Rockwell Automation 2094-xMxx-S User Manual

Page 1

User Manual

Kinetix 6000 Multi-axis Servo Drives

Catalog Numbers 2094-ACxx-Mxx-S, 2094-BCxx-Mxx-S, 2094-AMxx-S, 2094-BMxx-S 2094-ACxx-Mxx, 2094-BCxx-Mxx, 2094-AMxx, 2094-BMxx, 2094-BSP2, 2094-PRF, 2094-SEPM-B24-S

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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, DriveExplorer, Guardmaster, HPK-Series, Integrated Architecture, Kinetix, LDC-Series, LDL-Series, Logix5000, MP-Series, RSLinx, RSLogix, SCANport, SoftLogix, RDD-Series, Rockwell Automation, Rockwell Software, Studio 5000, TechConnect, and TL-Series are trademarks of Rockwell Automation, Inc.

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

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This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table contains the changes made to this revision.

Top ic Pa ge

Studio 5000™ Logix Designer application is the rebranding of RSLogix™ 5000 software. General references to RSLogix 5000 software have been replaced by the Logix Designer application. References to specific RSLogix 5000 software versions did not change.

Updated references to safe-off (SO) as safe torque-off (STO), per EN61800-5-2.

Updated references to series A and B drives. The 230V drive modules previously labeled as series A are now series A and C. The 460V drives previously labeled as series B are now series B and C.

Added LDAT-Series linear thrusters to system overview table. 16

Added LDAT-Series linear thrusters to typical system installation diagrams. 17…18

Updated System Mounting Requirements for enclosure rating from IP2x to IP54. 26

Added AC line filter selection table. 27

Updated safe torque-off (STO) connector pinout table with series C descriptions for safety enable inputs.

Updated motor/resistive brake circuitry diagram and text with changes for the new solid-state relay. 71

Added the LDAT-Series linear thruster interconnect diagram with Kinetix® 6000 drive. 207

Added the Configure the Load Observer Feature appendix. 235

Throughout this manual

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 3

Page 4

Summary of Changes

Notes:

4 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Preface

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

Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

Chapter 1

Start

Planning the Kinetix 6000 Drive System Installation

IAM/AM Module Series Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

About the Kinetix 6000 Drive Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Typical Hardware Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Typical Communication Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Kinetix Drive Component Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Kinetix 6000M Integrated Drive-Motor System Compatibility . . . . . . 23

Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

CE Requirements (system without LIM module) . . . . . . . . . . . . . . . 24

CE Requirements (system with LIM module). . . . . . . . . . . . . . . . . . . 24

Chapter 2

System Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

System Mounting Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

AC Line Filter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Circuit Breaker/Fuse Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Enclosure Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Minimum Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Electrical Noise Reduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Bonding Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Bonding Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Establishing Noise Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cable Categories for Kinetix 6000 Systems . . . . . . . . . . . . . . . . . . . . . 45

Noise Reduction Guidelines for Drive Accessories. . . . . . . . . . . . . . . 47

Mounting the Kinetix 6000 Drive System

Chapter 3

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Using the 2094 Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Installing the 2094 Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Determine Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Mount Modules on the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 5

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Table of Contents

Chapter 4 Connector Data and Feature Descriptions

2094 IAM/AM Module Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Safe Torque-off Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Motor Feedback Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Auxiliary Feedback Connector Pinout. . . . . . . . . . . . . . . . . . . . . . . . . . 64

IAM Input Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

IAM and AM Motor Power and Brake Connector Pinout. . . . . . . . 66

Control Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Sercos Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Contactor Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Power and Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Motor/Resistive Brake Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Input Power Cycle Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Peak Enhancement Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Absolute Position Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Motor Feedback Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Feedback Power Supply Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 79

Auxiliary Position Feedback Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Connecting the Kinetix 6000 Drive System

Chapter 5

Basic Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Building Your Own Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Routing the Power and Signal Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Determine the Input Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 83

Grounded Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Ungrounded and High-impedance Grounded

Power Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

DC Common Bus Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Common Bus Fusing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Setting the Ground Jumper in Ungrounded Power Configurations . . . 87

Set the Ground Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Grounding the Kinetix 6000 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . 93

Ground the Power Rail to the System Subpanel . . . . . . . . . . . . . . . . . 93

Ground Multiple Subpanels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Power Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Power Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Wiring the IAM/AM Module Connectors . . . . . . . . . . . . . . . . . . . . . . . . . 98

Wire the Control Power (CPD) Connector . . . . . . . . . . . . . . . . . . . . 98

Wire the Input Power (IPD) Connector. . . . . . . . . . . . . . . . . . . . . . . . 99

Wire the Contactor Enable (CED) Connector. . . . . . . . . . . . . . . . . 101

Wiring the Safe Torque-off (STO) Connector . . . . . . . . . . . . . . . . . 102

6 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Configure and Start the Kinetix 6000 Drive System

Table of Contents

Wire the Motor Power (MP) Connector . . . . . . . . . . . . . . . . . . . . . . 103

Wire the Motor/Resistive Brake (BC) Connector. . . . . . . . . . . . . . 111

Apply the Motor Cable Shield Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Feedback and I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Flying-lead Feedback Cable Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Wiring the Feedback and I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . 120

Connect Premolded Motor Feedback Cables . . . . . . . . . . . . . . . . . . 120

Connect Panel-mounted Breakout Board Kits . . . . . . . . . . . . . . . . . 121

Wire Low-profile Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

External Shunt Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

IPIM Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

RBM Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Sercos Fiber-optic Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Kinetix 6000M Integrated Drive-Motor Sercos Connections . . . . . . . 131

Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Chapter 6

Configure the Kinetix 6000M Integrated Drive-Motor System . . . . . 133

Configure the Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Configure the Logix5000 Sercos interface Module . . . . . . . . . . . . . . . . . 140

Configure the Logix5000 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . 140

Configure the Logix5000 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Configure the Kinetix 6000 Drive Modules. . . . . . . . . . . . . . . . . . . . 144

Configure the Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Configure Axis Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Apply Power to the Kinetix 6000 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Test and Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Tune the Axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Configure Drive Parameters and System Variables . . . . . . . . . . . . . . . . . 160

Tools for Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Monitor System Variables with Analog Test Points . . . . . . . . . . . . 161

Troubleshooting the Kinetix 6000 Drive System

Chapter 7

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Kinetix 6000M IDM System Error Codes . . . . . . . . . . . . . . . . . . . . . 164

Kinetix 6000 Drive System Error Codes. . . . . . . . . . . . . . . . . . . . . . . 165

IAM/AM Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Shunt Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

General System Anomalies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Logix5000/Drive Fault Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 7

Page 8

Table of Contents

Chapter 8 Removing and Replacing the Kinetix 6000 Drive Modules

Interconnect Diagrams

Upgrading the Drive Firmware

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Remove Kinetix 6000 Drive Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Replace Kinetix 6000 Drive Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Remove the Power Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Replace the Power Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Appendix A

Interconnect Diagram Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Power Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

DC Common Bus Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Shunt Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Axis Module/Rotary Motor Wiring Examples . . . . . . . . . . . . . . . . . . . . . 196

Axis Module/Linear Motor/Actuator Wiring Examples . . . . . . . . . . . . 205

Kinetix 6000M Integrated Drive-Motor Wiring Example. . . . . . . . . . . 210

Controlling a Brake Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

System Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Appendix B

Upgrade Kinetix 6000M System Firmware . . . . . . . . . . . . . . . . . . . . . . . . 215

Upgrade Drive Firmware with ControlFLASH Software . . . . . . . . . . . 216

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Configure Logix5000 Communication . . . . . . . . . . . . . . . . . . . . . . . . 217

Upgrade Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Verify the Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

DC Common Bus Applications

Appendix C

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Calculate Total Bus Capacitance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Calculate Additional Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Bulletin 2094 Drive Capacitance Values. . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Common Bus Capacitance Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Set the Additional Bus Capacitance Parameter . . . . . . . . . . . . . . . . . . . . . 229

Remove Sercos Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Set the Additional Bus Capacitance Parameter . . . . . . . . . . . . . . . . . 230

Save the Add Bus Cap Parameter to Nonvolatile Memory. . . . . . . 231

Verify the Parameter Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Reconnect Sercos Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

8 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 9

Appendix D

Table of Contents

Configure the Load Observer Feature

Changing the Default IDN Parameter Values

Enhanced Peak Performance

Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Out-of-Box Gain Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Auto-tune Gain Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Tuning Mode Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Manual Tuning for Further Optimization . . . . . . . . . . . . . . . . . . . . . 244

Setting Gains with Sercos IDN Write Messages. . . . . . . . . . . . . . . . . . . . 246

Compensate for High Frequency Resonances. . . . . . . . . . . . . . . . . . . . . . 247

Appendix E

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Change IDN Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Read the Present IDN Parameter Value . . . . . . . . . . . . . . . . . . . . . . . 250

Calculate the New IDN Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Write the New IDN Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . 253

Appendix F

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Enhanced Peak Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Enhanced Peak Example Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . 260

Change the Drive Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Sercos IDN Write Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

DriveExplorer Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

RBM Module Interconnect Diagrams

Appendix G

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

RBM Module Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Index

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 9

Page 10

Table of Contents

Notes:

10 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 11

Preface

IMPORTANT

About This Publication

Audience

Conventions Used in This Manual

This manual provides detailed installation instructions for mounting, wiring, and troubleshooting Kinetix 6000 drives; and system integration for your drive and motor/actuator combination with a Logix controller.

For information on wiring and troubleshooting your Kinetix 6000 servo drive with the safe torque-off feature, refer to the Kinetix Safe Torque-off Feature Safety Reference Manual, publication GMC-RM002

This manual is intended for engineers or technicians directly involved in the installation and wiring of the Kinetix 6000 drives; and programmers directly involved in the operation, field maintenance, and integration of these drives with a sercos interface module.

If you do not have a basic understanding of the Kinetix 6000 drives, contact your local Rockwell Automation sales representative for information on available training courses.

The conventions starting below are used throughout this manual.

• Bulleted lists such as this one provide information, not procedural steps.

• Numbered lists provide sequential steps or hierarchical information.

• Acronyms for the Kinetix 6000 drive modules are shown in the table

below and are used throughout this manual.

Kinetix 6000 Drive Modules Cat. No. Acronym

Integrated Axis Module 2094-xCxx-Mxx-x IAM

Axis Module 2094-xMxx-x AM

Line Interface Module 2094-xLxx and 2094-xLxxS-xx LIM

Resistive Brake Module 2090-XBxx-xx RBM

Kinetix 6000M Drive Modules Cat. No. Acronym

Integrated Drive-Motor MDF-SBxxxxx IDM

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

Throughout this publication, when the IAM or AM module catalog number is followed by -x, for example 2094-BMP5-x, the variable (x) indicates that the drive module may or may not include the safe torque-off feature.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 11

Page 12

Preface

Studio 5000 Environment

The Studio 5000 Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Logix Designer application is the rebranding of RSLogix 5000 software and will continue to be the product to program Logix5000 controllers for discrete, process, batch, motion, safety, and drive-based solutions.

The Studio 5000 environment is the foundation for the future of Rockwell Automation® engineering design tools and capabilities. It is the one place for design engineers to develop all the elements of their control system.

Additional Resources

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

Table 1 - Additional Resources

Resource Description

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 2090-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 Safe Torque-off Feature Safety Reference Manual, publication GMC-RM002

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

Provides information on the installation of Bulletin 2094 mounting brackets.

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

Provides information on proper handling, installing, testing, and troubleshooting fiberoptic cables.

Provides information on mounting and wiring the Bulletin 1394 shunt modules with Bulletin 2094 servo drive systems.

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

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

Provides information on wiring and troubleshooting your Kinetix 6000 servo drives with the safe torque-off feature.

12 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 13

Table 1 - Additional Resources (continued)

Resource Description

Kinetix Motion Control Selection Guide, publication GMC-SG001

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

Kinetix Rotary Motion Specifications Technical Data, publication GMC-TD001

Kinetix Linear Motion Specifications Technical Data, publication GMC-TD002

Kinetix Servo Drives Specifications Technical Data, publication GMC-TD003

Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004

Download Motion Analyzer software from:

http://www.ab.rockwellautomation.com/motion-control/motion-analyzer-software

Rockwell Automation Configuration and Selection Tools, website http://www.ab.com

Rockwell Automation Product Certification, website http://www.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 Provides information on configuring and troubleshooting SoftLogix PCI cards.

ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-QS105 For ControlFLASH™ information not specific to any drive family.

National Electrical Code, published by the National Fire Protection Association of Boston, MA

Rockwell Automatio n Industrial Automation Glossary, publication AG-7 .1

Provides 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.

Provides information to determine and 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. Includes system performance specifications and torque/speed cur ves (rotary motion) and force/velocity cur ves (linear motion) for your motion application.

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

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

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

Provides product specifications for Bulletin 2090 motor and interface cables, low-profile connector kits, drive power components, and other servo drive accessory items.

Comprehensive motion application sizing tool used for analysis, optimization, selection, and validation of your Kinetix Motion Control system.

Provides online product selection and system configuration tools, including AutoCad (DXF) drawings.

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

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

Provides information to create a motion coordinate system with sercos or analog motion modules.

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

An article on wire sizes and types for grounding electrical equipment.

A glossary of industrial automation terms and abbreviations.

Preface

You can view or download publications at

http://www.rockwellautomation.com/literature

. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 13

Page 14

Preface

Notes:

14 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 15

Chapter 1

IMPORTANT

Start

Use this chapter to become familiar with the design and installation requirements for Kinetix 6000 drive systems.

Top ic Pa ge

IAM/AM Module Series Changes 15

About the Kinetix 6000 Drive Systems 16

Typical Ha rdware Configurations 17

Typical Communication Configurations 21

Catalog Number Explanation 22

Kinetix Drive Component Compatibility 23

Kinetix 6000M Integrated Drive-Motor System Compatibility 23

Agenc y Compliance 24

IAM/AM Module Series Changes

Before your drive can deliver enhanced peak performance, you must enable the peak enhancement feature by configuring your drive with DriveExplorer™ software or the Logix Designer application.

Refer to Appendix appropriate Axis Properties dialog box in the Logix Designer application.

For more information on setting axis properties, refer to Configure Axis Properties on page 149

Series B drives included the peak current enhancement and applied to only the 460V (series A) IAM and AM modules. The peak current ratings of the Kinetix 6000 (460V) drives are configured at the factory as 150% of continuous current. However, you can program 460V AM modules and the equivalent IAM (inverter) modules, for up to 250% of continuous inverter current.

Table 2 - Kinetix 6000 Enhanced Peak Performance Series Change

IAM Module Cat. No.

2094-BC01-MP5-S 2094-BMP5-S 150% 250%

2094-BC01-M01-S 2094-BM01-S 150% 250%

2094-BC02-M02-S 2094-BM02-S 150% 250%

2094-BC04-M03-S 2094-BM03-S 150% 250%

2094-BC07-M05-S 2094-BM05-S 150% 200%

AM Module Cat. No.

Series A (inverter) Series B and C (inverter)

Peak Current Rating

F on page 255 to recalculate torque and acceleration or deceleration limit values, and paste them into the

In series C drives, a mechanical relay for the brake circuit and another for the safe torque-off inputs are replaced by solid-state relays and apply to the 230V (series A) and 460V (series B) IAM and AM modules. All wiring is consistent with previous series releases.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 15

Page 16

Chapter 1 Start

About the Kinetix 6000 Drive Systems

The Kinetix 6000 multi-axis servo drives are designed to provide a Kinetix Integrated Motion solution for your drive/motor/actuator applications.

Table 3 - Kinetix 6000 Drive System Overview

System Component

Integrated Axis Module

Axis 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

Slot-filler Module

Logix5000™ Controllers

Studio 5000 Environment

Rotary Servo Motors

Linear Motors LDC-Series, LDL-Series Compatible motors include LDC-Series iron core (200V and 400V-class) and LDL-Series ironless (200V-class) linear motors.

Linear Actuators

Cables

AC Line Filters 2090-XXLF-xxxx Bulletin 2090-XXLF-xxxx three-phase AC line filters are required to meet CE in all 200V and 400V-class drive systems.

Line Interface Modules

External Shunt Modules

Resistive Brake Module

Cat. No. Description

2094-xCxx-Mxx-S

2094-xCxx-Mxx

2094-xMxx-S

2094-xMxx

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-RLD300xxE

MP-Series, TL-Series, RDD-Series, 1326AB, F-Series

MP-Series

LDAT-Series LDAT-Series integrated linear actuators are compatible with 200V and 400V-class drive systems.

2090-Series motor/actuator cables

Kinetix 6000M integrated drive-motor cables

Communication

2094-xLxx 2094-xLxxS 2094-XL75S-Cx

1394-SRxxxx

2090-XBxx-xx

(1) (2)

Integrated Axis Modules (IAM) with the safe torque-off fea ture with 200V or 400V-c lass AC input power. Contains an inver ter and converter section. The peak enhancement feature is available on 400V-class (series B and C) IAM modules.

Integrated Axis Modules (IAM), with 200V or 400V-class AC input power (does not include the safe torque-off or peak-enhanced feature). Contains an inverter and converter section.

Axis Modules (AM) with safe torque-off are shared DC-bus inverters and rated for 200 or 400V-class operation. The AM module must be used with an IAM module. The peak enhancement feature is available on 400V-class (series B and C) AM mo dules.

Axis Modules (AM) are shared DC-bus inverters rated for 200V or 400V-class input power (does not include the safe torque-off or peak-enhanced feature). The AM module must be used with an IAM 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 controllers and the Kinetix 6000 drive system. The communication link uses the IEC 61491 SErial Real-time COmmunication System (sercos) protocol over a fiber-optic cable.

The Kinetix 6000M IPIM module connects to the EtherNet/IP network for monitoring, diagnostics, and firmware upgrades.

The Logix Designer application provides support for programming, commissioning, and maintaining the Logix5000 family of controllers.

Compatible rotary motors include the MP-Series (Bulletin MPL, MPM, MPF, and MPS) 200V and 400V-class motors; RDD-Series; TL-Series; 1326AB (M2L/S2L) and 1326AB (resolver); and F-Series motors.

Compatible actuators include MP-Series (200V and 400V-class) Bulletin MPAS single-axis and Bulletin MPMA multi-axis integrated linear stages, and MP-Series (200V and 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 straig ht connectors that connec t to servo motors. Feedback cables have flying leads that wire to low-profile connector kits on the drive end and straight connectors on the motor end.

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.

letin 2090 ser

Bul

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

Line interface modules (LIM) include the circuit breakers, AC line filter (catalog numbers 2094-AL09 and 2094-BL02 only), power supplies, and safety contactor required for Kinetix 6000 operation. The LIM module does not mount to the power rail. You can purchase individual components separately in place of the LIM module.

You can use Bulletin 1394 external passive shunt modules when the IAM/AM 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 ma gnet motor brought to an immediate stop. This module does not mount to the power rail.

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

(1) Refer to the Kinetix Safe Torque-off Feature Safety Reference Manual, publication GMC-RM002, for more information. (2) Refer to Peak Enhancement Specifications on page 73

16 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

for more information on drive performance in the Peak-enhanced mode.

Page 17

Start Chapter 1

MAIN VAC

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

SERIES A

www.ab.com

MADE IN USA

Kinetix 6000 Multi-axis Servo Drive System

2094-xLxxS Line Interface Module (optional component)

2094-xMxx-S Axis Modules (5)

Three-Phase

Input Power

2094-xCxx-Mxx-S

IAM Module

2094-BSP2 Shunt Module (optional component)

2090-XXLF-xxxx

AC Lin e Filter

(required for CE)

2094-PRSx

Power Rail

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

I/O Connections

To I np ut S en sor s

and Control String

115/230V

Control Power

2090-K6CK-Dxxx

Low Profile Connector Kits for

I/O, Motor Feedback, and Aux Feedback

Bulletin 2090

Motor Feedback Cables

Bulletin 2090

Motor Power Cables

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

MP-Series and TL-Series Rotary Motors

(MPL-Bxxxx motors shown)

MP-Series Electric Cylinders (MPAR-Bxxxx electric cylinder shown)

LDC-Series Linear Motors

(LDC-Cxxxxxxx linear motor shown)

RDD-Series Direct Drive Motors

(1)

(RDB-Bxxxx motor shown)

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

LDL-Series Linear Motors

(LDL-xxxxxxxx linear motor shown)

LDAT-Series Linear Thrusters

(LDL-Sxxxxxx-xBx linear thrusters only)

Typical Hardware Configurations

Typical Kinetix 6000 system installations include three-phase AC configurations, with and without the line interface module (LIM), and DC common-bus configurations.

SHOCK HAZARD: To avoid personal injury due to electrical shock, place a 2094-PRF slot-filler module in all empty slots on the power rail. Any power rail connector without a module installed disables the Bulletin 2094 system; however, control power is still present.

Figure 1 - Typical Kinetix 6000 System Installation (with LIM)

(1) RDD-Series direct-drive motors require the 2090-K6CK-KENDAT low-profile feedback module.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 17

Page 18

Kinetix 6000 Multi-axis Servo Drive System

Line Disconnect Device

Magnetic Contac tor

Input Fusing

Three-phase Input Power

Single-phase

Control Power

2094-xCxx-Mxx-S

IAM Module

2094-PRSx

Power Rail

I/O Connections

To I np ut S en sor s

and Control String

2094-xMxx-S Axis Modules (5)

2094-BSP2 Shunt Module (optional component)

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

2090-K6CK-Dxxx

Low Profile Connector Kits for

I/O, Motor Feedback, and Aux Feedback

2090-XXLF-xxxx

AC Lin e Filter

(required for CE)

MP-Series and TL-Series Rotary Motors

(MPL-xxxx motors shown)

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

Bulletin 2090

Motor Feedback Cables

Bulletin 2090

Motor Power Cables

MP-Series Electric Cylinders (MPAR-Bxxxx electric cylinder shown)

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

RDD-Series Direct Drive Motors

(1)

(RDB-Bxxxx motor shown)

LDC-Series Linear Motors

(LDC-Cxxxxxxx linear motor shown)

LDL-Series Linear Motors

(LDL-xxxxxxxx linear motor shown)

2090-XXLF-xxxx

AC Lin e Filter

(required for CE)

LDAT-Series Linear Thrusters

(LDL-Sxxxxxx-xBx linear thrusters only)

Chapter 1 Start

Figure 2 - Typical Kinetix 6000 System Installation (without LIM)

www.ab.com

MADE IN USA

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

SERIES A

(1) RDD-Series direct-drive motors require the 2090-K6CK-KENDAT low-profile feedback module.

18 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 19

Start Chapter 1

Three-phase Input Power

Kinetix 6000 Multi-axis

Servo Drive System

2094-BSP2 Shunt Module (optional component)

2094-SEPM-B24-S IPIM Module

2094-PRSx Power Rai l

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,

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-UM001H-EN-P - June 2013 19

Page 20

Chapter 1 Start

Kinetix 6000 Multi-axis Servo Drive System

Three-p hase Input Power

115/230V Control Power

2094-BCxx-Mxx-S

IAM Module

Common Bus Leader

2094-PRSx

Power Rail

2094-BMxx-S Axis Modules (5)

2094-BSP2 Shunt Module (optional component)

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

2094-BCxx-Mxx-S

IAM Module

Common Bus Follower

2094-PRSx

Power Rail

2094-BMxx-S Axis Modules (5)

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

2094-BLxxS Line Interface Module (optional component)

DC Common Bus

2090-XXLF-xxxx

AC Lin e Filter

(required for CE)

2094-SEPM-B24-S IPIM Module

IMPORTANT

Figure 4 - Typical (400V-class) 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 C

page 225,

for more information.

If total bus capacitance of your system exceeds the leader IAM module precharge rating and input power is applied, the IAM module seven-segment status indicator displays error code E90 (pre-charge timeout fault).

, beginning on

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

20 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 21

Start Chapter 1

SERCOS interface

Tx (rear)

Rx (front)

0.2 m

(7.1 in.)

0.1 m

(5.1 in.)

0.1 m

(5.1 in.)

62006200

SAFE SPEED

62006200

SAFE SPEED

0.1 m

(5.1 in.)

0.2 m

(7.1 in.)

TX RX

Logix5000 Sercos interface Module

Logix5000 Controller (ControlLogix controller is shown)

The Logix Designer

Application

2090-SCxxx-x

Sercos Fiber-optic Cable

Logix5000 Controller Programming Network

2094-xMxx-S Axis Modules (5)

2094-xCxx-Mxx-S

IAM Module

0.1 m (5.1 in.)

Kinetix 6000 Drive-to-Drive Sercos Cables

Kinetix 6000 Single-wide

2094-BCxx-Mxx-S

IAM Module

Kinetix 6000 Double-wide

2094-BCxx-Mxx-S

IAM Module

2094-BMxx-S Single-wide AM Module

2094-BMxx-S Double-wide AM Module

2094-BMxx-M Single-wide AM Power Modules

with 2094-SE02F-M00-Sx Control Modules

2094-SEPM-B24-S IPIM Module

2094-BMxx-S Single-wide AM Module

Kinetix 6200 (top view) Sercos Connectors

Kinetix 6000 and

Kinetix 6000M (top view)

Sercos Connectors

2094-PRSx

Power Rail

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 Logix5000 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-UM001H-EN-P - June 2013 21

Page 22

Chapter 1 Start

IMPORTANT

Catalog Number Explanation

Integrated Axis Modules (230V)

Kinetix 6000, IAM, 200V-class, 3 kW conver ter, 5 A inverter 2094-AC05-MP5-S 2094-AC05-MP5

Kinetix 6000, IAM, 200V-class, 3 kW converter, 9 A inverter 2094-AC05-M01-S 2094-AC05-M01

Kinetix 6000, IAM, 200V-class, 6 kW converter, 15 A inverter 2094-AC09-M02-S 2094-AC09-M02

Kinetix 6000, IAM, 200V-class, 11 kW converter, 24 A inverter 2094-AC16-M03-S 2094-AC16-M03

Kinetix 6000, IAM, 200V-class, 23 kW converter, 49 A inverter 2094-AC32-M05-S 2094-AC32-M05

Integrated Axis Modules (460V)

Kinetix 6000, IAM, 400V-class, 6 kW conver ter, 4 A inver ter 2094-BC01-MP5-S

Kinetix 6000, IAM, 400V-class, 6 kW conver ter, 9 A inver ter 2094-BC01-M01-S

Kinetix 6000, IAM, 400V-class, 15 kW converter, 15 A inverter 2094-BC02-M02-S

Kinetix 6000, IAM, 400V-class, 28 kW converter, 30 A inverter 2094-BC04-M03-S

Kinetix 6000, IAM, 400V-class, 45 kW converter, 49 A inverter 2094-BC07-M05-S

Axis Modules (230V)

Kinetix 6000, AM, 200V-class, 5 A 2094-AMP5-S 2094-AMP5

Kinetix 6000, AM, 200V-class, 9 A 2094-AM01-S 2094-AM01

Kinetix 6000, AM, 200V-class, 15 A 2094-AM02-S 2094-AM02

Kinetix 6000, AM, 200V-class, 24 A 2094-AM03-S 2094-AM03

Kinetix 6000, AM, 200V-class, 49 A 2094-AM05-S 2094-AM05

Axis Modules (460V)

Kinetix 6000, AM, 400V-class, 4 A 2094-BMP5-S

Kinetix 6000, AM, 400V-class, 9 A 2094-BM01-S

Kinetix 6000, AM, 400V-class, 15 A 2094-BM02-S

Kinetix 6000, AM, 400V-class, 30 A 2094-BM03-S

Kinetix 6000, AM, 400V-class, 49 A 2094-BM05-S

Kinetix 6000 (Bulletin 2094) drive catalog numbers and descriptions are listed in the tables below.

Table 4 - Kinetix 6000 Drive Catalog Numbers

Cat. No. (with safe torque-off feature)

(1)

(2)

(1)

(2)

Cat. No. (without safe torque-o ff feature)

2094-BC01-MP5

2094-BC01-M01

2094-BC02-M02

2094-BC04-M03

2094-BC07-M05

2094-BMP5

2094-BM01

2094-BM02

2094-BM03

2094-BM05

(1) You can configure the peak inver ter current rating of this 46 0V (series B and C) IAM or AM module for 250% of continuous inverter current. (2) You can configure the peak inver ter current rating of this 46 0V (series B and C) IAM or AM module for 200% of continuous inverter current. Refer to Peak Enhancement

Specifications on page 73, for more information on drive performance in the peak-enhanced mode.

Table 5 - Kinetix 6000 Drive Component Catalog Numbers

Drive Components Cat. No.

Integrated power inter face (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

22 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Start Chapter 1

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 6 - 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-M (IAM) and 2094-BMxx-M (AM) modules, refer to the Kinetix 6200 and Kinetix 6500 Multi-axis Servo Drives User Manual, publication 2094-UM002

Bulletin 2094 power rails with Kinetix 6000 (series B and C) 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 7 - IPIM Module Compatibility

IAM Module Control Module

2094-BCxx-Mxx-S (series B and C)

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

N/A

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

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 23

Page 24

Chapter 1 Start

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 can cause damage to the filter. For grounding examples, refer to Grounded Power Configurations on page 83

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 6000 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 6000 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 or 160 m (525 ft) with 200V-class systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft).

• Use 2090 series motor feedback cables or use connector kits and properly terminate the feedback cable shield. Drive-to-motor feedback cables must not exceed 90 m (295.5 ft).

• Install the Kinetix 6000 system inside an enclosure. Run input power wiring in conduit (grounded to the enclosure) outside of the enclosure. Separate signal and power cables.

Refer to Appendix power wiring and drive/motor interconnect diagrams.

A on page 185 for interconnect diagrams, including input

CE Requirements (system with LIM module)

To meet CE requirements when your Kinetix 6000 system includes the LIM module, follow all the requirements as stated in CE Requirements (system

without LIM module) and these additional requirements as they apply to the AC

line filter.

• Install the LIM module (catalog numbers 2094-AL09 or 2094-BL02) as close to the IAM module as possible.

• Install the LIM module (catalog numbers 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx) with line filter (catalog number 2090-XXLF-xxxx) as close to the IAM module as possible.

When the LIM module (catalog numbers 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx) supports two IAM modules, each IAM module requires an AC line filter installed as close to the IAM module as possible.

24 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 25

Chapter 2

Planning the Kinetix 6000 Drive System Installation

This chapter describes system installation guidelines used in preparation for mounting your Kinetix 6000 drive components.

Top ic Pa ge

System Design Guidelines 26

Electrical Noise Reduction 34

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-UM001H-EN-P - June 2013 25

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Chapter 2 Planning the Kinetix 6000 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 6000 drive system must be enclosed in a grounded conductive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP54 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 or 160 m (525 ft) with 200V-class systems. Driveto-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.

• 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

26 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 27

Planning the Kinetix 6000 Drive System Installation Chapter 2

IMPORTANT

Transformer Selection

The IAM module does not require an isolation transformer for three-phase input power. However, a transformer can 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 6000 power specifications in the Kinetix Servo Drives Technical Data, publication

GMC-TD003

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

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).

AC Line Filter Selection

These AC line filters are available for your servo drive input power.

Table 8 - Kinetix 6000 (three-phase) AC Line Filter Selection

Drive Cat. No.

2094-AC05-MP5-S

2094-AC09-M02-S

2094-AC16-M03-S 75 5.2 (11.4) 2090-XXLF-375

2094-AC32-M05-S 100 9.5 (20.9) 2090-XXLF-3100

2094-BC01-MP5-S

2094-BC02-M02-S

2094-BC04-M03-S 75 5.2 (11.4) 2090-XXLF-375B

2094-BC07-M05-S 100 9.5 (20.9) 2090-XXLF-3100

Voltag e

500V AC 50/60 Hz

Current

A @ 50 °C (122 °F)

30 2.7 (5.9) 2090-XXLF-X330B2094-AC05-M01-S

30 2.7 (5.9) 2090-XXLF-X330B2094-BC01-M01-S

Refer to the Kinetix Motion Accessories Specifications Technical Data, publication GMC-TD004

, for additional AC line filter specifications.

Weight, a pprox

kg (lb)

AC Line Filter Cat. No.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 27

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Chapter 2 Planning the Kinetix 6000 Drive System Installation

Circuit Breaker/Fuse Options

The 2094-xCxx-Mxx-S and 2094-xMxx-S 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 short-circuit protection and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 200,000 A. Fuses or circuit breakers, with adequate withstand and interrupt ratings, as defined in NEC or applicable local codes, are permitted.

The 2094-AL09 and 2094-BL02 LIM modules contain supplementary protection devices and, when protected by suitable branch circuit protection, are rated for use on a circuit capable of delivering up to 5000 A. When these modules are used, protection on the line side of the LIM module is required. Fuses must be class J or CC only.

The 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-Cx LIM modules contain branch circuit rated devices suitable for use on a circuit capable of delivering up to 65,000 A (400V-class) or 100,000 A (200V-class).

Refer to the Line Interface Module Installation Instructions, publication

2094-IN005

, for power specifications and more information on using the LIM

module.

The Bulletin 140M and 140U products are another acceptable means of protection. As with fuses and circuit breakers, you must make sure that the selected components are properly coordinated and meet applicable codes including any requirements for branch circuit protection. When applying the 140M/140U 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 meets the NEC requirements or applicable local codes, and provide the full drive capabilities. Use dual element, time delay (slow-acting) fuses to avoid nuisance trips during the inrush current of power initialization.

28 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Planning the Kinetix 6000 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-xCxx-Mxx-S IAM modules when the Line Interface Module (LIM) is not used.

LIM Modules (catalog numbers 2094-ALxxS, 2094-BLxxS, and 2094-XL75S-Cx) provide branch circuit protection to the IAM module. Follow all applicable NEC and local codes.

Table 9 - Kinetix 6000 Circuit Breaker and Fuse Selection

V AC Input Power Control Input Power DC Common Bus Fuse

IAM Module Cat. No.

2094-AC05-MP5-S

2094-AC05-M01-S

2094-AC09-M02-S KTK-R-30 (30 A) 1492-SP3D400 140M-F8E-C20 FWH-35B A50P35-4

2094-AC16-M03-S LPJ-45SP (45 A) N/A 140U-H6C3-C50

2094-AC32-M05-S LPJ-80SP (80 A) N/A 140U-H6C3-C90 FWH-125B A50P125-4

2094-BC01-MP5-S

2094-BC01-M01-S

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

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

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

Bussmann Fuse

KTK-R-20 (20 A) 1492-SP3D300 140M-F8E-C16

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)

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

Allen-Bradley

(1)

Circuit Breaker

1492-SP2D060

1492-SP2D200

1492-SP2D060 or 1492-SP1D150

(2)

Bussmann Fuse

N/A A50P20-1

FWH-60B A50P60-4

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, for additional power specifications for your IAM module.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 29

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Chapter 2 Planning the Kinetix 6000 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:

Size the Bulletin 2094 servo drive and LIM module and use the results to predict the amount of heat dissipated into the enclosure. You 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 10 - Bulletin 2094 System Heat Dissipation Example

Enclosure Component Description Loading

2094-BC02-M02-x

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

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

2094-BM01-x 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 6000 system wattage 578

Integrated axis module (IAM), 400/460V

• 6-axis Bulletin 2094 servo drive system

• Line Interface Module (LIM)

• ControlLogix chassis and modules (controller)

(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 Ta bl e 12 on page 32.

30 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Planning the Kinetix 6000 Drive System Installation Chapter 2

75 60 45 30 15 0

0 20 40 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 11 - 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 6 - 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.

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Chapter 2 Planning the Kinetix 6000 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, do not include that portion 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, consider some means of cooling in a smaller cabinet to be more efficient. Contact your cabinet manufacturer for options available to cool your cabinet.

Table 12 - Power Dissipation Specifications

Usage as % of Rated Power Output

Bulletin 2094 Drive Modules

IAM (converter) module

2094-AC05-MP5-S 8 11 15 19 24

2094-AC05-M01-S 9 12 16 20 25

2094-AC09-M02-S 1420283646

2094-AC16-M03-S 1930435874

2094-AC32-M05-S 41 68 100 136 176

2094-BC01-MP5-S

2094-BC01-M01-S 33

2094-BC02-M02-S 3644546475

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

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

IAM (inverter) module or AM module

2094-AC05-MP5-S or 2094-AMP5-S 28 32 37 41 46

2094-AC05-M01-S or 2094-AM01-S 31 38 46 54 62

2094-AC09-M02-S or 2094-AM02-S 34 45 57 70 84

2094-AC16-M03-S or 2094-AM03-S 48 68 91 116 144

2094-AC32-M05-S or 2094-AM05-S 104 156 212 274 342

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

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

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

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

2094-BC07-M05-S or 2094-BM05-S 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.

32 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Planning the Kinetix 6000 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 6000 Drive System

Mounted on 2094 Power Rail

Power Rai l

(2094-PRSx is shown)

50.8 (2.0 in.) clearance below drive for airflow and installation.

Drive Cat. No. Series F

2094-AC05-Mxx-x 2094-AC09-M02-x

A and C

237 mm (9.3) in.

2094-AMP5-x, 2094-AM01-x, 2094-AM02-x

2094-AC16-M03-x 2094-AC32-M05-x

A and C

420 mm (16.5) in.

2094-AM03-x, 2094-AM05-x

2094-BC01-Mxx-x 2094-BC02-M02-x

A, B, and C

287 mm (11.3) in.

2094-BMP5-x, 2094-BM01-x, 2094-BM02-x

2094-SEPM-B24-S 2094-BSP2

2094-BC04-M03-x 2094-BM03-x

A, B, and C

374 mm (14.7) in.

2094-BC07-M05-x 2094-BM05-x

B and C

2094-BC07-M05-x 2094-BM05-x

A and C

436 mm (17.2) in.

Refer to Power Dissipation Specifications on page 32, and

Kinetix Servo Drives Technical Data, publication GMC-TD003

for Kinetix 6000 drive dimensions.

(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.) le ft of the IAM module and right of the last module mounted on the rail.

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 7

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 7 - Minimum Clearance Requirements

Table 13 - Minimum Cabinet Depth

Drive Cat. No. Cabinet Depth, min

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

2094-AC05-Mxx-x, 2094-AC09-M02-x, 2094-AMP5-x, 2094-AM01-x, 2094-AM02-x

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

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

198 mm (7.8 in.)

272 mm (10.7 in.)

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 33

(1)

Drive Cat. No. Cabinet Depth, min

2094-AC16-M03-x, 2094-AC32-M05-x, 2094-AM03-x, 2094-AM05-x

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

198 mm (7.8 in.)

272 mm (10.7 in.)

(1)

Page 34

Chapter 2 Planning the Kinetix 6000 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 6000 system installations. For more information on the concept of high-frequency (HF) bonding, the ground plane principle, and electrical noise reduction, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001

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.

34 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Planning the Kinetix 6000 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 8 - Recommended Bonding Practices for Painted Panels

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 35

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Chapter 2 Planning the Kinetix 6000 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. If subpanels are not bonded together, and do not share a common low impedance path, the difference in impedance can affect networks and other devices that span multiple panels:

Figure 9 - Multiple Subpanels and Cabinet Recommendations

• 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.

36 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 37

Planning the Kinetix 6000 Drive System Installation Chapter 2

Line Interface Module

Kinetix 6000 System

Dirty Wireway

Clean Wireway

I/O

(1)

and Feedback Cables

Motor Power Cables

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded cables.

Fiber-optic Ca ble

VAC L oad

VAC L ine

AC Lin e Filter

(required for CE)

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Establishing Noise Zones

Observe these guidelines when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in the Bulletin 2094 system and mounted left of the IAM module with the AC (EMC) line filter mounted above the LIM module:

• The clean zone (C) is to the right and beneath the Bulletin 2094 system (gray wireway).

• The dirty zone (D) is to the left and above the Bulletin 2094 system, and above and below the LIM module (black wireway).

• The very dirty zone (VD) is from the filter output to IAM module. Shielded cable is required on the EMC filter (load side) and the braided shield attached to the clamp provided.

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

Figure 10 - 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 cabl e 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-UM001H-EN-P - June 2013 37

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Chapter 2 Planning the Kinetix 6000 Drive System Installation

I/O

(1)

and Feedback Cables

Line Interface Module

Kinetix 6000

System

Clean Wireway

Dirty Wireway

Motor Power Cables

VAC L oad

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 I/O

shielded cable.

Route encoder/analog/registration shielded cables.

Fiber-optic Cable

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Observe these guidelines when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in the Bulletin 2094 system and mounted right of the IAM module with the AC (EMC) line filter mounted behind the IAM module:

Figure 11 - Noise Zones (LIM with EMC filter behind 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.

38 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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

Page 39

Planning the Kinetix 6000 Drive System Installation Chapter 2

LIM

PRS

LIM

I/O

(1)

and Feedback Cables

Line Interface Module

(2094-ALxxS shown)

Kinetix 6000

System

Clean Wireway

Dirty Wireway

Motor Power Cables

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)

Route 24V DC I/O

shielded cable.

Route encoder/analog/registration shielded cables.

Fiber-optic Cable

2094 Mounting

(3)

Brackets x2

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Observe these guidelines when the 2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in the Bulletin 2094 system and mounted right of the drive with the AC (EMC) line filter mounted behind the LIM module:

• The clean zone (C) is to the left and beneath the Bulletin 2094 system (gray wireway).

• The dirty zone (D) is to the right and above the Bulletin 2094 system, and above and below the LIM module (black wireway).

• The very dirty zone (VD) is from the filter output to drive. Shielded cable is required on the EMC filter (load side) and the braided shield attached to the clamp (when provided).

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

Figure 12 - 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-UM001H-EN-P - June 2013 39

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Chapter 2 Planning the Kinetix 6000 Drive System Installation

Line Interface Module

Kinetix 6000 System (leader IAM)

Dirty Wireway

Clean Wireway

I/O

(1)

and Feedback Cables

Motor Power Cables

VAC Line, AUX VAC Output, 24V

VAC L ine

AC Line Filter

(required for CE)

VAC Loa d

I/O

(1)

and Feedback Cables

Kinetix 6000 System (follower IAM)

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Very Dirty DC Bus Connections

Segregated (not in wireway)

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded 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-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM module is used in a DC common-bus configuration and the follower IAM module is mounted below the leader IAM module.

Figure 13 - Noise Zones (DC common bus)

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

40 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 41

Planning the Kinetix 6000 Drive System Installation Chapter 2

(1)

Line Interface Module

Kinetix 6000 System

Dirty Wireway

Clean Wireway

I/O

(1)

and Feedback Cables

Motor Power Cables

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded cables.

Fiber-optic Cable

No sensitive

(2)

equipment within

150 mm (6.0 in.).

Observe these guidelines when the 2094-AL09 or 2094-BL02 LIM module is used in the Bulletin 2094 system and mounted left of the IAM module:

• The clean zone (C) is to the right and beneath the Bulletin 2094 system (gray wireway).

• The dirty zone (D) is to the left and above the Bulletin 2094 system, and above and below the LIM module (black wireway).

• The very dirty zone (VD) is limited to where the LIM module VAC output jumpers over to the IAM module. Shielded cable is required only if the very dirty cables enter a wireway.

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

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

Figure 14 - Noise Zones (LIM mounted left of IAM module)

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

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 41

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Chapter 2 Planning the Kinetix 6000 Drive System Installation

Line Interface Module

Kinetix 6000 System

Dir ty Wireway Clean Wireway

Motor Power Cables

Very dirty LIM/IAM

(1)

connections must be shielded with braid clamp at both ends.

I/O

(2)

and Feedback Cables

No sensitive

(3)

equipment within

150 mm (6.0 in.).

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded cables.

Fiber-optic Cab le

Observe these guidelines when the 2094-AL09 or 2094-BL02 LIM module is used in the Bulletin 2094 system and mounted above the IAM module:

Figure 15 - Noise Zones (LIM mounted above 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.

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

42 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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

Page 43

Planning the Kinetix 6000 Drive System Installation Chapter 2

(1)

2094-BL02 or 2094-BLxxS

Line Interface Module

Kinetix 6000 System

Dirty Wireway

Clean Wireway

I/O

(1)

, Feedback, and

Network Cables

Motor and Hybrid Cables

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded cables.

Fiber-optic Cables and

IPIM Digital Input Wires

No sensitive

(2)

equipment within

150 mm (6.0 in.).

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 can 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 16 - Noise Zones (Bulletin 2094 power rail with IPIM module)

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

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 43

Page 44

Chapter 2 Planning the Kinetix 6000 Drive System Installation

(1)

(4)

(3)

Dir ty Wireway Clean Wireway

Motor Power Cables

24V Motor

Brake PS

Circuit

Breaker

XFMR

Line Filter

(required

for CE)

Filter

Contac tors

Kinetix 6000 System

(2)

I/O

(1)

and Feedback Cables

Very Dirty Filter/IAM Connections

Segregated (not in wireway)

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded 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:

Figure 17 - Noise Zones (without LIM module)

• 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.

(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

examples, refer to the System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001 (3) This is a clean 24V DC available for any device that requires 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.

44 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 45

Planning the Kinetix 6000 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 Logix5000 sercos interface module:

• The clean zone (C) is beneath the less noisy modules (I/O, analog, encoder, registration, an so forth (gray wireway).

• The dirty zone (D) is above and below the power supply and noisy modules (black wireway).

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

Figure 18 - Noise Zones (ControlLogix chassis)

Cable Categories for Kinetix 6000 Systems

These tables indicate the zoning requirements of cables connecting to the Kinetix 6000 drive components.

Table 14 - IAM 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

DPI DPI X X

IPD

Very Dirty

Dirty Clean

Ferrite Sleeve

Shielded Cable

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 45

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Chapter 2 Planning the Kinetix 6000 Drive System Installation

Table 15 - AM 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

COM, PWR (24V DC), safety enable, and feedback signals for safe torque-off feature

Motor feedback MF X X

Auxiliary feedback AF X X

Registration and analog outputs

Others X

Fiber-optic Rx and Tx No restrictions

Zone Method

Very Dirty

Dirty Clean

Ferrite Sleeve

Shielded Cable

(1)

(2)

STO X

IOD

(1) This is a clean 24V DC available for any device that requires it. (2) This is a dirty 24V DC available for motor brakes and contactors.

Table 16 - Line Interface Module (LIM)

Zone Method

Wire/Cable Connector

Very Dirty

Dirty Clean

Ferrite Sleeve

VAC line (main input) IPL X

Aux power input APL X

VAC load (shielded option)

OPL

VAC load (unshielded option) X

Control power output CPL X

MBRK PWR, MBRK COM P1L/PSL X

Status I/O IOL X

Aux power output P2L X

Table 17 - Shunt Module

Zone Method

Wire/Cable Connector

COL, DC+ (shielded option)

COL, DC+ (unshielded option) X

Thermal switch TS X X

Fan (if present) N/A X

Very Dirty

Dirty Clean

Ferrite Sleeve

Shielded Cable

46 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 47

Table 18 - IDM Power Interface Module (IPIM)

IMPORTANT

Planning the Kinetix 6000 Drive System Installation Chapter 2

Wire/Cable

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

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)

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

Zone Method

Table 19 - Resistive Brake Module (RBM)

Wire/Cable Connections

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

Resistive brake module I/O

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

230V power TB4 X

TB1-1…TB1-5 and TB3-8

Very Dirty Dirty Clean Ferrite Sleeve Shielded Cable

Zone Method

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 44

• Mount the AC line filter on the same panel as the Kinetix 6000 drive and as close to the power rail as possible.

• Good HF bonding to the panel is critical. For painted panels, refer to the examples on page 35

• 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 can perform satisfactorily, but the user takes legal responsibility.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 47

Page 48

Chapter 2 Planning the Kinetix 6000 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.

(1)

Line Interface Module

Kinetix 6000 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

Shunt Power Wiring Methods:

Twisted pair in conduit (1st choice).

Shielded twisted pair (2nd choice).

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

Metal Conduit (where re quired by local code)

I/O and Feedback Cables

Shunt thermal Switch and Fan Wires (when present)

No sensitive

equipment within

150 mm (6.0 in.).

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded cables.

External Shunt Modules

Observe these guidelines when mounting your external shunt module outside the enclosure:

Figure 19 - 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.

48 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 49

Planning the Kinetix 6000 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 6000 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Enclosure

2094-BSP2 Shunt Module

I/O and Feedback Cables

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.).

Route 24V DC I/O shielded cable.

Route encoder/analog/registration

shielded 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 20 - External Shunt Module Inside the Enclosure

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 49

Page 50

Chapter 2 Planning the Kinetix 6000 Drive System Installation

Line Interface Module

Kinetix 6000 System

Dirty Wireway

Clean Wireway

Motor Power Cables

Very Dirty LIM/IAM Connections

Segregated (not in wireway)

RBM I/O

LIM VAC Input Power

IAM/AM Feedback and

(clean) I/O

LIM and IAM/AM (dirty) I/O

No sensitive

equipment within

150 mm (6.0 in.).

Fiber-optic Cable

Resistive Brake Modules

Observe these guidelines when mounting your RBM module:

Figure 21 - Noise Zones (RBM mounted above AM 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.

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 111 wiring guidelines. Refer to Axis Module/Rotary Motor Wiring Examples beginning on page 196 combination.

50 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

for the interconnect diagram of your drive/motor

for

Page 51

Chapter 3

Mounting the Kinetix 6000 Drive System

This chapter provides the system installation procedures for mounting your Kinetix 6000 drive components on the Bulletin 2094 power rail.

Top ic Pa ge

Before You Begin 51

Determine Mounting Order 52

Mount Modules on the Power Rail 54

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.

Before You Begin

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 can 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 6000 drive system.

, when using mounting brackets with your

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 51

Page 52

Chapter 3 Mounting the Kinetix 6000 Drive System

Installing the 2094 Power Rail

The Bulletin 2094 power rail comes in lengths to support one IAM module and up to seven additional AM/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.

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.

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

, 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 22

. 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 20 - Kinetix 6000 (200V-class) Axis Modules

Attribute 2094-AMP5-S 2094-AM01-S 2094-AM02-S 2094-AM03-S 2094-AM05-S

Continuous Power Output, nom

Table 21 - Kinetix 6000 (400V-class) Axis Modules

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

Continuous Power Output, nom

Table 22 - Kinetix 6000M (400V-class) IPIM Module

1.2 kW 1.9 kW 3.4 kW 5.5 kW 11.0 kW

1.8 kW 3.9 kW 6.6 kW 13.5 kW 22.0 kW

Attribute 2094-SEPM-B24-S

Continuous Power Output, nom 15.0 kW

52 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 53

Figure 22 - Module Mounting Order Example

Highest Power Utilization

Lowest Power Utilization

Integrated Axis Module

2094-BC02-M02-x

IPIM Module

2094-SEPM-B24-S

Axis Module

2094-BM02-x

Axis Module

2094-BM02-x

Axis Module

2094-BM01-x

Axis Module

2094-BM01-x

Shunt Module

2094-BSP2

Slot-filler Module

2094-PRF

IMPORTANT

Mounting the Kinetix 6000 Drive System Chapter 3

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 can 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 disable the internal, rail mounted, and external shunt modules.

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Chapter 3 Mounting the Kinetix 6000 Drive System

TIP

IMPORTANT

Slots for additional axis modules,

shunt module, or slot-filler modules.

Power Rail Sl ot

Mounting Bracket

Power Rai l

Kinetix 6000 IAM, AM, IPIM, Shunt, or Slot-filler Module (IAM module is shown)

Mount Modules on the Power Rail

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.

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

ATT EN TI ON : To avoid damage to the pins 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.

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

54 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Mounting the Kinetix 6000 Drive System Chapter 3

Guide Pin Holes

Power rail (side view)

in upright vertical position.

Guide Pins

Pivot module downward

and align with guide pins.

Kinetix 6000 IAM, AM, IPIM, Shunt,

or Slot-filler Module, Side View

(IAM module is shown)

Kinetix 6000 IAM, AM, IPIM, Shunt,

or Slot-filler Module, Rear View

(IAM module is shown)

TIP

Power Rail

Bracket secured in slot.

Kinetix 6000 IAM, AM, IPIM, Shunt, or Slot-filler Module (IAM module is shown)

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

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.

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Chapter 3 Mounting the Kinetix 6000 Drive System

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

Bottom front view of

double-wide IAM or AM module

(AM module is shown).

Mounting Screws

IMPORTANT

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

There are two mounting screws when mounting 2094-AC32-M05-x, 2094BC04-M03-x, and 2094-BC07-M05-x (double-wide) IAM modules, and 2094BM03-x and 2094-BM05-x (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

56 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 57

Chapter 4

Connector Data and Feature Descriptions

This chapter illustrates drive connectors and indicators, including connector pinouts, and provides descriptions for Kinetix 6000 drive features.

Top ic Pa ge

2094 IAM/AM Module Connector Data 58

Control Signal Specifications 67

Power and Relay Specifications 71

Feedback Specifications 77

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

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Chapter 4 Connector Data and Feature Descriptions

Kinetix 6000 IAM Module, Top View (2094-AC05-M01-S module is shown)

Kinetix 6000 IAM Module, Front View

(2094-AC05-M01-S module is shown)

2094 IAM/AM Module Connector Data

1 2

CTRL 2 CTRL 1

1 2 3 4 5 6

DCDC+

L3 L2 L1

1 2

CONT ENCONT EN+

1 2 3 4 5 6 7 8 9

MBRK -

MBRK +

COM PWR

DBRK -

DBRK +

DPI

1 2 3 4

1 2 3 4 5 6

Use these illustrations to identify the connectors and indicators for the IAM/AM 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 DriveMotor System User Manual, publication 2094-UM003

Although the physical size of the 400V-class module is larger than the 200V-class module, the location of the features and indicators is identical.

Figure 23 - Integrated Axis Module Features and Indicators

BAUD RATE

16 17 18

Item Description Item Description

1 Safe to rque-off (S TO) connec tor 11 Sercos receive (Rx) connector

2 Contactor enable (CED) connector 12 Mounting screw

3 DC bus/AC input power (IPD) connector 13 I/O (IOD) connector

4 Control power (CPD) connector 14 Sercos node address switch

5 Motor cable shield clamp 15 Seven-segment fault status indicator

6 Motor power (MP) connector 16 Drive status indicator

7 Motor/resistive brake (BC) connector 17 COMM status indicator

Sercos communication rate and

optical power switches

18 Bus status indicator

9 Sercos transmit (Tx) connector 19 Motor feedback (MF) connector

10 DPI connector 20 Auxiliary feedback (AF) connector

58 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 59

Figure 24 - Axis Module Features and Indicators

BAUD

RATE

MBRK MBRK +

COM

PWR DBRK DBRK +

1 2 3 4

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

6 7

12 13 14

Kinetix 6000 AM Module, Top View (2094-AM01-S module is shown)

Kinetix 6000 AM Module, Front View

(2094-AM01-S module is shown)

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

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

Connector Data and Feature Descriptions Chapter 4

Item Description Item Description

1 Safe torque-off (STO) connector 9 Mounting screw

2 Motor cable shield clamp 10 I/O (IOD) connector

3 Motor power (MP) connector 11 Seven-segment fault status indicator

4 Motor/resistive brake (BC) connector 12 Drive status indicator

5 Sercos communication rate and optical power switches 13 COMM status indicator

6 Sercos transmit ( Tx) connector

7 Sercos receive (Rx) connector

8 Ethernet (PORT1 and PORT 2) connectors

(1) The Rx and Tx sercos connectors on the Kinetix 6000M IPIM module are in the same position as on the Kinetix 6000 AM modules. For the remainder of the IPIM module

features and indicators, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

(2) The Kinetix 6000M IPIM module has two Ethernet ports. These ports are used only for connecting to the EtherNet/I P network for Logix5000 programming.

(1)

(2)

14 Bus status indicator

15 Motor feedback (MF) connector

16 Auxiliary feedback (AF) connector

Table 23 - Kinetix 6000 IAM/AM Module Connectors

Designator Description Connector Module

IOD User I/O (drive) 26-pin high-density D-shell (female) IAM/AM

MF Motor feedback 15-pin high-density D-shell (female) IAM/AM

AF Auxiliary feedback 15-pin high-density D-shell (male) IAM/AM

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

STO Safe torque-off 9-position plug/header IAM/AM

Tx and Rx Sercos transmit and receive Sercos fiber-optic (2) IAM/AM

DPI DPI DPI IAM

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Chapter 4 Connector Data and Feature Descriptions

Motion-allowed Jumper

Wiring P lug Hea der

Kinetix 6000 IAM/AM Module

(AM module is shown)

Safe Torque-off

(STO) Connector

IMPORTANT

Safe Torque-off Connector Pinout

Each 2094-xCxx-Mxx-S IAM module and 2094-xMxx-S AM module ships with the (9-pin) wiring-plug header and motion-allowed jumper installed in the safe torque-off (STO) connector. With the motion-allowed jumper installed, the safe torque-off feature is not used.

Figure 25 - Motion-allowed Jumper

Headers in this table extend the safe torque-off (STO) connector signals for use in wiring single and multiple safe torque-off drive configurations, or to defeat (not use) the safe torque-off feature.

Table 24 - IAM/AM Safe Torque-off 9-pin (STO) Connector

Safe Torque-off (STO)

Connector Pin

2 Other side of the normally-closed monitoring contact of relay 2 FDBK2-

3 One side of the normally-closed monitoring contact of relay 1 FDBK1+

4 Other side of the normally-closed monitoring contact of relay 1 FDBK1-

5 Safety enable 2 input SAFETY ENABLE2+

6 Return for safety enable power (both inputs) SAFETY ENABLE-

7 Safety enable 1 input SAFETY ENABLE1+

9 Power return used for continuous enable of safety function 24V_COM

Applies to These STO Connector Headers Description Signal

One side of the normally-closed monitoring contact of relay 2 FDBK2+

• Wiring plug header used in single-drive applications

• First-drive wiring header (catalog number 2090-XNSM-W) used in multiple-drive applications

• Wiring plug header

• Motion-allowed jumper

Power for continuous enable of the safety function, 500 mA max 24V+

Pins STO-8 and STO-9 (24V+) are used by only the motion-allowed jumper. When wiring to the wiring-plug header, the 24V supply must come from an external source.

Refer to the Kinetix Safe Torque-off Feature Safety Reference Manual,

60 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

publication GMC-RM002 headers.

, for more information on wiring safe torque-off

Page 61

Connector Data and Feature Descriptions Chapter 4

IMPORTANT

Pin 18

Pin 26

Pin 1

Pin 9

Pin 10

Pin 19

26-pin IAM/AM

I/O Connector

I/O Connector Pinout

Table 25 - IAM/AM I/O 26-pin (IOD) Connector

IOD Pin Description Signal IOD Pin Description Signal

1 Hardware enable 24V DC power supply +24V_PWR 14 High speed registration 1 input REG1

2 Hardware enable input ENABLE 15 Common for registration REG_COM

3 Common +24V_COM 16 24V registration power REG_24V

4 Home switch 24V DC power supply +24V_PWR 17 High speed registration 2 input REG2

5 Home switch input HOME 18 Common for registration REG_COM

6 Common +24V_COM 19 Reserved –

7 Positive overtravel 24V DC power supply +24V_PWR 20 Reserved –

8 Positive overtravel limit switch input OT+ 21 Reserved –

9 Common +24V_COM 22 Reserved –

10 Negative overtravel 24V DC power supply +24V_PWR 23 Analog output 0 DAC0

11 Negative overtravel limit switch input OT- 24 Analog output common DAC_COM

12 Common +24V_COM 25 Analog output 1 DAC1

13 24V registration power REG_24V 26 Analog output common DAC_COM

Signals +24V_PWR and +24V_COM are a 24V DC source you can use only for the inputs listed above.

Figure 26 - Pin Orientation for 26-pin I/O (IOD) Connector

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Chapter 4 Connector Data and Feature Descriptions

Motor Feedback Connector Pinout

Table 26 - Stegmann Hiperface (SRS/SRM)

MF Pin Description Signal MF Pin Description Signal

1 Sine differential input+ SIN+ 9 Reserved –

2 Sine differential input- SIN- 10 Hiperface data channel DATA-

3 Cosine differential input+ COS+ 11 Motor thermal switch (normally closed)

4 Cosine differential input- COS- 12 Reserved –

5 Hiperface data channel DATA+ 13 Reserved –

6 Common ECOM 14 Encoder power (+5V) EPWR_5V

7 Encoder power (+9V) EPWR_9V

(2)

15 Reserved –

8Reserved –

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

Common (TS-) signal for thermal switch is tied to MF-6 (ECOM) in Bulletin 2090 cables.

(2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

Table 27 - TTL or Sine/Cosine with Index Pulse and Hall Commutation

MF Pin Description Signal MF Pin Description Signal

1 AM+ / Sine differential input+ AM+ / SIN+ 9 Reserved –

2 AM- / Sine differential input- AM- / SIN- 10 Index pulse- IM-

3 BM+ / Cosine differential input+ BM+ / COS+ 11 Motor thermal switch (normally closed)

4 BM- / Cosine differential input- BM- / COS- 12 Single-ended 5V hall effect commutation S1

5 Index pulse+ IM+ 13 Single-ended 5V hall effect commutation S2

6 Common ECOM 14 Encoder power (+5V) EPWR_5V

7 Encoder power (+9V) EPWR_9V

8 Single-ended 5V hall effect commutation S3

(2)

15 Reserved –

(1)

TS+

(2)

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

Common (TS-) signal for thermal switch is tied to MF-6 (ECOM) in Bulletin 2090 cables.

(2) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

Table 28 - Resolver Transmitter (transformation ratio = 0.25)

MF Pin Description Signal MF Pin Description Signal

1 Sine differential input+ S2 9 Reserved –

2 Sine differential input- S4 10 Resolver excitation R2

3 Cosine differential input+ S1 11 Motor thermal switch (normally closed)

4 Cosine differential input- S3 12 Reserved –

5 Resolver excitation R1 13 Reserved –

6 Common ECOM 14 Reserved –

7 Reserved – 15 Reserved –

8Reserved –

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

Common (TS-) signal for thermal switch is tied to MF-6 (ECOM) in Bulletin 2090 cables.

(2) If using 1326AB (resolver-based) motors, use 2090-K6CK-D15MF Low-profile Connector Kits that connect the filtered thermal switch (pins 16 and 17) to MF-11 and MF-6.

62 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

(1) (2)

TS+

Page 63

Connector Data and Feature Descriptions Chapter 4

IMPORTANT

Pin 11

Pin 6

Pin 15

Pin 1

Pin 10

Pin 5

15-pin IAM/AM

Motor Feedback Connector

Kinetix 6000 drives do not support Heidenhain EnDat high-resolution feedback; however, you can use the 2090-K6CK-KENDAT feedback module to

convert Heidenhain EnDat high-resolution feedback to Stegmann Hiperface. Pin numbers in the table below refer to pins in the feedback module.

Only 2094-xCxx-Mxx-S and 2094-xMxx-S drives with firmware revision 1.116 or later support the use of 2090-K6CK-KENDAT feedback modules for Heidenhain EnDat feedback.

Table 29 - Heidenhain EnDat

Pin Description Signal Pin Description Signal

1 Sine differential input+ SIN+ 8 Serial data clock signal - CLK-

2 Sine differential input- SIN- 9 Serial data differential signal+ DATA+

3 Cosine differential input+ COS+ 10 Serial data differential signal - DATA-

4 Cosine differential input- COS- 11 Motor thermal switch+

5 Encoder power (+5V) EPWR_5V 12 Motor thermal switch-

6 Common ECOM 13 Reserved –

7 Serial data clock signal + CLK+

(1)

(2)

TS+

TS-

(1) Not applicable unless motor has integrated thermal protection. (2) When used with Allen-Bradley motors and Bulletin 2090 cables, pin 12 is reserved.

Figure 27 - Pin Orientation for 15-pin Motor Feedback (MF) Connector

Combined motor-power cable length for all axes on the same DC bus must not exceed 240 m (787 ft) with 460V systems or 160 m (525 ft) with 230V systems. Drive-to-motor power cables must not exceed 90 m (295.5 ft).

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

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Chapter 4 Connector Data and Feature Descriptions

15-pin IAM/AM

Auxiliary Feedback Connector

Auxiliary Feedback Connector Pinout

For TTL devices, the position count increases when A leads B. For sinusoidal devices, the position count increases when cosine leads sine.

Table 30 - Stegmann Hiperface (SRS and SRM only)

AF Pin Description Signal AF Pin Description Signal

1 Sine differential input+ SIN+ 9 Reser ved –

2 Sine differential input- SIN- 10 Hiperface data channel DATA-

3 Cosine differential input+ COS+ 11 Reserved –

4 Cosine differential input- COS- 12 Reserved –

5 Hiperface data channel DATA+ 13 Reserved –

6 Common ECOM 14 Encoder power (+5V) EPWR_5V

7 Encoder power (+9V) EPWR_9V

8Reserved –

(1) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

Table 31 - TTL or Sine/Cosine with Index Pulse

(1)

15 Reserved –

(1)

AF Pin Description Signal AF Pin Description Signal

1 A+ / Sine differential input+ A+ / SIN+ 9 Reser ved –

2 A- / Sine differential input- A- / SIN- 10 Index pulse- I-

3 B+ / Cosine differential input+ B+ / COS+ 11 Reserved –

4 B- / Cosine differential input- B- / COS- 12 Reserved –

5 Index pulse+ I+ 13 Reserved –

6 Common ECOM 14 Encoder power (+5V) EPWR_5V

7 Encoder power (+9V) EPWR_9V

8Reserved –

(1) Encoder power supply uses either 5V or 9V DC based on encoder/motor used.

(1)

15 Reserved –

Figure 28 - Pin Orientation for 15-pin Auxiliary Feedback (AF) Connector

Pin 6

Pin 11

Pin 15

Pin 1

Pin 5 Pin 10

(1)

64 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Connector Data and Feature Descriptions Chapter 4

IAM Input Connector Pinout

Table 32 - Control Power Connector

CPD Pin Description Signal

2CTRL 1

Control power VAC input

Table 33 - DC Bus and Input Power Connector

IPD Pin Description Signal

1 An integral, unregulated power supply, consisting

2DC+

3 Chassis ground.

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

CTRL 2

DC-

5L2

6L1

Three-phase input power.

Table 34 - 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.

CONT EN-

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Chapter 4 Connector Data and Feature Descriptions

IMPORTANT

IAM and AM Motor Power and Brake Connector Pinout

Table 35 - Motor Power Connector

MP Pin Description Signal

4 Chassis ground

Three-phase motor power

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

Table 36 - 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-

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Connector Data and Feature Descriptions Chapter 4

IMPORTANT

Control Signal Specifications

IOD Pin Signal Description Capture Time

IOD-2 ENABLE

IOD-5 HOME

IOD-14 IOD-17

IOD-8 IOD-11

REG1 REG2

OT+ OT-

This section provides a description of the Kinetix 6000 drive I/O (IOD), communication, contactor enable (CED), brake (BC), and control power (CPD) connectors.

Digital Inputs

Two fast registration inputs and four other inputs are available for the machine interface on the IAM module and AM module. Each IAM and AM module supplies 24V DC @ 250 mA for the purpose of registration, home, enable, overtravel 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 each input.

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.

Table 37 - Understanding Digital Inputs

Edge/Level Sensitive

Optically isolated, single-ended active high signal. Current lo ading is nominally 10 mA. A 24V DC input is applied to this terminal to enable each axis.

Optically isolated, single-ended active high signal. Current loading is nominally 10 mA. Home switch (normally open contact) inputs for each axis require 24V DC (nominal).

Fast registration inputs are required to inform the motor interface to capture the positional information with less than 3 µs uncertainty. Optically isolated, single-ended active high signal. Current loading is nominally 10 mA. A 24V DC input is applied to this terminal to enable each axis.

Overtravel detection is available as an optically isolated, single-ended ac tive high signal. Current loading is nominally 10 mA per input. The pos/neg limit switch (normally closed contact) inputs for each axis require 24V DC (nominal).

20 ms Level

500 ns Edge

30 ms Level

Table 38 - Digital Input Specifications

Parameter Description Min Max

On-state voltage

On-state current Current flow to guarantee an on-state. 3.0 mA 10.0 mA

Off-state voltage Voltage applied to the input, with respect to IOCOM, to guarantee an off-state. -1. 0V 3.0V

Voltage applied to the input, with respect to IOCOM, to guarantee an on-state.

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ENABLE, HOME, and OT+/OT- 10.8V 26.4V

REG1 and REG2 21.6V 26.4V

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Chapter 4 Connector Data and Feature Descriptions

3k Ω

0.1

511 Ω

VCC

CTRL_INPUT

IO_COM

IOD-1, -4, -7, -10

IOD-2, -5, -8, -11

IOD-3, -6, -9, -12

1k Ω

Kinetix 6000 IAM/AM Module

Customer-supplied Input Device

24V DC

I/O SUPPLY

(1)

INPUT

(2)

3k Ω

511 Ω

VCC

REG_INPUT

INPUT

IO_COM

HCPL-0631

I/O SUPPLY

+24V DC

IOD-13, -16

IOD-14, -17

IOD-15, -18

0.001

1k Ω

Kinetix 6000 IAM/AM Module

Customer-supplied Registration

Input Device

Figure 29 - Enable, Home, and Overtravel Digital Input Circuits

(1) 24V DC source (range) = 21.6V - 26.4V (supplied by drive, not to exceed 250 mA total). (2) Maximum current input = 10 mA.

Figure 30 - Registration Digital Input Circuits

68 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Sercos Communication Specifications

The Rx and Tx sercos connectors are provided on the Kinetix 6000 IAM and AM module for communication with the Logix5000 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 01…99

(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

(1)

(2)

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.

Page 69

Connector Data and Feature Descriptions Chapter 4

CH1CH1

CH2CH2

DAC

OscilloscopeKinetix 6000 IAM/AM

Module

(second channel not shown)

IMPORTANT

Analog Outputs

The IAM and AM modules include two analog outputs (IOD-23 and IOD-25) that you can configure through software to represent drive variables.

Figure 31 - Analog Output Circuit

Output values can vary during powerup until the specified power supply voltage is reached.

Table 39 - Analog Output Specifications

Parameter Description Min Max

Resolution

Output current Current capability of the output. 0 +2 mA

Output signal range

Offset error Deviation when the output is expected to be at 0V. – 1 mV

Bandwidth Frequency response of the analog output DC 7.2k Hz (3 db)

Number of states that the output signal is divided into, which

(to the number of bits)

is 2

Range of the output voltage.

2094-xCxx-Mxx and 2094-xMxx drives

2094-xCxx-Mxx-S and 2094-xMxx-S drives

–±11 bits

0+5V

0+10V

Table 40 - Linear Scaling Specifications

Drive Cat. No.

2094-xCxx-Mxx or 2094-xMxx

2094-xCxx-Mxx-S or 2094-xMxx-S

Speed rpm

10,000 5.0 1000

02.50

-10,000 0 -1000

10,000 10.0 1000

05.00

-10,000 0 -1000

Value V DC

Tor que %

For configuration/set up of the analog outputs, refer to Configure Drive Parameters and System Variables beginning on page 160

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Chapter 4 Connector Data and Feature Descriptions

IMPORTANT

Normally

Open Relay

Kinetix 6000

IAM 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 190

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

for a wiring example.

Figure 32 - Contactor Enable Relay Circuit

CONT EN+

CONT EN-

Table 41 - 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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Connector Data and Feature Descriptions Chapter 4

24V PWR (BC-3)

FQB22P10

MBRK+ (BC-5)

MBRK– (BC-6)

(1)

DBRK+ (BC-1)

DBRK– (BC-2)

24V COM (BC-4)

24V PWR (BC-3)

FQB22P10

(1)

24V COM (BC-4)

Resistive Brake Module Circuitry

Kinetix 6000

IAM/AM Module

Motor Brake Circuitry

Kinetix 6000

IAM/AM Module

Control

Board

Control

Board

IMPORTANT

Power and Relay Specifications

This section provides a description of the Kinetix 6000 brake relay (BC), input power (IPD), motor power (MP), and control power (CPD) connectors.

Motor/Resistive Brake Relay

Series C brake circuits use solid-state relays. Series A and B drive modules used mechanical relays. The solid-state brake driver circuit provides the following:

• Brake thermal overload protection

• Brake current overload protection

• Brake short circuit protection

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 Figure 33 releases. Connections are rated for +24V and current as shown in Ta b l e 4 2

An active signal releases the motor brake (BC-5 and BC-6). The brake signal turn-on and turn-off delays are specified by the brake active delay and brake inactive delay (configurable in the Logix Designer application). Refer to the Axis Module/Rotary Motor Wiring Examples beginning on page 196 Controlling a Brake Example on page 211

. Wiring is consistent with all series

and the

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 the software. Refer to RBM Module Interconnect Diagrams beginning on page 265 for wiring examples.

Figure 33 - Brake Relay Circuit (series C)

(1) Noise suppression device.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 71

Motor parking-brake switching frequency must not exceed 10 cycles/min.

Page 72

Chapter 4 Connector Data and Feature Descriptions

Table 42 - Brake Relay Output Specifications

Attribute Description IAM/AM Module

2094-AC05-Mxx,-x 2094-AC09-M02-x, 2094-AMP5-x, 2094-AM01-x, 2094-AM02-x

2094-BC01-Mxx-x, 2094-BC02-M02-x,

Current flow when the

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)

relay is closed

2094-BMP5-x, 2094-BM01-x, 2094-BM02-x

2094-AC16-M03-x, 2094-AC32-M05-x, 2094-AM03-x, 2094-AM05-x

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

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.

Brake Current Value, max

Series A Series B Series C

N/A

1.0 A

3.0 A

1.3 A N/A

3.0 A 3.0 A

The cycle capability also depends on the converter power rating and the total system capacitance. Refer to Appendix C on page 225

to calculate total system

capacitance.

Table 43 - Maximum Input Power Cycling Specifications (230V)

Attribute 2094-AC05-MP5-S 2094-AC05-M01-S 2094-AC09-M02-S 2094-AC16-M03-S 2094-AC32-M05-S

Main AC input power cycling (cycles per minute for 10,000 μf) 0.69 4.30

Table 44 - Maximum Input Power Cycling Specifications (460V)

Attribute 2094-BC01-MP5-S 2094-BC01-M01-S 2094-BC02-M02-S 2094-BC04-M03-S 2094-BC07-M05-S

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

For example, in a 4 axis system with a 2094-BC02-M02-S IAM 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.

72 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Connector Data and Feature Descriptions Chapter 4

IMPORTANT

Peak Enhancement Specifications

Drives that support the Peak-enhanced mode have the capability of increasing the maximum inverter peak current to achieve greater overload performance.

The peak enhancement feature requires the use of RSLogix 5000 software or the Logix Designer application, and drive firmware as specified in Tab le 4 5

Table 45 - Peak Enhancement Software and Firmware Requirements

IAM Module Cat. No.

2094-BC01-MP5-S 2094-BMP5-S 16 or later 1.111 or later

2094-BC01-M01-S 2094-BM01-S 16 or later 1.111 or later

2094-BC02-M02-S 2094-BM02-S 16 or later 1.111 or later

2094-BC04-M03-S 2094-BM03-S 17 or later 1.117 or later

2094-BC07-M05-S 2094-BM05-S 17 or later 1.117 or later

AM Module Cat. No.

RSLogix 5000 Software Vers ion

Kinetix 6000 Drive Firmware Revision

Table 46 - Kinetix 6000 Inverter Peak Overload Support

Kinetix 6000 Drives Cat. No.

2094-BCxx-Mxx IAM

2094-BMxx AM

2094-BCxx-Mxx-S IAM

2094-BMxx-S AM

(1) Standard mode is enabled by default to preserve backward compatibility, but you can enable the Peak-enhanced mode to achieve

increased peak current performance.

Module

Safe Torqueoff Drive

Non Safe Tor q u e- o f f

Safe Tor q u e- o f f

Series A Series B and C

Standard N/A

Standard

Standard or Peak Enhanced

(1)

Table 47 - Kinetix 6000 Peak Current Ratings

IAM/AM Module Cat. No.

2094-BC01-MP5-S 150% 250% 200% 250%

2094-BC01-M01-S 150% 250% 200% 250%

2094-BC02-M02-S 150% 250% 200% 250%

2094-BC04-M03-S 150% 250% 200% 250%

2094-BC07-M05-S 150% 200% 200% 300%

2094-BMP5-S 150% 250% N/A N/A

2094-BM01-S 150% 250% N/A N/A

2094-BM02-S 150% 250% N/A N/A

2094-BM03-S 150% 250% N/A N/A

2094-BM05-S 150% 200% N/A N/A

Peak Inverter Current Rating Peak Converter Current Rating

Standard Peak Enhanced Series A Series B and C

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 73

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Chapter 4 Connector Data and Feature Descriptions

D =

T T

x 100%

Cont

Base

D =

T T

x 100%

Figure 34 - Load Duty-cycle Profile Example

Table 48 - Peak Duty Cycle Definition of Terms

Term Definition

Continuous Current Rating (I

Peak Curre nt Rati ng (I

Duty Cycle (D)

) 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:

(1)

PKmax

Time at Peak (T

Peak Curre nt (I

)

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

PKmax

must be less than or

of the drive.

PKMAX)

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

Base Current (I

Loading Profile

Base

)

profile. I of the drive.

The loading profile is comprised of IPK, I completely specify the operation of the drive in an overload situation. These

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

Base

, TPK, and D (or T) values and

Base

Cont)

values are collectively defined as the Loading Profile of the drive.

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

(1) All current values are specified as RMS.

(TPK) and I

Base

74 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 75

50%

Applies to these Kinetix 6000 drives: 2094-BC01-MP5-S, 2094-BMP5-S, 2094-BC01-M01-S, 2094-BM01-S, 2094-BC02-M02-S, 2094-BM02-S, 2094-BC04-M03-S, 2094-BM03-S

Applies to these Kinetix 6000 drives: 2094-BC07-M05-S, 2094-BM05-S

45%

40%

Connector Data and Feature Descriptions Chapter 4

Figure 35 - 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 36 - 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%

(1)

Legend

I = 150%

I = 200%

40%

% Base Current (I /I )

(1) Base current (I

60%

Base

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

Base

80%20%

Cont

100%

Cont

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 75

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Chapter 4 Connector Data and Feature Descriptions

IMPORTANT

Control Power

The IAM 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 187

Control power isolation, via a step-down transformer, is required for all 460V applications. Source the 2094-ACxx-Mxx-x (230V) IAM module control power from the three-phase input power (line-to-line). Supplying control power from any other source requires an isolation transformer. Do not ground the transformer secondary to avoid ground fault conflicts with IAM module.

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 49 - 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 50 - 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 5 0

for the number of axes on the power rail.

76 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 77

Connector Data and Feature Descriptions Chapter 4

4096 Turns, Kinetix 6000 Drives

Position at Power D own

Feedback Specifications

The IAM and AM modules can accept motor and auxiliary feedback signals from these types of encoders:

• Stegmann Hiperface

• TTL or Sine/Cosine with index pulse and Hall commutation

• Resolver Transmitter TR = 0.25 (motor feedback only)

Motor feedback from Heidenhain EnDat high-resolution encoders is also accepted, but only when using drive firmware revision 1.116 and the 2090K6CK-KENDAT low-profile feedback module for EnDat to Hiperface conversion.

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 51 - Absolute Position Designator Examples

Encoder Type

Stegmann Hiperface

Heidenhain EnDat -7 RDB-B21519-7

Motor Cat. No. Designator

-M MPL-B310P-M

-V MPL-B230P-V

Motor Cat. No. Example

Figure 37 - Absolute Position Retention Limit

+2048+1024-2048 -1024

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 77

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Chapter 4 Connector Data and Feature Descriptions

10k Ω

+5 V

1k Ω

56 pF

10k Ω

1k Ω

10k Ω

1k Ω

100 pF

56 pF

Drive

AM and BM Channel Inputs

IM Channel Input

Motor Feedback Specifications

AM, BM, and IM input encoder signals are filtered by using analog and digital filtering. The inputs also include illegal state change detection.

Figure 38 - AM, BM, and IM Motor Encoder Input Circuits

Table 52 - Motor Encoder Feedback Specifications

Attribute Value

Encoder types Incremental, A quad B, sine/cosine, intelligent, resolver, and absolute

Maximum input frequency

Commutation feedback Hall sensor

500 kHz (TTL input) per channel

250 kHz (sine/cosine input)

78 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Connector Data and Feature Descriptions Chapter 4

Table 53 - AM, BM, and IM Input Specifications for TTL Encoders

Parameter Description Min Max

AM, BM, and IM On-state input voltage

AM, BM, and IM Off-state input voltage

Common mode input voltage

DC current draw Current draw into the + or - input. -30 mA 30 mA

AM, BM input signal frequency

IM pulse width

AM, BM phase error

2.5 MHz line frequency

AM, BM phase error 1 MHz line frequency

Input voltage difference between the plus (+) input and the minus (-) input that is detected as an on-state.

Input voltage difference between the plus (+) input and the minus (-) input that is detected as an off-state.

Potential difference between any encoder signal and logic ground.

Frequency of the AM or BM signal inputs. The count frequency is 4 times this frequency, because the circuitr y counts all four transitions.

Pulse width of the index input signal. Because the index is active for a percentage of a revolution, the speed determines the pulse width.

Amount that the phase relationship between the AM and BM inputs can deviate from the nominal 90°.

+1.0V +7.0V

-1.0V -7.0V

-7.0V +12.0V

–500 kHz

125 nS –

-22.5° +22.5°

-45° +45°

Table 54 - AM, BM, and IM Input Specifications for Sine/Cosine Encoders

Parameter Description Min Max

Sine/cosine input signal frequency

Sine/cosine input voltage

Frequency of the Sine or Cosine s ignal inputs. – 250 kHz

Peak-to-peak input voltages of the Sine or Cosine inputs. 0.8V (p-p) 1.2V (p-p)

Table 55 - Specifications for Heidenhain EnDat Encoders

Command Set

EnDat 2.2 EnDat 01 1V p-p Sin/Cos, <2 MHz clock frequency

Order Designation

Description

Feedback Power Supply Specifications

The IAM and AM power circuit board generates +5V and +9V DC for motor and auxiliary feedback power. Short circuit protection and separate common mode filtering for each channel is included.

Supply Reference

+5V DC EPWR_5V 4.9 5.25 5.4 0 400

+9V DC EPWR_9V 8.3 9.1 9.9 0 275

Voltage Current mA

Min Nominal Max Min Max

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 79

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Chapter 4 Connector Data and Feature Descriptions

Auxiliary Position Feedback Encoders

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

Refer to the Kinetix Motion Accessories Technical Data, publication

GMC-TD004

, for more information on these Allen-Bradley encoders.

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

80 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 81

Chapter 5

Connecting the Kinetix 6000 Drive System

This chapter provides procedures for wiring your Kinetix 6000 system components and making cable connections.

Top ic Pa ge

Basic Wiring Requirements 81

Determine the Input Power Configuration 83

Setting the Ground Jumper in Ungrounded Power Configurations 87

Grounding the Kinetix 6000 Drive System 93

Power Wiring Requirements 95

Power Wiring Guidelines 97

Wiring the IAM/AM Module Connectors 98

Apply the Motor Cable Shield Clamp 114

Feedback and I/O Cable Connections 115

Wiring the Feedback and I/O Connectors 120

External Shunt Module Connections 125

IPIM Module Connections 126

RBM Module Connections 127

Sercos Fiber-optic Cable Connections 128

Kinetix 6000M Integrated Drive-Motor Sercos Connections 131

Ethernet Cable Connections 132

Basic Wiring Requirements

This section contains basic wiring information for the Kinetix 6000 drive modules.

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 can have voltage present even when not in use.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 81

Page 82

Chapter 5 Connecting the Kinetix 6000 Drive System

IMPORTANT

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.

Building Your Own Cables

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.

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 with a complete 360° connection.

• Use twisted pair cable whenever possible. Twist differential signals with 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 34 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

82 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 83

Connecting the Kinetix 6000 Drive System Chapter 5

BAUD RATE

DPI

1 2 3 4 5 6 7 8 9

DCDC+

L3 L2 L1

CONT ENCONT EN+

MBRK -

MBRK +

COM

PWR

DBRK -

DBRK +

CTRL 2 CTRL 1

1 2 3 4

1 2 3 4 5 6

1 2

1 2 3 4 5 6

1 2

Transformer

Kinetix 6000 IAM Module,

Top Vie w

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

Determine the Input Power Configuration

Before wiring input power to your Kinetix 6000 system, you must determine the type of input power you are connecting to. The IAM module is designed to operate in both grounded and ungrounded environments.

ATT EN TI ON : When using a LIM module with your IAM module, the VAC LINE input power must come from a grounded configuration (refer to Figure 39

). When not using a LIM module with your IAM module, ungrounded configurations are permitted, but you must set the jumper to the ungrounded position for proper drive operation. Refer to Setting the Ground Jumper in Ungrounded Power Configurations on

page 87

for more information.

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 39 - Grounded Power Configuration (WYE Secondary)

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 83

Refer to Power Wiring Examples beginning on page 187 for input power interconnect diagrams with and without the LIM module.

Page 84

Chapter 5 Connecting the Kinetix 6000 Drive System

DCDC+

L3 L2 L1

CONT ENCONT EN+

V U

MBRK -

MBRK +

COM

PWR

DBRK -

DBRK +

CTRL 2 CTRL 1

1 2 3 4

1 2 3 4 5 6

1 2

1 2 3 4 5 6

1 2

BAUD

RATE

DPI

1 2 3 4 5 6 7 8 9

Transformer (Delta) Secondary

Bonded Cabinet

Ground

Transformer

Ground Grid or

Power Distribution Ground

Kinetix 6000 IAM Module,

Top Vi ew

Connect to power rail ground stud.

Three-phas e AC Lin e Filter

Input Fusing

Contactor

IMPORTANT

Figure 40 - Grounded (B-Phase) Power Configuration (Delta Secondary)

The IAM module has a factory-installed ground jumper configured for grounded power distribution.

If you determine that you have grounded power distribution in your plant, you do not need to modify your IAM module.

Refer to Appendix A on page 187

, for input-power interconnect diagrams with

and without the LIM module.

84 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Connecting the Kinetix 6000 Drive System Chapter 5

IMPORTANT

DCDC+

L3 L2 L1

CONT ENCONT EN+

MBRK -

MBRK +

COM

PWR DBRK DBRK +

CTRL 2 CTRL 1

1 2 3 4

1 2 3 4 5 6

1 2

1 2 3 4 5 6

1 2

1 2 3 4 5 6 7 8 9

BAUD RATE

DPI

Transformer

Kinetix 6000 IAM Module,

Top Vie w

Three-phase

Input VAC

Chassis Ground

Bonded Cabinet

Ground

Ground Grid or Power Distribution Ground

Connect to power rail ground stud.

Input Fusing

Contac tor

Ungrounded and High-impedance Grounded Power Configurations

Ungrounded and high-impedance grounded power configurations are allowed, but you must jumper across a 120 kΩ resistor (internal to the IAM module). The ungrounded power configuration (shown below) does not provide a neutral ground point. The IAM 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 inside the IAM module.

Refer to Setting the Ground Jumper in Ungrounded Power Configurations on

page 87

for more information.

Figure 41 - Ungrounded Power Configuration

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 ground.

Refer to Appendix A on page 187, for input-power interconnect diagrams with and without the LIM module.

Rockwell Automation Publication 2094-UM001H-EN-P - June 2013 85

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Chapter 5 Connecting the Kinetix 6000 Drive System

IMPORTANT

DCDC+

L3 L2 L1

CONT ENCONT EN+

MBRK MBRK +

COM

PWR

DBRK -

DBRK +

CTRL 2 CTRL 1

1 2 3 4

1 2 3 4 5 6

1 2

1 2 3 4 5 6

1 2

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

DCDC+

L3 L2 L1

CONT ENCONT EN+

MBRK MBRK +

COM

PWR DBRK DBRK +

CTRL 2 CTRL 1

1 2 3 4

1 2 3 4 5 6

1 2

1 2 3 4 5 6

1 2

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

N.C. N.C. N.C.

1 2 3 4 5 6 7 8 9

BAUD RATE

DPI

BAUD RATE

DPI

BAUD RATE

2094-xCxx-Mxx-x

Common-bus Leader

IAM Module

2094-xMxx-x AM Modules or

2094-SEPM-B24-S IPIM Modules

Bonded Cabinet Ground

Three-p hase

Input Power

Kinetix 6000

DC Common Bus

Connections

2094-xCxx-Mxx-x

Common-bus Follower

IAM Module

2094-xMxx-x AM Modules or

2094-SEPM-B24-S IPIM Modules

DC Common Bus Configurations

When the IAM module is used in a DC common-bus configuration, the IAM module is known as a leader IAM or follower IAM module. The IAM (noncommon 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 56 - 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 the Logix Designer application.

Use Kinetix 6000 drive firmware revision 1.85 and the Logix Designer Application or RSLogix 5000 software, version 15 or later, for common-bus power configurations.

The Kinetix 6000 leader IAM module can operate with non-Kinetix 6000 follower drives, as can the Kinetix 6000 follower IAM module operate with nonKinetix 6000 common-bus leader drives. However, non-Kinetix 6000 leader and follower drives must meet the same functional requirements as the Kinetix 6000 leader and follower IAM modules.

Any non-Kinetix 6000 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 Kinetix 6000 common-bus follower IAM module.

Figure 42 - Typical DC Common-bus Configuration

86 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Connecting the Kinetix 6000 Drive System Chapter 5

IMPORTANT

Common Bus Fusing Requirements

When using a Kinetix 6000 leader IAM module, DC-bus fuses are required only when wiring to more than one Kinetix 6000 follower IAM module. When wiring multiple follower IAM modules, terminal blocks are required to extend the DC common-bus power to additional drives. Install fuses in both lines of the DC bus between the DC bus terminal block and each follower IAM module. Base these fuse ratings on the DC input current of each follower IAM module.

When using a non-Kinetix 6000 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. Base these fuse ratings on the common-bus leader drive DC output current. When using more than one follower IAM module, install fuses in both lines of the DC bus between the non-Kinetix 6000 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 28 breaker/fuse sizes. Refer to DC Common Bus Wiring Examples on page 191 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 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 Kinetix 6000 Drive System on page 93

Setting the ground jumper is best done when the IAM 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 6000 Drive System

IMPORTANT

To remove the IAM module from the power rail, refer to Remove Kinetix 6000 Drive Modules on page 180

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.

When using ungrounded input power in common-bus configurations, use this table to determine where to set the ground jumper.

Table 57 - Ground Jumper to Set

Leader Drive Follower Drive Set the Jumper in This Drive

Kinetix 6000 IAM module Kinetix 6000 IAM module Leader drive

Kinetix 6000 IAM module Non-Kinetix 6000 drive Leader drive

Non-Kinetix 6000 drive Kinetix 6000 IAM module

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 figures beginning on page 90 (460V IAM module) for an illustration of your actual hardware.

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 acts like a hinge and lets you swing the front panel open to access the ground jumper.

(230V IAM module) or page 91

88 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 89

3. Move the ground jumper.

Connecting the Kinetix 6000 Drive System Chapter 5

IAM Module (series A)

2094-ACxx-Mxx-x (230V)

2094-BC01-MP5-x (460V)

2094-BC02-M02-x (460V)

2094-BC04-M03-x (460V)

2094-BC07-M05-x (460V)

(1) Applies to series A and C (230V) drives.

IAM Module (series B and C)

2094-BC01-MP5-S (460V)

2094-BC01-M01-S (460V)

2094-BC02-M02-S (460V)

2094-BC04-M03-S (460V)

2094-BC07-M05-S (460V)

(1)

Grounded (default) Ungrounded

P15 and P16 P15 and P17

P13 and P14 P13 and P122094-BC01-M01-x (460V)

P14 and P13 P14 and P12

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 6000 Drive Modules on page 181

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Chapter 5 Connecting the Kinetix 6000 Drive System

P17

P16

P15

Top Scre w

2094-ACxx-Mxx-x IAM Module (230V)

Bottom Screw

Front Panel (opened)

Ground jumper set

for grounded configuration

(default setting).

Ground jumper set for ungrounded configuration.

IMPORTANT

Figure 43 - Setting the Ground Jumper (230V Series A and C IAM modules)

Use the default jumper setting or remove the jumper entirely for grounded power configurations. Move the jumper, as shown above, for ungrounded power.

90 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Page 91

P13

P14

P12

P13

P14

P12

Bottom Screw

Front Panel (opened)

Ground jumper set

for grounded configuration

(default setting).

Ground jumper set for ungrounded configuration.

Top Scre w

Bottom Screw

Front Panel (opened)

Ground jumper set

for grounded configuration

(default setting).

Ground jumper set for ungrounded configuration.

Top Scre w

2094-BC04-M03-x or 2094-BC07-M05-x IAM Module (460V)

2094-BC01-MP5-x, 2094-BC01-M01-x, or 2094-BC02-M02-x IAM Module (460V)

IMPORTANT

Connecting the Kinetix 6000 Drive System Chapter 5

Figure 44 - Setting the Ground Jumper (460V Series A IAM modules)

Use the default jumper setting or remove the jumper entirely for grounded power configurations. Move the jumper, as shown above, for ungrounded power.

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Chapter 5 Connecting the Kinetix 6000 Drive System

P16 P17

P18

P19

(behind P18)

P18

P19

Bottom Screw

Front Panel (opened)

Ground jumper set

for grounded configuration

(default setting).

Ground jumper set for ungrounded configuration.

Top Sc rew

2094-BC01-MP5-S, 2094-BC01-M01-S, 2094-BC02-M02-S, 2094-BC04-M03-S, or 2094-BC07-M05-S IAM Module (460V)

Figure 45 - Setting the Ground Jumper (460V Series B and C IAM modules)

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Connecting the Kinetix 6000 Drive System Chapter 5

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 Kinetix 6000 Drive System

All equipment and components of a machine or process system must 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 24

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 46 - Connecting the Braided Ground Strap Examples

For power rail dimensions, refer to the Kinetix 6000 Power Rail Installation Instructions, publication 2094-IN003

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Chapter 5 Connecting the Kinetix 6000 Drive System

IMPORTANT

Follow NEC and applicable local codes.

Bonded Ground Bus

Ground Grid or Power Distribution Ground

For mounting bracket dimensions, refer to the 2094 Mounting Brackets Installation Instructions, publication 2094-IN008

When 2094 mounting brackets are used to mount the power rail or LIM module over the AC line filter, the braided ground strap must be removed from the power rail and attached to a mounting bracket ground stud.

Ground Multiple Subpanels

In this figure, the chassis ground is extended to multiple subpanels.

Figure 47 - Subpanels Connected to a Single Ground Point

High-frequency (HF) bonding is not illustrated. For HF bonding information, refer to Bonding Multiple Subpanels on page 36

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Connecting the Kinetix 6000 Drive System Chapter 5

IMPORTANT

L3 L2 L1

DCDC+

L3 L2 L1

DCDC+

Power Wiring Requirements

Kinetix 6000 Drive Cat. No.

2094-AC05-Mxx-x

2094-AC09-M02-x

2094-AC16-M03-x

2094-AC32-M05-x 30 (3)

2094-BC01-Mxx-x 2094-BC02-M02-x

2094-BC04-M03-x

2094-BC07-M05-x 30 (3)

Description

DC bus and VAC input power

Wire must be copper with 75 °C (167 °F) minimum rating. Phasing of main AC power is arbitrary and earth ground connection is required for safe and proper operation.

For IPIM module power wiring requirements, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

Refer to Power Wiring Examples on page 187

for interconnect diagrams.

The National Electrical Code and local electrical codes take precedence over the values and methods provided.

Table 58 - IAM Power Wiring Requirements

Connects to Terminals Recommended

Pin Signal

IPD-1

(1)

IPD-2 IPD-3 IPD-4 IPD-5 IPD-6

IPD-1 IPD-2 IPD-3 IPD-4 IPD-5 IPD-6

Wire Size

(AWG)

6…2.5 (10…14)

6…4 (10…12)

30…10 (3…8)

10…2.5 (8…14)

10…6 (8…10)

Strip Length mm (in.)

10 (0.38)

16 (0.63)

10 (0.38)

16 (0.63)

Tor que V alue N•m (lb•in)

0.5…0.6 (4.4…5.3)

2.4…3.0 (21.6…26.5)

1.2…1.5 (10.6…13.2)

2.4…3.0 (21.6…26.5)

Control input power

2094-xCxx-Mxx-x

Contactor Enable

(1) Keep DC common-bus connections (leader IAM to follower IAM module) as short as possible. (2) The actual gauge of the contactor enable wiring depends on the system configuration. Consult your machine builder, the NEC, and applicable local codes.

CPD-1 CTRL 2

CPD-2 CTRL 1

CED-1 CONT EN-

CED-2 CONT EN+

4…2.5 (12…14)

10 (0.38)

(2)

ATT EN TI ON : To avoid personal injury and/or equipment damage, make sure installation complies with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment.

ATT EN TI ON : To avoid personal injury and/or equipment damage, make sure motor power connectors are used for connection purposes only. Do not use them to turn the unit on and off.

ATT EN TI ON : To avoid personal injury and/or equipment damage, make sure shielded power cables are grounded to prevent potentially high voltages on the shield.

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Chapter 5 Connecting the Kinetix 6000 Drive System

W V U

Table 59 - IAM/AM Power Wiring Requirements

Kinetix 6000 Drive Cat. No.

2094-AC05-Mxx-x, 2094-AC09-M02-x, 2094-BC01-Mxx-x, 2094-BC02-M02-x, 2094-AMP5-x, 2094-AM01-x, 2094-AM02-x, 2094-BMP5-x, 2094-BM01-x, 2094-BM02-x

2094-AC16-M03-x, 2094-AC32-M05-x, 2094-BC04-M03-x, 2094-AM03-x, 2094-AM05-x, 2094-BM03-x

2094-BC07-M05-x, 2094-BM05-x

IAM or AM (230 or 460V) 2094-xCxx-Mxx-x and 2094-xMxx-x

IAM or AM (230 or 460V) 20

94-xCxx-M

xx-S and

2094-xMxx-S

Description

Motor power

Brake power

Safe torque-off

Connects to Terminals Recommended

Wire Size

Pin Signal

Motor power cable depends on motor/ drive combination.

6…1.5

MP-4

(10…16)

MP-3 MP-2 MP-1

10…1.5 (8…16)

30…2.5 (3…14)

BC-6 BC-5 BC-4 BC-3 BC-2 BC-1

STO-1 STO-2 STO-3 STO-4 STO-5 STO-6 STO-7 STO-8 STO-9

MBRKMBRK+ COM PWR DBRKDBRK+

FDBK2+ FDBK2FDBK1+ FDBK1SAFETY ENABLE2+ SAFETY ENABLESAFETY ENABLE1+ 24V + 24V_COM

0.75 (18) 10 (0.38)

0.75 (18) (stranded wire with ferrule)

1.5 (16) (solid wire)

(AWG)

Strip Length mm (in.)

10 (0.38)

16 (0.63)

Tor que V alue N•m (lb•in)

0.5…0.6 (4.4…5.3)

1.2…1.5 (10.6…13.2)

2.4…3.0 (21.6…26.5)

0.22…0.25 (1.9…2.2)

7.0 (0.275) 0.235 (2.0)

Table 60 - Shunt Module Power Wiring Requirements

Drive Module Cat. No. Description

1394-SRxxxx

2094-BSP2 Shunt module (200/400V-class)

(1) 105 °C (221 °F), 600V.

External passive shunt module

Thermal switch

Connects to Terminals Recommended

Wire Size

Pin Signal

RC-1 DC+

RC-2 INT

10 (8)

RC-3 COL

TS-1 TS1

TS-2 TS2

0.75 (18)

(AWG)

(1)

Tor que V alue N•m (lb•in)

1.2…1.5 (10.6…13.2)

0.22…0.25 (1.9…2.2)

96 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

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Connecting the Kinetix 6000 Drive System Chapter 5

IMPORTANT

Power Wiring Guidelines

Use these guidelines as a reference when wiring the power connectors on your IAM and AM drive modules.

For IPIM module power wiring guidelines, refer to the Kinetix 6000M Integrated Drive-Motor System User Manual, publication 2094-UM003

For connector locations of the Kinetix 6000 drive modules, refer to 2094 IAM/ AM Module Connector Data on page 58

When tightening screws to secure the wires, refer to the tables beginning on

for torque values.

page 95

When removing insulation from wires, refer to the tables beginning on page 95 for strip lengths.

To improve system performance, run wires and cables in the wireways as established in Establishing Noise Zones on page 37

Follow these steps when wiring the connectors on your IAM and AM drive modules.

1. Prepare the wires for attachment to each connector plug by removing insulation equal to the recommended strip length.

Use caution not to nick, cut, or otherwise damage strands as you remove the insulation.

2. Route the cable/wires to your IAM and AM drive modules.

3. Insert wires into connector plugs.

Refer to connector pinout tables in Chapter diagrams in Appendix

4. Tighten the connector screws.

5. Gently pull on each wire to make sure it does not come out of its terminal;

reinsert and tighten any loose wires.

6. Insert the connector plug into the module connector.

4 or the interconnect

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Chapter 5 Connecting the Kinetix 6000 Drive System

CTRL 2

CTRL 1

1 2

Kinetix 6000 IAM Module, Top View

Wiring the IAM/AM Module Connectors

This section provides examples and wiring tables to assist you in making connections to the IAM and AM modules.

Wire the Control Power (CPD) Connector

This example applies to any IAM, leader IAM, or follower IAM module.

Figure 48 - IAM Module (CPD connector)

Table 61 - Control Power (CPD) Connector

CPL Connector (LIM module) or Other Single-phase Input

2094-ALxxS, 2094-BLxxS, or 2094-XL75S-Cx LIM Module

CPL Pin Signal CPL Pin Signal CPD Pin Signal

1 CTRL 1 2 L1 1 CTRL 2

2 CTRL 2 1 L2/N 2 CTRL 1

2094-AL09 and 2094-BL02 LIM Module

CPD Connector

(IAM module)

Recommended Wire Size

(AWG)

2.5 (14) 10 (0.38)

Strip Length mm (in.)

Tor que V alue N•m (lb•in)

0.5…0.6 (4.4…5.3)

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Connecting the Kinetix 6000 Drive System Chapter 5

DC-

DC+

1 2 3 4 5 6

Kinetix 6000 IAM Module, Top View

Wire the Input Power (IPD) Connector

This example applies to any IAM module or common-bus leader IAM module.

ATT EN TI ON : Make sure the input power connections are correct when wiring the IPD connector plug and that the plug is fully engaged in the module connector. Incorrect wiring/polarity or loose wiring can cause explosion or damage to equipment.

Figure 49 - IAM Module (IPD connector)

Table 62 - Input Power (IPD) Connections

OPL Connector (LIM module) or Other Three-phase Input

2094-AL09

LIM Module

OPL Pin Signal OPL Pin Signal IPD Pin Signal

1L1’4L1’6L1

2L2’3L2’5L2

3L3’2L3’4L3

413

2094-ALxxS, 2094-BLxxS, or

2094-XL75S-Cx LIM Modules

N/A

IPD Connector

(IAM or leader IAM module)

2DC+

1DC-

Table 63 - Termination Specifications

Recommended

IAM Module Cat. No. Input VAC

2094-AC05-Mxx-x

2094-AC09-M02-x 4.0 (12)

2094-AC16-M03-x 10 (8)

2094-AC32-M05-x 30 (3)

2094-BC01-Mxx-x 2094-BC02-M02-x

2094-BC04-M03-x 6 (10)

2094-BC07-M05-x 30 (3)

230V AC

460V AC

Wire Size

2.5 (14)

2.5 (14) 10 (0.38)

(AWG)

Strip Length mm (in.)

10 (0.38)

16 (0.63)

Tor que V alue N•m (lb•in)

0.5…0.6 (4.4…5.3)

2.4…3.0 (21.6…26.5)

1.2…1.5 (10.6…13.2)

2.4…3.0 (21.6…26.5)

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Chapter 5 Connecting the Kinetix 6000 Drive System

DC-

DC+

1 2 3 4 5 6

Kinetix 6000 IAM Module, Top View

IMPORTANT

This example applies to a common-bus follower IAM module.

ATT EN TI ON : Make sure the common-bus power connections are correct when wiring the IPD connector plug and that the plug is fully engaged in the module connector. Incorrect wiring/polarity or loose wiring can cause explosion or damage to equipment.

Figure 50 - IAM Module (IPD connector)

Table 64 - Input Power (IPD) Connections

IPD Connector (IAM or follower IAM module)

IPD Pin Signal

6N.C.

5N.C.

4N.C.

2DC+

1DC-

Do not connect three-phase input power to the common-bus follower IAM module.

Table 65 - Termination Specifications

Recommended

IAM Module Cat. No. Input VAC

2094-AC05-Mxx-x

2094-AC09-M02-x 4.0 (12)

2094-AC16-M03-x 10 (8)

2094-AC32-M05-x 30 (3)

2094-BC01-Mxx-x 2094-BC02-M02-x

2094-BC04-M03-x 6 (10)

2094-BC07-M05-x 30 (3)

230V AC

460V AC

Wire Size

2.5 (14)

2.5 (14) 10 (0.38)

(AWG)

Strip Length mm (in.)

10 (0.38)

16 (0.63)

Tor que V alue N•m (lb•in)

0.5…0.6 (4.4…5.3)

2.4…3.0 (21.6…26.5)

1.2…1.5 (10.6…13.2)

2.4…3.0 (21.6…26.5)

100 Rockwell Automation Publication 2094-UM001H-EN-P - June 2013

Rockwell Automation 2094-xMxx-S 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

Audience

Conventions Used in This Manual

Studio 5000 Environment

Additional Resources

IAM/AM Module Series Changes

About the Kinetix 6000 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

AC Line Filter 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 6000 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

2094 IAM/AM Module Connector Data

Safe Torque-off Connector Pinout

I/O Connector Pinout

Motor Feedback Connector Pinout

Auxiliary Feedback Connector Pinout

IAM Input Connector Pinout

IAM and AM Motor Power and Brake Connector Pinout

Control Signal Specifications

Digital Inputs

Sercos Communication Specifications

Analog Outputs

Contactor Enable Relay

Power and Relay Specifications

Motor/Resistive Brake Relay

Input Power Cycle Capability

Peak Enhancement Specifications

Control Power

Feedback Specifications

Absolute Position Feature

Motor Feedback Specifications

Feedback Power Supply Specifications

Auxiliary Position Feedback Encoders

Basic Wiring Requirements

Building Your Own Cables

Routing the Power and Signal Cables

Determine the Input Power Configuration

Grounded Power Configurations

Ungrounded and High-impedance Grounded Power Configurations

DC Common Bus Configurations

Common Bus Fusing Requirements

Setting the Ground Jumper in Ungrounded Power Configurations

Set the Ground Jumper

Grounding the Kinetix 6000 Drive System