delay (configurable in RSLogix 5000 software). Refer to Axis Module/Rotary Motor Wiring Examples beginning on page 242

page 252

for wiring examples.

The resistive brake relay (BC-1 and BC-2) controls the resistive brake module (RBM) contactor. The RBM module is wired between the drive and motor by using an internal contactor to switch the motor between the drive and a resistive load. The RBM module contact delay is the time it takes to fully close the contactor across the motor power input lines, and must be configured in RSLogix 5000 software. Refer to RBM Module Interconnect Diagrams beginning on page 277

for wiring examples.

and Controlling a Brake Example on

Figure 35 - Brake Relay Circuit

(1) Noise suppression device.

Table 29 - Brake Relay Output Specifications

Attribute Description IAM/AM Power Module Value, Max

2094-BC01-Mxx-M, 2094-BC02-M02-M,

Current flow when the relay

On-state current

On-state resistance Contact resistance when the relay is closed 1 Ω

Off-state voltage Voltage across the contacts when the relay is open 30V

(1) For motors requiring more than the maximum current specified, a relay must be added.

(1)

is closed

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 75

2094-BMP5-M, 2094-BM01-M, 2094-BM02-M

2094-BC04-M03-M, 2094-BC07-M05-M, 2094-BM03-M, 2094-BM05-M

3.0 A

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Input Power Cycle Capability

The power cycle capability is inversely proportional to the system capacitance (including DC bus follower), but cannot exceed 2 contactor cycles per minute with up to 4 axes or 1 contactor cycle per minute with 5…8 axes.

The cycle capability also depends on the converter power rating and the total system capacitance. Refer to Appendix C on page 267 capacitance.

Table 30 - Maximum Input Power Cycling Specifications (460V)

to calculate total system

Attribute

Main AC input power cycling (cycles per minute for 10,000 μf) 0.12 0.52 2.15 4.30

2094-BC01-MP5-M, 2094-BC01-M01-M

2094-BC02-M02-M 2094-BC04-M03-M 2094-BC07-M05-M

For example, in a 4 axis system with a 2094-BC02-M02-M IAM power module and 2,000 μF total capacitance, the calculated capability is 0.52 x 10,000/2000 =

2.6 cycles per minute. However, this value is reduced to 2.0 by the 4 axes per system limitation.

76 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Peak Current Specifications

D =

T T

x 100%

Cont

Base

D =

T T

x 100%

Figure 36 - Load Duty-cycle Profile Example

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

Table 31 - Peak Duty Cycle Definition of Terms

Term Definition

Continuous Current Rating (I

Peak Curre nt Rati ng (I

) The maximum value of current that can be output continuously.

Cont

PKmax

)

The maximum value of peak current that the drive can output. This rating is valid only for overload times less than T

The ratio of time at peak to the Application Period and is defined as:

Duty Cycle (D)

Time at Peak (T

Peak Curre nt (IPK)

)

The time at peak current (IPK) for a given loading profile. Must be less than or equal to T

The level of peak current for a given loading profile. I equal to the Peak Current Rating (T

The level of current between the pulses of peak current for a given loading

Base Current (I

Base

)

profile. I of the drive.

The loading profile is comprised of I

Loading Profile

completely specify the operation of the drive in an overload situation. These values are collectively defined as the Loading Profile of the drive.

Application Period (T) The sum of the times at IPK (TPK) and I

(1) All current values are specified as RMS.

(1)

PKmax

must be less than or

of the drive.

PKMAX)

must be less than or equal to the continuous current rating (I

Base

, I

, TPK, and D (or T) values and

Base

Cont)

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 77

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Applies to these Bulletin 2094 power modules: 2094-BC01-MP5-M, 2094-BMP5-M, 2094-BC01-M01-M, 2094-BM01-M, 2094-BC02-M02-M, 2094-BM02-M, 2094-BC04-M03-M, 2094-BM03-M

Applies to these Bulletin 2094 power modules: 2094-BC07-M05-M, 2094-BM05-M

50%

45%

40%

Figure 37 - Peak Inverter Overload (TPK < 2.0 s)

35%

max

30%

25%

20%

15%

Maximum Duty Cycle (D )

10%

50%

45%

40%

% Base Current (I /I )

(1) Base current (I

60%

Cont

Base

) and peak current (IPK) are a percentage of the continuous drive current rating (I

Base

80%20%

Figure 38 - Peak Inverter Overload (TPK < 2.0 s)

100%

Legend

(1)

I = 150%

I = 200%

I = 250%

Cont

35%

max

30%

25%

20%

15%

Maximum Duty Cycle (D )

10%

40%

% Base Current (I /I )

(1) Base current (I

60%

Cont

Base

) and peak current (IPK) are a percentage of the continuous drive current rating (I

Base

80%20%

78 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

100%

Legend

(1)

I = 150%

I = 200%

Cont

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

IMPORTANT

Control Power

The IAM power module requires AC input power for logic circuitry.

The control power input requires an AC (EMC) line filter for CE certification. For wiring examples, refer to the Power Wiring Examples on page 233

Control power isolation, via a step-down transformer, is required for all 460V applications.

The National Electrical Code and local electrical codes take precedence over the values and methods provided. Implementation of these codes is the responsibility of the machine builder.

Table 32 - Control Power Input Power Specifications

Attribute Value

Input voltage 95…264V AC rms, single-phase

Input power frequency 47…63 Hz

Control power AC input current

Nom @ 220/230V AC rms Nom @ 110/115V AC rms Max inrush (0-pk)

6 A 6 A 98 A

(1)

(1) For eight axis systems with 230V AC control input voltage and 50 °C (122°F) ambient temperature the maximum inrush duration is

less than 1/2 line cycle. Use this equation to calculate maximum inrush current for systems with different axis count and control input voltage.

= 0.043 x (VIN) + 6.72 x (# of axes) + 0.000333 x (V

) - 0.816 x (# of axes)2 + 0.0358 x (# of axes x VIN)

Table 33 - Control Power Current Requirements

110/115V AC Input 220/230V AC Input

Modules on Power Rail

IAM module only 0.56 67 0.36 85

IAM and 1 AM module 0.99 119 0.64 153

IAM and 2 AM module 1.43 172 0.92 220

IAM and 3 AM module 1.87 224 1.20 287

IAM and 4 AM module 2.31 277 1.48 354

IAM and 5 AM module 2.74 329 1.75 421

IAM and 6 AM module 3.18 382 2.03 488

IAM and 7 AM module 3.62 434 2.31 555

IDM power interface module (IPIM)

Input Current

For specifications and an example for calculating the IPIM module current requirements, refer to the Kinetix 6000M Integrated Drive-Motor User Manual, publication 2094-UM003

Input VA

Input Current

Input VA

For Kinetix 6000M systems, calculate the sum of the control power current requirements for each IPIM module on the power rail and add that value with the appropriate value from Ta b l e 3 3

for the number of axes on the power rail.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 79

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

TIP

4096 turns, Kinetix 6200 drives, Stegmann Hiperface encoders

2048 turns, Kinetix 6500 drives, Stegmann Hiperface encoders

128 turns, Kinetix 6200 and Kinetix 6500 drives,

RDD-Series direct-drive motors or

Heidenhain EnDat 2.1 or 2.2 encoders on third-party motors

(1)

Position at Power D own

Feedback Specifications

Attribute Motor Feedback Auxiliary Position Feedback

Feedback device support

Power supply voltage (MTR_EPWR5V)

Power supply current (MTR_EPWR5V)

Power supply voltage (MT R_EPWR9V)

Power supply current (MTR_EPWR9V)

Thermost at

(1) The EPWR_5V and EPWR_9V power supplies are shared between the motor feedback interface and the auxiliary feedback interface on the I/O (IOD) connector.

The control module accepts motor and auxiliary feedback signals from the following types of encoders with these general specifications.

Table 34 - Motor and Auxiliary Feedback General Specifications

• Stegmann Hiper face

• Generic TTL Incremental

• Generic Sine/Cosine Incremental

• Tamagawa 17-bit Serial

• Heidenhain EnDat 2.1

• Heidenhain EnDat 2.2

(1)

5.1…5.4V

300 mA, max

8.3…9.9V

150 mA, max Single-ended, under 500 Ω = no fault,

over 10 kΩ = fault

• Stegmann Hiperface

• Generic TTL Incremental

• Generic Sine/Cosine Incremental

• Heidenhain EnDat 2.1

• Heidenhain EnDat 2.2

N/A

Auto-configuration in RSLogix 5000 software of intelligent absolute, highresolution, and incremental encoders is possible only with Allen-Bradley motors.

Absolute Position Feature

The drive’s absolute position feature tracks the position of the motor, within the multi-turn retention limits, while the drive is powered off. The absolute position feature is available with only these multi-turn encoders.

Table 35 - Absolute Position Designator Examples

Encoder Type

Stegmann Hiperface

Heidenhain EnDat -7 RDB-B21519-7

Figure 39 - Absolute Position Retention Limits

Motor Cat. No. Designator

-M MPL-B310P-M

-V MPL-B23 0P-V

Motor Cat. No. Example

(1) Absolute position retention limit (±64) for Heidenhain EnDat 2.2 is the worst case.

80 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

+64-64

+2048+1024-2048 -1024

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

Kinetix 6200 or Kinetix 6500 Control Module

Motor Feedback Specifications

The Kinetix 6200 and Kinetix 6500 control modules support multiple types of feedback devices by using the 15-pin (MF) motor feedback connector and sharing connector pins in many cases.

Table 36 - Motor Feedback Signals by Device Type

MF Pin

1 MTR_SIN+ MTR_AM+ MTR_AM+ – MTR_SIN+ –

2 MTR_SIN- MTR_AM- MTR_AM- – MTR_SIN- –

3 MTR_COS+ MTR_BM+ MTR_BM+ – MTR_COS+ –

4 MTR_COS- MTR_BM- MTR_BM- – MTR_COS- –

5 MTR_DATA+ MTR_IM+ MTR_IM+ MTR_DATA+ MTR_DATA+ MTR_DATA+

6 MTR_ECOM MTR_ECOM MTR_ECOM MTR_ECOM MTR_ECOM MTR_ECOM

7MTR_EPWR9V–––––

8 – MT R_S3 MTR_S 3 – – –

9 – – – – MTR_ CLK+ MT R_CLK+

10 MT R_DATA- MTR_I M- MTR_ IM- MT R_DATA- MTR_DATA- MTR _DATA-

11 MT R_TS MT R_TS MTR _TS MTR_ TS MTR_T S MTR_TS

12 – MTR_S1 MTR_S1 – – –

13 – MTR_S2 MTR_S2 – – –

14 – MTR_EPWR5V MTR_EPWR5V MTR_EPWR5V MTR_EPWR5V MTR_EPWR5V

15 – – – – MT R_CLK- MTR_ CLK-

Stegmann Hiperface

Generic TTL Incremental

Generic Sine/Cosine Incremental

Tamagawa 17-bit Serial

Heidenhain EnDat 2.1

Heidenhain EnDat 2.2

This is the motor thermostat interface schematic. Although the thermostat signal is shown for all feedback types, some motors may not support this feature because it is not part of the feedback device.

Figure 40 - Motor Thermostat Interface

+5V

8.25 k

Ω

1 k

Ω

MTR_TS

0.1

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 81

+5V

µF

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

56 pF

MTR_SIN+ or MTR_COS+

MTR_SIN- or MTR_COS-

1 k

Ω

to AqB Counter

1 k

Ω

1 k

Ω

1 k

Ω

121

Ω

56 pF

220 pF

2 k

Ω

220 pF

to A/D Converter

2 k

Ω

+2.5V

Kinetix 6200 or Kinetix 6500 Control Module

Shaded area indicates components that are part of the circuit, but support other feedback device types (not used for Stegmann Hiperface support).

Kinetix 6200 or Kinetix 6500 Control Module

Table 37 - Stegmann Hiperface Specifications

Attribute Value

Protocol Hiperface

Memory support Not programmed, or programmed with Allen-Bradley motor data

Hiperface data communication 9600 baud, 8 data bits, no parity

Sine/cosine interpolation 2048 counts/sine period

Input frequency (AM/BM) 250 kHz, max

Input voltage (AM/BM) 0.6...1.2V, p-p, measured at the drive inputs

Line loss detection (AM/BM) Average (sin

+ cos2) > constant

Noise filtering (AM and BM) Two-stage coarse count pulse reject filter with rejected pulse tally

Incremental position verification

Position compare between incremental accumulator and serial data performed every 50 ms or less

Figure 41 - Stegmann Hiperface Interface, MTR_SIN and MTR_COS Signals

Figure 42 - Stegmann Hiperface Interface, MTR_DATA Signals

1 k

Ω

MTR_DATA+

121

Ω

1 k

Ω

MTR_DATA-

56 pF

100 pF

+5V

Ω

1 k

82 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Ω

1 k

100 pF

56 pF

to AqB Counter

to UART

from UART

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

MTR_AM- or MTR_BM-

1 k

Ω

to A/D Converter

56 pF

+2.5V

56 pF

1 k

Ω

121

Ω

MTR_AM+ or MTR_BM+

2 k

Ω

1 k

Ω

1 k

Ω

220 pF

2 k

Ω

to AqB Counter

Shaded area indicates components that are part of the circuit, but support other feedback device types (not used for Generic TTL incremental support).

Kinetix 6200 or Kinetix 6500 Control Module

Table 38 - Generic TTL Incremental Specifications

Attribute Value

TTL incremental encoder support 5V, differential A quad B

Quadrature interpolation 4 counts / square wave period

Differential input voltage (MTR_AM, MTR_BM, and MTR_IM)

DC current draw (MTR_AM, MTR_BM, and MTR_IM)

Input signal frequency (MTR_AM, MTR_BM, and MTR_IM)

Edge sepa ration (MTR_AM and MTR_BM)

Line loss detection (MTR_AM and MTR_BM)

Noise filtering (MTR_AM and MTR_BM)

Commutation verification

Hall inputs (MTR_S1, MTR_S2, and MTR_S3)

1.0…7.0V

30 mA, max

5.0 MHz, max

42 ns min, between any two edges

Average (MTR_AM

+ MTR_BM2) > constant

Two-stage coarse count pulse reject filter with rejected pulse tally

Commutation angle verification performed at every Hall signal transition

Single-ended, TTL, open collector, or none

Figure 43 - Generic TTL Incremental, MTR_AM and MTR_BM Signals

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 83

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

to UART

from UART

MTR_IM-

56 pF

MTR_IM+

1 k

Ω

to AqB Counter

1 k

Ω

1 k

Ω

1 k

Ω

121

Ω

56 pF

100 pF 100 pF

+5V

Shaded area indicates components that are part of the circuit, but support other feedback device types (not used for Generic TTL incremental support).

Kinetix 6200 or Kinetix 6500 Control Module

Figure 44 - Generic TTL Interface, MTR_IM Signals

Figure 45 - Generic TTL Interface, MTR_S1, MTR_S2, or MTR_S3 Signals

215

MTR_S1, MTR_S2,

or MTR_S3

Ω

0.1

µF

+5V

3.32 k

+5V

Ω

84 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

Table 39 - Generic Sine/Cosine Incremental Specifications

Attribute Value

Sine/Cosine interpolation 2048 counts/sine wave period

Input frequency (MTR_SIN and MTR_COS)

Differential input voltage (MTR_SIN and MTR_COS)

Line loss detection (MTR_SIN and MTR_COS)

Noise filtering (MTR_SIN and MTR_COS)

Commutation verification

Hall inputs (MTR_S1, MTR_S2, and MTR_S3)

250 kHz, max

0.6…1.2V, p-p

Average (sin

Two-stage coarse count pulse reject filter with rejected pulse tally

Commutation angle verification performed at every Hall signal transition

Single-ended, TTL, open collector, or none

+ cos2) > constant

Refer to page 82 for the generic sine/cosine interface schematic. It is identical to the Stegmann Hiperface (MTR_AM and MTR_BM) signals schematic.

Refer to page 84

for the Hall (MTR_S1, MTR_S2, and MTR_S3) signals

schematic.

Table 40 - Tamagawa 17-bit Serial Specifications

Attribute Value

Tamagawa model support TS5669N124

Protocol Tamagawa proprietary

Memory support Programmed with Allen-Bradley motor data

Differential input voltage 1.0…7.0V

Data communication 2.5 Mbps, 8 data bits, no parity

Battery 3.6V, located external to drive in low-profile connector kit

Refer to page 82 for the Tamagawa 17-bit serial interface schematic. It is identical to the Stegmann Hiperface (MTR_DATA) signals schematic.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 85

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Shaded area indicates components that are part of the circuit, but support other feedback device types (not used for EnDat support).

Kinetix 6200 or Kinetix 6500 Control Module

Table 41 - EnDat 2.1 Interface Specifications

Attribute Value

Protocol EnDat 2.1

Memory support Unprogrammed

EnDat 2.1 data communication 4 Mbps, synchronous

Sine/Cosine interpolation 2048 counts/sine wave period

Input frequency (MTR_SIN and MTR_COS)

Differential input voltage (MTR_SIN and MTR_COS)

Line loss detection (MTR_SIN and MTR_COS)

Noise filtering (MTR_SIN and MTR_COS)

Incremental position verification

250 kHz, max

0.6…1.2V, p-p

Average (sin

Two-stage coarse count pulse reject filter with rejected pulse tally

Position compare between incremental accumulator and serial data performed every 50 ms or less.

+ cos2) > constant

Refer to page 82 for the EnDat sine/cosine interface schematic. It is identical to the Stegmann Hiperface (MTR_SIN and MTR_COS) schematic.

Figure 46 - EnDat 2.1 and EnDat 2.2 Interface Schematic for Serial Communication

Table 42 - EnDat 2.2 Interface Specifications

Attribute Value

Memory support Unprogrammed

EnDat 2.2 data communication 4 Mbps, synchronous

86 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

IMPORTANT

Table 43 - Support Requirements for EnDat Encoders on Third-party Motors

Requirement

Supported models –

Cable length, max – 50 m (164 ft)

Position initialization – Digital

Position tracking – Uses sine/cosine signals Digital Uses sine/cosine signals

Cabling – Shielded, twisted pair Heidenhain EnDat 2.2 cable only Shielded, twisted pair

Blob programming – Not required

Commissioning/ field replacement

Data frequency – 100 kHz 4.125 MHz 100 kHz

Sine/cosine frequency – 0…250 kHz – 0…250 kHz

EnDat 2.1 (digital only)

–

EnDat 2.1 (with sine/cosine)

ECI1319 / EQI1331 ECI1118 / EQI1130

Kinetix 6200 or Kinetix 6500 drives: A one-time procedure must be executed via message instructions to program the blob file in the encoder (using a Kinetix 6500 drive) so that it can be operated like any other Rockwell Automation motor. This is similar to the Stegmann encoder third-party motor requirement, except that a Kinetix 6500 drive is used instead of a Kinetix 6000 drive.

Kinetix 6500 drives only: The RSLogix 5000 software commutation test procedure (released with version 19) must be executed to obtain the commutation offset value and store it in the controller. This procedure must be executed any time a drive is connected to a new motor.

EnDat 2.2 (digital only)

LC4 83 LIC4000 ECN125 ROQ437 ECN1123 / EQN1135 ECN1325 / EQN1337

EnDat 2.2 (with sine/cosine)

ECN113 ECN1313 / EQN1325 ECN413 / EQN425 ROQ425

To properly support system EnDat feedback, the keying configuration on the drive Module Properties tab of RSLogix 5000 software must be selected to the correct firmware revision as follows:

• For EnDat 2.1 encoders, use Kinetix 6200 drive firmware revision 1.35 or later

• For EnDat 2.2 encoders, use Kinetix 6200 drive firmware revision 1.40 or later

To make sure your drive and motor integration is successful, refer to commissioning notes relative to Endat encoders on third-party motors.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 87

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Auxiliary Position Feedback Specifications

The Kinetix 6200 and Kinetix 6500 control modules support multiple types of feedback devices by using the 44-pin (IOD) connector and sharing connector pins in many cases.

Table 44 - Auxiliary Feedback Signals by Device Type

IOD Pin

1 AUX_SIN+ AUX_AM+ AUX_SIN+ AUX_SIN+ –

2 AUX_SIN- AUX_AM- AUX_SIN- AUX_SIN- –

3 AUX_COS+ AUX_BM+ AUX_COS+ AUX_COS+ –

4 AUX_COS- AUX_BM- AUX_COS- AUX_COS- –

5 AUX_DATA+ AUX_IM+ AUX_IM+ AUX_DATA+ AUX_DATA+

6 AUX_DATA- AUX_IM- AUX_IM- AUX_DATA- AUX_DATA-

7–––AUX_CLK+AUX_CLK+

8–––AUX_CLK-AUX_CLK-

9 AUX_EPWR5V AUX_EPWR5V AUX_EPWR5V AUX_EPWR5V AUX_EPWR5V

10 AUX_ECOM AUX_ECOM AUX_ECOM AUX_ECOM AUX_ECOM

11 AUX_EPWR9V – – – –

Stegmann Hiperface

Generic TTL Incremental

Generic Sine/Cosine Incremental

Heidenhain EnDat 2.1

Heidenhain EnDat 2.2

Specifications for the auxiliary feedback channel are identical to the motor feedback channel, except for specifications related to commutation.

The 9.0V and 5.0V power supplies for auxiliary feedback devices are shared with the motor feedback channel, and the total current capability is outlined in the table on page 80

Allen-Bradley Bulletin 842HR, 844D, 845H, and 845T encoders are the preferred encoders for auxiliary feedback connections.

Cat. No. Description

842HR-MJDZ115FWYD (multi-turn) 842HR-SJDZ115FWYD (single-turn)

844D-B5CC1FW

844D-B5CC1CS

844D-B5CC1DR

845H-SJDN14FWY2

845H-SJDN14CSY2

845H-SJDN14DRY2

845T-DN13EFW

845T-DN13ECS

Size 25, sine/cosine, square flange, 3/8 in. shaft, 5V or 9V DC, digital RS-485 interface, M23 17-pin connector

Size 20, incremental, square flange, 3/8 in. shaft, 5V DC, 5V DLD output, radial connector

Size 25, incremental, square flange, 3/8 in. shaft, 5V DC, 5V DLD output, radial connector

HS35, hollow shaft incremental, 5/8 in. shaft, tether 3/8 in. bolt on, 5V DC, 5V DLD output, 10 pin connector

Refer to the Kinetix Motion Accessories Technical Data, publication

GMC-TD004

88 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

, for more information on these Allen-Bradley encoders.

Kinetix 6200 and Kinetix 6500 Connector Data Chapter 4

Safe Speed Monitoring Safety Features

Kinetix 6200 and Kinetix 6500 control modules with Safe Speed Monitoring, catalog number 2094-xx02x-Mxx-S1, incorporate safe torque-off functionality as well as safe speed monitoring and door control/monitoring. Speed monitoring allows for other stop categories such as a controlled stop and disable or even a controlled stop and hold position.

The table on page 90

summarizes the safety modes of operation supported by the safe speed monitoring control modules. The table also describes which I/O is active depending on the operation mode. In addition to the modes listed in the table, the safe speed monitoring control modules support two additional safety features.

• Safe Maximum Speed

• Safe Direction Monitoring

You can operate these features independent of the other modes, relying on the Safe Stop function.

When the Safe Maximum Speed feature is activated through a software configuration, the feedback velocity is monitored and compared against a userprogrammable limit. If the measured velocity exceeds the limit, the Safe Stop function is executed.

Safe Direction Monitoring is also activated through software configuration and monitors the feedback direction and executes the Safe Stop function when motion in the illegal direction is detected.

When a new safe speed monitoring control module is installed, it is preconfigured in the Disabled operation mode. When installing a new module, you must first complete the basic drive configuration by using RSLogix 5000 software. Next, you use the safety configuration tool to configure the safety functions. As a part of the safety configuration process, you verify that the safety functions are configured, operate correctly, and you lock the safety circuitry.

Connections for safety functions are made at the IOD connector by using the 2090-K6CK-D44M low-profile connector kit. A customer-supplied 24V power supply (IOD-17 and IOD-18) is required to support the safety inputs and outputs.

Table 45 - Safety I/O Power Supply Specifications

Attribute Value

Vol tage rati ng

Current rating 0.105 A max

21.6…28.8V DC (24V nom) per IEC/EN 60204 and IEC/EN 61558-1

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 89

Chapter 4 Kinetix 6200 and Kinetix 6500 Connector Data

Table 46 - Safety Modes of Operation

(1)

Safety Mode Description

SS Input

SLS Input

ESM Input

LM Input

DM Input

Disabled In this mode, all safety functions are disabled. ––––––

Safe Stop

Safe Stop with Door Monitoring In addition to monitoring for Safe Stop, the drive monitors the status of the door. √ ––√√√

Safe Limited Speed

Safe Limited Speed with Door Monitoring

Safe Limited Speed with Enabling Switch Control

Safe Limited Speed with Door Monitor and Enabling Switch

Safe Limited Speed (status only)

Slave, Safe Stop

Slave, Safe Limited Speed

Slave, Safe Limited Speed (status only)

The drive activates the configured Stop Category upon deactivation of the Safe Stop input or the occurrence of a Stop Category Fault.

In addition to monitoring for Safe Stop, the drive monitors the feedback velocity and compares it to a configurable Safe Speed Limit. If the velocity exceeds the limit, the drive initiates the configured Stop Category.

In addition to monitoring for Safe Stop and Safe Limited Speed, the drive monitors the status of the door.

In addition to monitoring for Safe Stop and Safe Limited Speed, the drive monitors the status of the Enabling Switch input.

In addition to monitoring for Safe Stop and Safe Limited Speed, the drive monitors the status of the door and the Enabling Switch input.

In addition to monitoring for Safe Stop, the drive monitors the feedback velocity and compares it to a configurable Safe Speed Limit. If the velocity exceeds the limit, the system status is made available as a safe output intended for a safety programmable logic controller. No stopping action takes place.

The drive performs the same functions as Safe Stop. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

The drive performs the same functions as Safe Limited Speed mode. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

The drive performs the same functions as Safe Limited Speed Status Only mode. However, it regards the Door Monitor input as a Door Control output from an upstream axis, and performs a logical AND with its internal Door Control signal to form the cascaded Door Control output.

√ ––√ – √

√√– √ – √

√√– √√√

√√√√– √

√√√√√√

√√– √ – √

√ ––––√

√√–––√

DC Output

(1) Use of this input is optional.

Safe Torque-off Safety Features

Refer to the Kinetix 6200 and Kinetix 6500 Safe Speed Monitoring Safety Reference Manual, publication 2094-RM001

, for more information on

configuring and wiring the safety functions.

Kinetix 6200 and Kinetix 6500 control modules with safe torque-off, catalog numbers 2094-xx02x-Mxx-S0, incorporate the capability to safely turn off the power transistors on the inverter board in response to a monitored digital input, also known as a Category 0 Stop. These drives also support dual-channel outputs that allow for cascading of the safe torque-off function to additional axes, and a safety circuit reset input. The 2090-K6CK-D44S0 connector kit and 2090-CS0DSDS-AAxx cable were designed specifically for this purpose. Refer to

Figure 70 on page 127

for more information.

Refer to the Kinetix 6200 and Kinetix 6500 Safe Torque-off Safety Reference Manual, publication 2094-RM002

, for more information on configuring and

wiring the safety functions.

90 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Chapter 5

Connecting the Kinetix 6200 and Kinetix 6500 Drive System

This chapter provides procedures for wiring your Kinetix 6200 and Kinetix 6500 system components and making cable connections.

Top ic Pa ge

Basic Wiring Requirements 91

Determine the Input Power Configuration 93

Setting the Ground Jumper in Ungrounded Power Configurations 97

Grounding the Modular Drive System 100

Power Wiring Requirements 102

Power Wiring Guidelines 104

Wiring the IAM/AM Module Connectors 105

Apply the Motor Cable Shield Clamp 118

Feedback and I/O Cable Connections 119

Wiring the Feedback and I/O Connectors 123

External Shunt Module Connections 128

IPIM Module Connections 129

RBM Module Connections 130

Sercos Fiber-optic Cable Connections 131

Kinetix 6000M Integrated Drive-Motor Sercos Connections 134

Ethernet Cable Connections 135

Basic Wiring Requirements

This section contains basic wiring information for the Kinetix 6200 and Kinetix 6500 drive modules.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 91

Chapter 5 Connecting the Kinetix 6200 and Kinetix 6500 Drive System

IMPORTANT

Building Your Own Cables

Follow these guidelines when building cables for compatible motors and actuators:

• Connect the cable shield to the connector shells on both ends of the cable

• Use twisted pair cable whenever possible. Twist differential signals with

This section contains common PWM servo system wiring configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.

Factory-made cables are designed to minimize EMI and are recommended over hand-built cables to optimize system performance.

Building your own cables is not an option for the hybrid and network cables used in Kinetix 6000M integrated drive-motor systems.

with a complete 360° connection.

each other and twist single-ended signals with the appropriate ground return.

Refer to the Kinetix Motion Accessories Technical Data, publication

GMC-TD004

and motor-end connector kit catalog numbers.

, for low-profile connector kit, drive-end (mating) connector kit,

Routing the Power and Signal Cables

Be aware that when you route power and signal wiring on a machine or system, radiated noise from nearby relays, transformers, and other electronic drives can be induced into motor or encoder feedback signals, input/output communication, or other sensitive low voltage signals. This can cause system faults and communication anomalies.

Refer to Electrical Noise Reduction on page 36 low voltage cables in wireways. Refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 information.

for examples of routing high and

, for more

92 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Connecting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 5

Transformer

Three-p hase

Input VAC

Phase Ground

Transformer (WYE) Secondary

Bonded Cabinet

Ground

Ground Grid or

Power Distribution Ground

Connect to power rail ground stud.

Three-phase

AC Lin e Filter

Input Fusing

Contac tor

Bulletin 2094

IAM Power Module, Top View

Determine the Input Power Configuration

Before wiring input power to your Kinetix 6200 or Kinetix 6500 system, you must determine the type of input power you are connecting to. The IAM power module is designed to operate in both grounded and ungrounded environments.

ATT EN TI ON : When using a LIM module with your IAM power module, the VAC LINE input power must come from a grounded configuration (refer to the figure below). When not using a LIM module with your IAM power module, ungrounded configurations are permitted, but you must set the jumper to prevent high electrostatic build-up. Refer to Setting the Ground Jumper in Ungrounded Power Configurations on

for more information.

page 97

Grounded Power Configurations

The grounded (WYE) power configuration lets you ground your three-phase power at a neutral point. This type of grounded power configuration is preferred.

Figure 47 - Grounded Power Configuration (WYE Secondary)

1 2

CTRL 2 CTRL 1

1 2 3 4 5 6

1 2

CONT ENCONT EN+

DCDC+

L3 L2 L1

Refer to Power Wiring Examples beginning on page 233 for input power interconnect diagrams with and without the LIM module.

MBRK -

MBRK +

DBRK DBRK +

COM PWR

1 2 3 4

1 2 3 4 5 6

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Chapter 5 Connecting the Kinetix 6200 and Kinetix 6500 Drive System

Transformer (Delta) Secondary

Bonded Cabinet

Ground

Transformer

Ground Grid or

Power Distribution Ground

Connect to power rail ground stud.

Three-phase

AC Line Filte r

Input Fusing

Contactor

Bulletin 2094

IAM Power Module, Top View

IMPORTANT

Figure 48 - Grounded (B-Phase) Power Configuration (Delta Secondary)

1 2

CTRL 2 CTRL 1

1 2 3 4 5 6

DCDC+

1 2

L3 L2 L1

CONT ENCONT EN+

MBRK -

MBRK +

DBRK DBRK +

COM

PWR

W V

1 2 3 4

1 2 3 4 5 6

The IAM power module has a factory-installed ground jumper configured for grounded power distribution.

Refer to Appendix A on page 233 and without the LIM module.

If you determine that you have grounded power distribution in your plant, you do not need to modify your IAM power module.

, for input-power interconnect diagrams with

94 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Connecting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 5

IMPORTANT

Transformer

Three-phase

Input VAC

Chassis Ground

Bonded Cabinet

Ground

Ground Grid or

Power Distribution Ground

Connect to power rail ground stud.

Three-phas e AC Lin e Filter

Input Fusing

Contac tor

Bulletin 2094

IAM Power Module, Top View

Ungrounded Power Configurations

Ungrounded power configurations are allowed, but you must jumper across a 120 kΩ resistor (internal to the IAM power module) to prevent high electrostatic build-up. The ungrounded power configuration (shown below) does not provide a neutral ground point. The IAM power module has a ground jumper set for grounded power distribution (default configuration).

If you determine that you have ungrounded or high-impedance grounded power distribution in your facility, you need to move the default jumper (configured for grounded power) to the ungrounded power position to prevent electrostatic buildup inside the IAM power module.

Refer to Setting the Ground Jumper in Ungrounded Power Configurations on

page 97

for more information.

Figure 49 - Ungrounded Power Configuration

1 2

CTRL 2 CTRL 1

1 2 3 4 5 6

1 2

DCDC+

L3 L2 L1

CONT ENCONT EN+

ATT EN TI ON : Ungrounded systems do not reference each phase potential to a power distribution ground. This can result in an unknown potential to earth

MBRK -

MBRK +

DBRK -

DBRK +

COM PWR

1 2 3 4

1 2 3 4 5 6

ground.

Refer to Appendix A on page 233, for input-power interconnect diagrams with and without the LIM module.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 95

Chapter 5 Connecting the Kinetix 6200 and Kinetix 6500 Drive System

IMPORTANT

N.C. N.C. N.C.

1 2

DCDC+

L3 L2 L1

CONT ENCONT EN+

CTRL 2 CTRL 1

1 2

1 2 3 4 5 6

MBRK MBRK +

COM

PWR DBRK DBRK +

1 2 3 4

1 2 3 4 5 6

MBRK MBRK +

COM

PWR DBRK DBRK +

1 2 3 4

1 2 3 4 5 6

MBRK MBRK +

COM

PWR DBRK DBRK +

1 2 3 4

1 2 3 4 5 6

1 2

DCDC+

L3 L2 L1

CONT ENCONT EN+

CTRL 2 CTRL 1

1 2

1 2 3 4 5 6

MBRK MBRK +

COM

PWR DBRK DBRK +

1 2 3 4

1 2 3 4 5 6

MBRK -

MBRK +

COM PWR

DBRK -

DBRK +

1 2 3 4

1 2 3 4 5 6

MBRK MBRK +

COM PWR

DBRK -

DBRK +

1 2 3 4

1 2 3 4 5 6

MBRK MBRK +

COM

PWR DBRK DBRK +

1 2 3 4

1 2 3 4 5 6

2094-BCxx-Mxx-M

Common-bus Leader

IAM Power Module

2094-BMxx-M Power Modules or 2094-SEPM-B24-S IPIM Modules

Bonded Cabinet Ground

Three-phase

Input Power

Bulletin 2094

Power Module

DC Common Bus

Connections

2094-BCxx-Mxx-M

Common-bus Follower

IAM Power Module

2094-BMxx-M Power Modules or 2094-SEPM-B24-S IPIM Modules

DC Common Bus Configurations

When the IAM power module is used in a DC common-bus configuration, the IAM module is known as a leader IAM or follower IAM module. The IAM (non-common bus) and leader IAM module have identical three-phase input power connections. The leader IAM module is responsible for discharging the DC bus, and for providing common-bus follower drives with DC bus pre-charge, bus regulation, phase-loss detection, and ground fault detection. Follower IAM modules do not have three-phase input power connections, but have DC bus connections from a leader IAM module.

Table 47 - IAM Module Terminology and Use

This Module Is Wired And is

IAM With three-phase input power. Not wired in Common-bus mode.

Leader IAM

Follower IAM

With three-phase input power, but has DC common-bus connections to a follower IAM module.

Without three-phase input power, but has DC common-bus connections from a leader IAM module.

Wired in Common-bus mode.

Wired in Common-bus mode and configured by using RSLogix 5000 software.

The Bulletin 2094 leader IAM power module can operate with non-Bulletin 2094 follower drives, as can the Bulletin 2094 follower IAM module operate with non-Bulletin 2094 common-bus leader drives. However, non-Bulletin 2094 leader and follower drives must meet the same functional requirements as the Bulletin 2094 leader and follower IAM modules.

Any non-Bulletin 2094 common-bus leader IAM module that does not provide pre-charge is required to add an additional external pre-charge circuit before connecting to any Bulletin 2094 common-bus follower IAM module.

Figure 50 - Typical DC Common-bus Configuration

96 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

Connecting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 5

IMPORTANT

Common Bus Fusing Requirements

When using a Bulletin 2094 leader IAM power module, DC-bus fuses are required only when wiring to more than one Bulletin 2094 follower IAM module. When wiring multiple follower IAM modules, terminal blocks are required to extend the DC common-bus power to additional drives. You should install fuses in both lines of the DC bus between the DC bus terminal block and each follower IAM module. These fuses should be rated based on the DC input current of each follower IAM module.

When using a non-Bulletin 2094 common-bus leader drive, DC bus fuses are required in both lines of the DC bus, between the common-bus leader drive and follower IAM module. These fuses should be rated based on the common-bus leader drive DC output current. When using more than one follower IAM module, fuses should be installed in both lines of the DC bus between the nonBulletin 2094 common-bus leader and the terminal block as well as between the DC bus terminal block and each follower IAM module.

Setting the Ground Jumper in Ungrounded Power Configurations

Refer to Circuit Breaker/Fuse Options on page 30 breaker/fuse sizes. Refer to DC Common Bus Wiring Examples on page 237 interconnect diagrams.

Setting the ground jumper is necessary only when using an ungrounded or highimpedance grounded power configuration. Setting the jumper involves removing the IAM power module from the power rail, opening the IAM module, and moving the jumper.

If you have grounded power distribution, you do not need to set the ground jumper. Go to Grounding the Modular Drive System on page 100

Setting the ground jumper is best done when the IAM power module is removed from the power rail and placed face-up on a solid surface equipped as a grounded static-safe workstation.

ATT EN TI ON : To avoid personal injury and/or damage to equipment, remove the IAM module from the power rail before setting the ground jumper.

By setting the ground jumper for ungrounded power configurations, you no longer maintain line-to-neutral voltage protection.

, for recommended circuit

for

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Chapter 5 Connecting the Kinetix 6200 and Kinetix 6500 Drive System

IMPORTANT

To remove the IAM power module from the power rail, refer to Remove Kinetix 6200 and Kinetix 6500 Drive Modules on page 224

When using ungrounded input power in common-bus configurations, use this table to determine where to set the ground jumper.

Table 48 - Ground Jumper to Set

Leader Drive Follower Drive Set the Jumper in This Drive

Kinetix 6200/6500 IAM power module

Non-Kinetix 6200/6500 drive

ATT EN TI ON : This drive contains electrostatic discharge (ESD) sensitive parts and assemblies. You are required to follow static-control precautions when you install, test, service, or repair this assembly. If you do not follow ESD control procedures, components can be damaged. If you are not familiar with static control procedures, refer to Guarding Against Electrostatic Damage, publication

8000-4.5.2

, or any other applicable ESD awareness handbook.

Kinetix 6200/6500 IAM power module

Non-Kinetix 6200/6500 drive Leader drive

Kinetix 6200/6500 IAM power module

Leader dri ve

Follower drive (if no setting exists in the leader drive)

Set the Ground Jumper

Follow these steps to set the ground jumper for ungrounded power.

1. Remove the top and bottom front-panel screws.

Refer to the figure on page 99

2. Swing the front panel open to the right, as shown, and locate the ground jumper.

Do not attempt to remove the front panel from the IAM module. The front panel status indicators and switches are also connected to the IAM module with a ribbon cable. The ribbon cable will act like a hinge and let you swing the front panel open and access the ground jumper.

for an illustration of your actual hardware.

98 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

3. Move the ground jumper.

P16

P18

P17

(behind P18)

P19

P18

P19

Bottom Screw

Front Panel

(removed)

Ground jumper set

for grounded configuration

(default setting).

Ground jumper set for ungrounded configuration.

Top Scre w

2094-BC01-MP5-M, 2094-BC01-M01-M, 2094-BC02-M02-M, 2094-BC04-M03-M, or 2094-BC07-M05-M IAM Power Module (460V)

Removable Jumper

IMPORTANT

Connecting the Kinetix 6200 and Kinetix 6500 Drive System Chapter 5

IAM Module

2094-BC01-MP5-M (460V)

2094-BC01-M01-M (460V)

2094-BC02-M02-M (460V)

2094-BC04-M03-M (460V)

2094-BC07-M05-M (460V)

Grounded (default) Ungrounded

P16 and P17 P18 and P19

Configuration

4. Replace the IAM module front panel and two screws.

Apply 1.6 N•m (14 lb•in) torque.

5. Mount the IAM module back on the power rail.

Refer to Replace Kinetix 6200 and Kinetix 6500 Drive Modules on

page 227

Figure 51 - Setting the Ground Jumper (460V IAM power modules)

Use the default jumper setting for grounded power configurations. Move the jumper, as shown above, for ungrounded power.

Rockwell Automation Publication 2094-UM002E-EN-P - May 2012 99

Chapter 5 Connecting the Kinetix 6200 and Kinetix 6500 Drive System

LIM

PRS

LIM

PR/PRS

LIM

PRS

LIM

PRS

Ground Grid or Power Distribution Ground

Bonded Cabinet Ground Bus

Braided

Ground Strap

2094 Power Rail

(2094-PRSx shown)

Bonded Cabinet Ground Bus

2094 Power Rail

on 2094 Mounting Brackets

(2094-PRSx shown)

Line Interface Module on 2094 Mounting Brackets (2094-ALxxS shown)

Ground Grid or Power Distribution Ground

Braided

Ground Strap

Braided Ground Strap

Ground Stud

2094 Mounting Bracket (2094-XNBRKT-1)

Grounding the Modular Drive System

All equipment and components of a machine or process system should have a common earth ground point connected to chassis. A grounded system provides a ground path for short circuit protection. Grounding your modules and panels minimize shock hazard to personnel and damage to equipment caused by short circuits, transient overvoltages, and accidental connection of energized conductors to the equipment chassis.

ATT EN TI ON : The National Electrical Code contains grounding requirements, conventions, and definitions. Follow all applicable local codes and regulations to safely ground your system. For CE grounding requirements, refer to Agency Compliance on page 25

Ground the Power Rail to the System Subpanel

The 2094-PRx and 2094-PRSx power rail ships with a braided ground strap, 100 mm (3.9 in.), that connects to the bonded cabinet ground bus. Connect the other end to either the power rail ground stud or mounting bracket ground stud, if mounting brackets are used.

Figure 52 - Connecting the Braided Ground Strap Examples

100 Rockwell Automation Publication 2094-UM002E-EN-P - May 2012

For power rail dimensions, refer to the Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003

Rockwell Automation 2094-EN02D-M01-Sx User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

New and Updated Information

Table of Contents

Preface

About This Publication

Who Should Use This Manual

Conventions Used in This Manual

Additional Resources

About the Kinetix 6200 and Kinetix 6500 Drive Systems

Typical Hardware Configurations

Typical Communication Configurations

Catalog Number Explanation

Kinetix Drive Component Compatibility

Kinetix 6000M Integrated Drive-Motor System Compatibility

Agency Compliance

CE Requirements (system without LIM module)

CE Requirements (system with LIM module)

System Design Guidelines

System Mounting Requirements

Transformer Selection

Circuit Breaker/Fuse Options

Circuit Breaker and Fuse Specifications

Enclosure Selection

Minimum Clearance Requirements

Electrical Noise Reduction

Bonding Modules

Bonding Multiple Subpanels

Establishing Noise Zones

Cable Categories for Kinetix 6200 and Kinetix 6500 Systems

Noise Reduction Guidelines for Drive Accessories

AC Line Filters

External Shunt Modules

Resistive Brake Modules

Motor Brake and Thermal Switch

Before You Begin

Using the 2094 Mounting Brackets

Installing the 2094 Power Rail

Determine Mounting Order

Mount Modules on the Power Rail

Mount the Control Modules

2094 Power Module and Control Module Features

I/O, Safety, and Auxiliary Feedback Connector Pinout

Motor Feedback Connector Pinout

Ethernet Communication Connector Pinout

IAM Input Connector Pinout

IAM and AM Motor Power and Brake Connector Pinout

Control Signal Specifications

Digital Inputs

Ethernet Communication Specifications

Sercos Communication Specifications

Contactor Enable Relay

Power and Relay Specifications

Motor/Resistive Brake Relay

Input Power Cycle Capability

Peak Current Specifications

Control Power

Feedback Specifications

Absolute Position Feature

Motor Feedback Specifications

Auxiliary Position Feedback Specifications

Safe Speed Monitoring Safety Features

Safe Torque-off Safety Features

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 Modular Drive System

Ground the Power Rail to the System Subpanel